Final Dossier For JT CP Secrificial Anode Replacement

FINAL DOSSIER FOR JT CP SACRIFICIAL
ANODE REPLACEMENT
FOR
ENGRO VOPAK TERMINAL LTD.

EVTL P.O. NO.: 3040002248
NPSL REF: ENGRO:07/047
BY
NURICON PETROSERVICES (PVT.) LTD.

CORPORATE OFFICE: 4th Floor, Mubarak Manzil, 39 Garden Road, Karachi, Pakistan
Phone No.(21) 3273 5051 (4 Lines) Fax : (21) 3273 4162
Email : [email protected], [email protected]
ISLAMABAD OFFICE: Plot No. 39, Street No. 1, I-10/3, Islamabad-44000, Pakistan
Phone No.(51) 410 2001 (4 Lines) Fax : (51) 444 3749
Email : [email protected], [email protected]
   DESIGN CERTIFICATION   
NPSL FILE DOCUMENT CHECKED / ISSUED
REV AUTHOR REPORT DISTRIBUTION
REF. No. ISSUE DATE REVIEWED BY FOR
ENGRO:07/047 00 19-DEC-2023 MZT KS FINAL EVTL 1
JH REPORT NPSL-KHI 1
MNS NPSL-ISB 1
FINAL DOSSIER FOR JETTY CP SACRIFICIAL ANODE
REPLACEMENT
CLIENT: ENGRO VOPAK TERMINAL LIMITED
PROJECT: JETTY CP SACRIFICIAL ANODE REPLACEMENT
P.O. NO.: 3040002248
P.O. DATE: 29-MAY-2023
ANODES INSTALLATION
SUPERVISION BY: M/S. KASHIF SARWAR & JAWWAD HUSSAIN
REPORT BY: MAQSOOD TEMURI-LEAD DESIGNER

NACE CORROSION SPECIALIST
FELLOW, ICORR UK
REPORT SUBMIITED BY: NURICON PETROSERVICES (PVT.) LTD.

KARACHI, PAKISTAN
   DESIGN CERTIFICATION   
NPSL FILE DOCUMENT CHECKED /
REV AUTHOR ISSUED FOR REPORT DISTRIBUTION
REF. No. ISSUE DATE REVIEWED BY
ENGRO:07/047 00 19-DEC-2023 MZT KS FINAL EVTL 1

REPORT
JH NPSL-KHI 1
MNS NPSL-ISB 1
Page 1
LIST OF CONTENTS
01. DEFINITIONS AND ABBREVIATIONS ................................................................................ 3

02. CODE AND STANDARDS .................................................................................................... 4
03. LIST OF ABBREVIATIONS .................................................................................................. 5
04. INTRODUCTION ................................................................................................................... 8
05. DESIGN & LIFE EXPECTANCY ........................................................................................... 9
06. POTENTIAL PROFILES FROM 2016 TO 2018 .................................................................... 9
07. SCOPE OF WORK ............................................................................................................... 13
07.1. CONTRACTOR ....................................................................................................... 13
07.2. PROPOSAL ............................................................................................................ 14
08. RECOMMENDATIONS ........................................................................................................ 15
APPENDIXES:
 APPENDIX-A INSTALLATION DATA
 APPENDIX-B TEST & INSPECTION REPORT
 APPENDIX-C COMMISSIONING REPORT
 APPENDIX-D RFP - REHABILITATION OF CATHODIC PROTECTION
SYSTEM AT EVTL JETTY
 APPENDIX-E EVTL ANODES INSTALLATION DETAILS
 APPENDIX-F EVTL PILES FOR ANODES INSTALLATION
 APPENDIX-G SKETCH OF TYPICAL SEA CROSSECTION FOR REFERENCE
 APPENDIX-H DRAWINGS
 APPENDIX-I INDUS DIVERS DIVING OPERATION REPORT & UNDERWATER IMAGES
Page 2
01. DEFINITIONS AND ABBREVIATIONS:
The following definitions and abbreviations have been used in the document:
General:
Client Engro Vopak Terminal Limited, Port Qasim

CP Vendor Nuricon Petroservices (Private) Limited (NPSL),
Karachi
Technical:
A or Amp(s) : Ampere.
Anode : The electrode through which current is
discharged into the electrolyte.
Cathode : The electrode through which direct current leaves
the electrolyte or the structure receiving corrosion
protection with installed CP System.
Cathodic : Technique to protect metallic structure in contact
Protection with an electrolyte by causing direct current to
flow from electrolytic environment to entire metal
surface.
Driving : Difference in potential between the anode and the
potential structure to be protected (cathode).
Electrolyte : A liquid or liquid component in composite material
like soil, in which electric current flows by
movement of ions.
Protected : The structure-to-electrolyte potential measured
Potential after application of cathodic protection.
Protected : A structure to which cathodic protection is applied
Structure for protection.
Protection : The current made to flow into a metallic structure
Current from electrolyte in order to protect the metallic
structure.
Reference Cell : An electrode that serves as basis of comparison
in the measurement of other electrode potentials.
Page 3
02. CODES AND STANDARDS:
The system shall be designed in accordance with the following project specifications,
prevailing industry norms, NACE and other international standards.
Project Specific Drawings and Specifications from Client:
EVTL RFP : Rehabilitation of Cathodic Protection system

at EVTL Jetty.
Doc. No. CHEC-EPTL-DW-96- : Detail of Anode Plan: Sheet 1 & Sheet 2 in a

002 Drawing No. C-02 Rev. 02 7 Page PDF.
Doc. No. CHEC-EPTL-DW-96- : Fender Detail.

002 Drawing No. B-02 Rev. 01
PDF File : Piles for anodes installation 2 pages.
International Standards:
BS 7361 Part 1 : Code of Practice for Land and Marine

Application.
NACE RP 067588 : Control of External Corrosion on Offshore Steel
Pipelines.
DNV RP B401 (1993) : Recommended Practice Cathodic Protection
Design 1993.
Page 4
03. LIST OF ABBREVIATIONS:
 3.14.... (a constant)
b or Pb Backfill resistivity (ohm-m)
s or Ps Soil resistivity (ohm-m)
A Ampere(s)
AC or ac Alternating Current
AJB / AJBs Anode Junction Box / Anode Junction Boxes
AP Anodic protection.
CCB Current Control Box
CD Chart Datum
Cd or Cd Current Density
CDT Current Drain Testing
CP Cathodic Protection
CPP Casing potential profile
CP Cathodic Protection System.
CSE Copper-Copper Sulfate Reference Electrode
CSP Casing to Soil Potential (with respect to Saturated Cu-CuSO 4 Reference
Electrode)
da or da Diameter of anode.
db or db Diameter of anode column/canister inclusive of backfill.
DC or dc Direct Current
Dia or dia Diameter
DP Drain Point (DC Source’s negative return connection at structure)
EPC Engineering, Procurement and Construction
EVTL Engro Vopak Terminal Limited
ft, in, Foot, inch
HMWPE High Molecular Weight Polyethylene
ICCP Impressed Current Cathodic Protection
KM or km Kilometer
LMFL Latif Main Flow Line (16” dia. Latif N1-Sawan Flow Line)
La or La Length of anode.
Lb or Lb Length of anode column/canister including backfill.
LS Long String
SS Short String
m Meter
mA Milliampere(s)
mv or MV Millivolt
cm Centimeter
mm Millimeter
Na No of anodes
Nuricon / NPSL Nuricon Petroservices (Pte.) Limited
PE Polyethylene
Potential Polarization Potential (with respect to Saturated Cu-CuSO 4 Reference
Electrode)
PSP Pipe to Soil Potential (with respect to Saturated Cu-CuSO4 Reference
Electrode if not specified otherwise) or Pile to Seawater Potential
PV Solar System Photo-Voltaic Solar System
PVC Polyvinyl Chloride Compound
Rc Cable resistance
Rg Resistance of single anode
Rgt Resistance of multiple anodes to remote earth
ROW Right of way
Page 5
Rs or Rs Resistance of structure to remote earth
Rt or Rt Total circuit resistance
S or s Spacing between the anode columns (wherever applicable)
Sa Spacing between bottom and top of consecutive anodes
SACP Sacrificial Anode Cathodic Protection (System)
Sav Center to center spacing between vertical anode/backfill columns
SCE Silver-Silver Chloride Reference Electrode
SGL Sales Gas Line
sqm Square meter
SSP Structure to Soil Potential (with respect to Saturated Cu-CuSO 4
Reference Electrode)
TEG Thermo-electric generator / Thermo-Electric Generators
XLPE Cross Linked Polyethylene
Page 6
FINAL DOSSIER
Page 7
04. INTRODUCTION:
ENGRO VOPAK Terminal Limited (EVTL) is a joint venture company of Royal Vopak
of Netherland and Engro Corp, Pakistan. EVTL operates a chemical and LPG storage
/ handling facility at Port Qasim (PQA) including a dedicated Jetty. Cathodic protection
readings are taken on annual basis of the complete facility ensuring health of the
metallic structure protection across the Terminal. The preventive maintenance of
EVTL’s onshore and offshore facilities identified the locations that require anode bed
and sacrificial anodes replacement.
EVTL awarded the contract to NPSL (Nuricon Petroservices Private Limited) for 26
No. zinc anodes installation, as a part of CP rehabilitation project for 10 No. piles, with
depleted anodes. Replacement of anodes was based on the previous, as well as on
newly acquired, CP potentials data.
Nuricon employed M/s. Indus Divers for welding of anodes at the piles. They are the
professional divers and mechanical installers for underwater works. The installation
procedures and underwater images are given in the corresponding appendix by Indus
Divers.
Prior to anodes installation, new potentials were retaken many times to ensure the
error free decision making. It was noticed that level of protection was variable for many
piles. The reason for variation could be the exposed pile surface area due to the tidal
variations. Tidal variation affects the level of protection in more than one way.
It was observed that the anodes are mostly consumed and are at the brink of full
consumption. This will put more load on the newer anodes and cause them to
consume prematurely. It is thus advisable to prepare a strategy for gradual and
planned replacement of remaining anodes. As per our advice, older anodes were kept
intact while new anodes were installed, additionally. This saved the cost of removal of
old anodes and saved the remaining anode material leading to enhanced life span of
the system.
The protection level should be at least -800 mv or more negative with respect to Ag-
AgCl Reference Electrode, however, satisfactory levels of -900 mv or more negative
are desirable.
Satisfactory protection levels of ≤-900 mv have been achieved after the replacement
of anodes.
Proper data regarding actual number of anodes installed on each pile is not available.
It is recommended to collect this data for each pile.
Page 8
05. DESIGN & LIFE EXPECTANCY:
Since the original design has completed its expected life of 20 years therefore it was
decided to maintain the original design and replace the consumed anodes on the piles
where protection potential became less negative than -800 mv. Replacement anodes
are expected to last for 20 years; however, it is to be kept in mind that this life will only
be achievable if the new anodes are also installed on other piles while they have
decayed by 80% or more. Random inspection dives have revealed that almost all the
inspected anodes have decayed by 70% or more.
06. POTENTIAL PROFILES FROM 2016 TO 2018:

Potential profiles provided by EVTL are given below which shows the decreasing trend
of potential.
Design & Replacement / installation of Sacrificial Anodes at Jetty Piles in line

with existing design.
2016 2017 2018

1100
1050
1000
950
mV
900
850
800
750
700
47.Pile NO.74 A…
57.Pile NO.74 N…
1.Pile…
3.Pile…
5.Pile…
7.Pile…
9.Pile…
53.Pile NO.74 J…
11.Pile NO.68…
13.Pile NO.68…
15.Pile NO.68…
17.Pile NO.69…
19.Pile NO.69…
21.Pile NO.69…
23.Pile NO.69…
25.Pile NO.70…
27.Pile NO.70…
29.Pile NO.70…
31.Pile NO.71…
33.Pile NO.72…
35.Pile NO.72…
37.Pile NO.73…
39.Pile NO.73…
41.Pile NO.73…
43.Pile NO.73…
45.Pile NO.73…
49.Pile NO.74 C…
51.Pile NO.74 E…
55.Pile NO.74 I…
59.Pile NO.63…
61.Pile NO.63…
63.Pile NO.64…
65.Pile NO.64… Jetty Piles
Page 9
Table 1: Piles Initially Selected for New Anodes Installation by EVTL:
EVTL Jetty Piles CP Survey (SGS Team)
SGS Reading (-mV) SGS Reading (-mV)

S.No. Location Piles#
April 22 Sep 22
1 58A 670 670
2 58B 643 670
Trestle area Piles
3 59A 692 711
4 59B 693 641
5 R69 785 750
6 Jetty Head Piles S69 810 756
7 T69 785 809
8 72A 747 710
9 Fenders 71F 814 725
10 72D 758 817
Table 2: Pile Potentials and Diameters:
27-Mar-23 Pile Dia.

DESCRIPTION 2016 2017 2018
by SGS (-mV) (m)
Pile NO. 58, Trestle Area, Steel Pile Filled By RC 640 / 724 609.6
Pile NO. 59, Trestle Area, Steel Pile Filled By RC 1001 980 940 565 / 560 609.6
Pile NO. 68 O, Jetty Head, Steel Pile Filled By RC 938 944 904 900 / 905 0.610
Pile NO. 68 V, Jetty Head, Steel Pile Filled By RC 900 / 901 0.610
Pile NO. 68 Q, Jetty Head, Steel Pile Filled By RC 905 0.610
Pile NO. 68 R, Jetty Head, Steel Pile Filled By RC 907 0.610
Pile NO. 68 S, Jetty Head, Steel Pile Filled By RC 909 0.610
Pile NO. 68 T, Jetty Head, Steel Pile Filled By RC 912 0.610
Pile NO. 68 U, Jetty Head, Steel Pile Filled By RC 905 0.610
Pile NO. 69 O, Jetty Head, Steel Pile Filled By RC 995 944 909 903 0.610
Pile NO. 69 V, Jetty Head, Steel Pile Filled By RC 915 0.610
Pile NO. 69 Q, Jetty Head, Steel Pile Filled By RC 910 / 906 0.610
Pile NO. 69 R, Jetty Head, Steel Pile Filled By RC 915 / 915 0.610
Page 10
27-Mar-23 Pile Dia.
by SGS (-mV) (m)
Pile NO. 69 S, Jetty Head, Steel Pile Filled By RC 920 / 920 0.610
Pile NO. 69 T, Jetty Head, Steel Pile Filled By RC 917 / 917 0.610
Pile NO. 69 U, Jetty Head, Steel Pile Filled By RC 917 / 915 0.610
Pile NO. 70 O, Jetty Head, Steel Pile Filled By RC 996 944 912 900 0.610
Pile NO. 70 V, Jetty Head, Steel Pile Filled By RC 895 0.610
Pile NO. 70 Q, Jetty Head, Steel Pile Filled By RC 902 / 900 0.610
Pile NO. 70 R, Jetty Head, Steel Pile Filled By RC 908 / 908 0.610
Pile NO. 70 S, Jetty Head, Steel Pile Filled By RC 913 / 913 0.610
Pile NO. 70 T, Jetty Head, Steel Pile Filled By RC 914 / 914 0.610
Pile NO. 70 U, Jetty Head, Steel Pile Filled By RC 910 / 907 0.610
Pile NO. 71 E, Breasting Dolphins Steel Pile 1002 944 912 903 1.420
Pile NO. 71 F, Breasting Dolphins Steel Pile 1000 944 910 905 1.420
Pile NO. 72 A, Breasting Dolphins Steel Pile 750 2.300
Pile NO. 72 B, Breasting Dolphins Steel Pile 904 2.300
Pile NO. 72 C, Breasting Dolphins Steel Pile 888 2.300
Pile NO. 72 D, Breasting Dolphins Steel Pile 910 2.300
Pile NO. 73 G, Mooring Steel Pile 890 1.820
Pile NO. 73 H, Mooring Steel Pile 870 1.820
Pile NO. 73 J, Mooring Steel Pile 850 1.820
Pile NO. 73 K, Mooring Steel Pile 905 1.820
Pile NO. 73 L, Mooring Steel Pile 910 1.820
Pile NO. 73 M, Mooring Steel Pile 894 1.820
Pile NO. 73 N, Mooring Steel Pile 898 1.820
Pile NO. 73 P, Mooring Steel Pile 912 1.820
Pile NO. 73 Q, Mooring Steel Pile 760 1.820
Pile NO. 73 R, Mooring, Steel Pile 1007 944 930 918 1.820
Pile NO. 74 A, Walkway, Steel Pile 1003 944 927 980 / 893 / 891 0.508
Pile NO. 74 B, Walkway, Steel Pile 888 / 888 / 888 0.508
Pile NO. 74 C, Walkway, Steel Pile 642 / 640 0.508
Pile NO. 74 D, Walkway, Steel Pile 850 / 850 / 860 0.508
Pile NO. 74 E, Walkway, Steel Pile 890 / 890 0.508
Pile NO. 74 F, Walkway, Steel Pile 915 / 915 / 912 0.508
Pile NO. 74 J, Walkway, Steel Pile 918 / 918 / 918 0.508
Pile NO. 74 K, Walkway, Steel Pile 875 / 870 / 873 0.508
Pile NO. 74 L, Walkway, Steel Pile 930 / 930 0.508
Pile NO. 74 M, Walkway, Steel Pile 890 / 890 / 891 0.508
Pile NO. 74 N, Walkway, Steel Pile 893 / 885 0.508
Pile NO. 74 P, Walkway, Steel Pile 908 / 908 / 910 0.508
Page 11
27-Mar-23 Pile Dia.
by SGS (-mV) (m)
Pile NO. 63.A (G0), P/H, Steel Pile Filled By RC 990 0.508
Pile NO. 64.B (G0), P/H, Steel Pile Filled By RC 980 0.508
Pile NO. 64.B (G1), P/H, Steel Pile Filled By RC 968 / 965 0.508
Page 12
07. SCOPE OF WORK:
Scope of work stipulated by EVTL is given in the following.
07.1. CONTRACTOR:
The contractor submitting the design should fulfil the following requirements.
 Accreditation: Cathodic Protection System shall be designed by a NACE

certified cathodic protection specialist, NACE Certified Corrosion
Specialist, Registered Professional Engineer with corrosion control
training, or a person with practical experience and training equivalent to
the applicable NACE Requirements.
 Need for electrical isolation of metallic structure electrically continuous

with pipeline shall be evaluated by designer.
 CP Criteria shall be defined according to NACE SP0169
 A minimum polarized potential of -850mv with respect to CSE and AgCl

electrode for a minimum design life of 20 Years for fire water line and jetty
piles.
 A pre-design site survey shall be performed and following to be taken into

consideration.
 Environmental Conditions.
 Neighboring Structures.
 Power Availability.
 Potential for Stray Current Occurrences.
 Water levels that may affect the operation of the CP System.
 The number and location of soil resistivity readings shall be determined

by the contractor and the report to be submitted.
 Current demand test with a temporary anode and rectifier to estimate the
actual current required to protect the entire structure or prior
experience/test data of similar installations.
 Anode ground beds shall be as per the standards mentioned in NACE.
 The current capacity of an anode bed shall be equal to or greater than the
rated capacity of the rectifier.
Page 13
 All cables shall be certified to meet the requirements of ASTM D1248.
 Rectifiers should be sized to provide 125% of maximum design voltage

for the CP System while not exceeding 90% of the design circuit
resistance.
 Each rectifier unit shall be complete with instrument cabinet, enclosure,

panel board, step down transformer, circuit breaker, rectifying element,
voltage control taps, fuses, and lighting surge protection devices.
 Enclosures shall be NEMA 4X.
07.2. PROPOSAL:
The submitted proposal should include the following:
 Detailed execution schedule.

 Basis of design report including methodology, test conditions,
observations, soil resistivity values etc.
 Risk analysis including mitigation plan.
 Organogram of the company.
 Project team profile.
 Challenges to be encountered.
 Rigging plan.
 Detailed BOQ with item wise price of all items.
 Manufacturer’s name.
 Anode type and model number.
 Anode mass and dimensions.
 Nominal and maximum anode output current capacity.
 Material composition.
 Cable material specification and construction details.
 Test data and certificate of compliance.
 2 Year Spares (NPSL Note: that there are no spares as anodes are
welded on to the piles).
 Inspection Plan.
Page 14
08. RECOMMENDATIONS:
1. According to the available drawings it is not certain that how many anodes
are installed on which piles. It is recommended that diving be arranged for
recording and ensuring the number of anodes as well as the condition of
anodes. This will facilitate to strategize the further improvements and
replacements in the CP System. Note that random diving on our part has
revealed that almost all anodes have been consumed over 70% and mostly
above 80%.
2. It is advisable to plan anodes replacements in a relatively shorter span of

time otherwise new anodes will be overloaded and consumed
preferentially. Span of time may be 1 to 1.5 years, preferably, one year.
3. During the execution of this project it was required to measure the

potentials of piles many times and boats were hired by EVTL for this
purpose; which, to our information is very expensive. It is possible to
engineer a system for measuring the potentials of piles from the surface.
We would recommend to check the feasibility of such a system.
Page 15
APPENDIX - A
INSTALLATION DATA
No. of Anodes
Two Three Four Five
One Anode Six Anodes
S. 27-03-2023 05-10-2023 10-10-2023 Anodes Anodes Anodes Anodes 13-11-2023
Job Description Installation Installation No.
No. -mV (-mV) (-mV) Installation Installation Installation Installation (-mV)
(-mV) (-mV) of
(-mV) (-mV) (-mV) (-mV)
piles
0.Pile NO.58 A/B,Tresstle

1 640 / 724 640 / 724 562 / 520 771 / 785 862 / 864 1030 / 1028 1030 / 1028
Area,Steel Pile Filled By RC
2 3

2 565 / 560 565 / 560 503 / 501 730 / 688 790 / 827 1040 / 1042 1040 / 1042
2 3
3 580 / 580 580 / 580 796 / 791 856 / 849 961 / 931 1037 / 1033 1037 / 1033
2 3
3.Pile NO.61,Tresstle
4 920 / 923 960 / 965
Area,Steel Pile Filled By RC 2
5 924 / 928 965 / 963
6 923 / 920 961 / 959
7 912 / 888 956 / 958
8 937 / 931 961 / 959
9 947 / 947 967 / 965
10 931 / 933 987 / 986
10.Pile NO.68 O,Jetty
11 900 / 905 987 / 991
Head,Steel Pile Filled By RC 9
11.Pile NO.68 V,Jetty
12 900 / 901 836 / 839 1025 / 1024 1025 / 1024
Head,Steel Pile Filled By RC 2 1
12.Pile NO.68 Q,Jetty
13 905 982
Head,Steel Pile Filled By RC
13.Pile NO.68 R,Jetty
14 907 988
14.Pile NO.68 S,Jetty
15 909 963
15.Pile NO.68 T,Jetty
16 912 939
16.Pile NO.68 U,Jetty
17 905 948
18 903 986
19 915 899 1022 1022
20 910 / 906 991 / 989
No. of Anodes
Two Three Four Five
(-mV) (-mV) of
(-mV) (-mV) (-mV) (-mV)
piles
20.Pile NO.69 R A/B,Jetty
21 915 / 915 657 / 651 823 / 831 988 / 976 1022 / 1025 1022 / 1025
22 920 / 920 961 / 944
23 917 / 917 961 / 944
24 917 / 915 946 / 961
25 900 994
26 895 836 1017 1017
27 902 / 900 971 / 981
27.Pile NO.70 R,Jetty
28 908 / 908 984 / 996
29 913 / 913 994 / 960
30 914 / 914 941 / 994
31 910 / 907 947 / 947
31.Pile NO.71 E,Breasting
32 903 987
Dolphins Steel Pile 2
32.Pile NO.71 F,Breasting
33 905 1009
Dolphins Steel Pile 4
33.Pile NO.72 A,Breasting
34 750 750 752 850 856 868 889 920 1058 1058
Dolphins Steel Pile 1 6
34.Pile NO.72 B,Breasting
35 904 1006
Dolphins Steel Pile
35.Pile NO.72 C,Breasting
36 888 1074
Dolphins Steel Pile
36.Pile NO.72 D,Breasting
37 910 960
Dolphins Steel Pile
37.Pile NO.73 G, Mooring
38 890 980
Steel Pile
38.Pile NO.73 H, Mooring
39 870 914
Steel Pile
39.Pile NO.73 J, Mooring
40 850 930
Steel Pile
40.Pile NO.73 K, Mooring
41 905 1007
Steel Pile
41.Pile NO.73 L, Mooring
42 910 1007
Steel Pile
No. of Anodes
Two Three Four Five
(-mV) (-mV) of
(-mV) (-mV) (-mV) (-mV)
piles
42.Pile NO.73 M, Mooring
43 894 939
Steel Pile
43.Pile NO.73 N, Mooring
44 898 947
Steel Pile
44.Pile NO.73 P, Mooring
45 912 966
Steel Pile
45.Pile NO.73 Q, Mooring
46 760 760 552 733 829 885 1007 1007
Steel Pile 1 4
46.Pile NO.73
47 918 976
R,Mooring,Steel Pile 10
47.Pile NO.74 A
48 980 / 893 / 891 1005
,Walkway,Steel Pile 32
48.Pile NO.74 B
49 888 / 888 / 888 994
,Walkway,Steel Pile
49.Pile NO.74 C A/B
50 642 / 640 642 / 640 728 / 733 884 / 870 963 / 960 963 / 960
,Walkway,Steel Pile 2 2
50.Pile NO.74 D
51 850 / 850 / 860 960
,Walkway,Steel Pile
51.Pile NO.74 E
52 890 / 890 987
,Walkway,Steel Pile
52.Pile NO.74 F
53 915 / 915 / 912 1009
,Walkway,Steel Pile
53.Pile NO.74 J
54 918 / 918 / 918 963
,Walkway,Steel Pile
54.Pile NO.74 K
55 875 / 870 / 873 910
,Walkway,Steel Pile
55.Pile NO.74 L
56 930 / 930 977
,Walkway,Steel Pile
56.Pile NO.74 M
57 890 / 890 / 891 958
,Walkway,Steel Pile
57.Pile NO.74 N
58 893 / 885 926
,Walkway,Steel Pile
58.Pile NO.74 P
59 908 / 908 / 910 966
,Walkway,Steel Pile
59.Pile NO.63.A
60 (G0),P/H,Steel Pile Filled By 990
RC
60.Pile NO.63.A
RC
61.Pile NO.63.A
RC
No. of Anodes
Two Three Four Five
(-mV) (-mV) of
(-mV) (-mV) (-mV) (-mV)
piles
62.Pile NO.63.A
RC
63.Pile NO.64.B
RC
64.Pile NO.64.B
65 (G1),P/H,Steel Pile Filled By 968 / 965
RC
65.Pile NO.64.B
RC
66.Pile NO.64.B
RC
Total anodes installed 26

APPENDIX - B
TEST & INSPECTION REPORT

Test Certificate
Invoice No.: YJ2023082S PO No.: ENGRO:07/047/2023

Product Name Specification & Type Quantity Melt No.
Size: 1600* (200+210)*220,
Anode Net Weight : 162.4 Kg
Anode Gross Weight: 200kg,
AL-ZN-IN Anode 26 PCS K23F291
Two iron plates with size 140MM x 140MM
on both ends
of steel core, with installing frame.
Type of Fixup Standard/Average Weight Surface Quality Chemical Composition
Welding 200KGS/200KGS Qualified Qualified
The chemical composition of the aluminum anodes and the manufacturing
quality found to be qualified, suitable to use.
Inspection: WU Siyu Date: 13-July 2023

Inspection Report
Invoice No.: YJ2023082S PO No.: ENGRO:07/047/2023
Drawing No.: A-Al-TSTC-1600-193.5-001

1. Appearance
No./Item Type Specification & Dimension Oxide Burr & Cracks Remarks
1600* (200+210)*220MM
AL-ZN-IN
1 Anode Net Weight : 162.4 Kg Qualified Qualified Accepted
Anode
Anode Gross Weight: 200kg
2. Weighing
Sampling Standard/Aver
No./Item Type Specification & Dimension Remarks
Quantity age Weight
1600* (200+210)*220MM
AL-ZN-IN
1 Anode Net Weight : 162.4 Kg 10PCS 200KGS/200KGS Accepted
Anode
Anode Gross Weight: 200kg
3. Chemical Composition
Element Standard Composition Test Results Comments
Al Balance Balance Qualified
Zn 2.5-4.5 3.75 Qualified
In 0.018-0.05 0.023 Qualified
Cd 0.005-0.02 0.012 Qualified
Fe ≤0.15 0.13 Qualified
Cu ≤0.01 0.0002 Qualified
Si ≤0.10 0.01 Qualified
4. Conclusion
After inspection, the anodes produced are in compliance with confirmed drawing and
specifications, qualified and suitable to use.
Inspection: WU Siyu Date: 14-July 2023

APPENDIX - C
COMMISSIONING REPORT
APPENDIX - D
RFP - REHABILITATION OF
CATHODIC PROTECTION SYSTEM AT
EVTL JETTY
01. INTRODUCTION:
ENGRO VOPAK Terminal Limited (EVTL) is a joint venture company of Royal Vopak
of Netherland and Engro Corp, Pakistan. EVTL operates a chemical and LPG storage
/ handling facility at Port Qasim (PQA) including a dedicated Jetty. Cathodic protection
readings are taken on annual basis of the complete facility ensuring health of the
metallic structure protection across the Terminal. The preventive maintenance of
EVTL’s onshore and offshore facilities identified the locations that require anode bed
and sacrificial anodes replacement.
02. PROJECT OVERVIEW:

The project focuses on rehabilitation of cathodic protection across the terminal. This
includes design, supply, installation, and commissioning on Jetty Piles. The design life
of the system should be at least 20 years. For details refer to scope of work mentioned
in Section 3 of the document
02.1. JETTY PILES CP REHABLITATION:

The current CP system installed on piles is galvanic sacrificial. The PSP
for the piles seems to be on a decreasing trend over the past couple of
years therefore to ensure reliability of the pile’s replacement is
necessary. As per the inspection report, 10 piles have their potentials
falling below the acceptable limits. Proposal for replacing these
sacrificial anodes is planned.
Design & Replacement / Installation of Sacrificial Anodes at Jetty

piles in line with existing design:
2016 2017 2018

1100
1050
1000
950
mV
900
850
800
750
700
1.Pile…
4.Pile…
7.Pile…
10.Pile…
13.Pile…
16.Pile…
19.Pile…
22.Pile…
25.Pile…
28.Pile…
31.Pile…
34.Pile…
37.Pile…
40.Pile…
43.Pile…
46.Pile…
49.Pile…
52.Pile…
55.Pile…
58.Pile…
61.Pile…
64.Pile…
Jetty Piles
Page 2
EVTL Jetty Piles CP Survey (SGS Team)
SGS Reading(-mV) SGS Reading (-mV)

S.No. Location Piles#
April 22 Sep 22
1 58A 670 670
2 58B 643 670
Trestle area Piles
3 59A 692 711
4 59B 693 641
5 R69 785 750
6 Jetty Head Piles S69 810 756
7 T69 785 809
8 72A 747 710
9 Fenders 71F 814 725
10 72D 758 817
Page 3
03. SCOPE OF WORK:
03.1. CONTRACTOR:
The contractor submitting the design should fulfil the following requirements.
 Accreditation: Cathodic Protection System shall be designed by a NACE

certified cathodic protection specialist, NACE Certified Corrosion
Specialist, Registered Professional Engineer with corrosion control
training, or a person with practical experience and training equivalent to
the applicable NACE Requirements.
 Need for electrical isolation of metallic structure electrically continuous

with pipeline shall be evaluated by designer.
 CP Criteria shall be defined according to NACE SP0169.
 A minimum polarized potential of -850mv with respect to CSE and AgCl

electrode for a minimum design life of 20 Years for fire water line and jetty
piles.
 A pre-design site survey shall be performed and following to be taken into

consideration.
 Environmental Conditions.
 Neighboring Structures.
 Power Availability.
 Potential for Stray Current Occurrences.
 Water levels that may affect the operation of the cp system.
 The number and location of soil resistivity readings shall be determined

by the contractor and report to be submitted.
 Current demand test with a temporary anode and rectifier to estimate the
actual current required to protect the entire structure or prior
experience/test data of similar installations.
 Anode ground beds shall be as per standards mentioned in NACE.
 The current capacity of an anode bed shall be equal to or greater than the
rated capacity of the rectifier.
 All cables shall be certified to meet the requirements of ASTM D1248.
Page 4
 Rectifiers should be sized to provide 125% of maximum design voltage
for the CP system while not exceeding 90% of the design circuit
resistance.
 Each rectifier unit shall be complete with instrument cabinet, enclosure,

panel board, step down transformer, circuit breaker, rectifying element,
voltage control taps, fuses, and lighting surge protection devices.
 Enclosures shall be NEMA 4X.
03.1.1. PROPOSAL:
The submitted proposal should include the following:
 Detailed execution schedule.
 Basis of design report including methodology, test conditions,

observations, soil resistivity values etc.
 Risk analysis including mitigation plan.
 Organogram of the company.
 Project team profile.
 Challenges to be encountered.
 Rigging plan.
 Detailed BOQ with item wise price of all items.
 Manufacturer’s name.
 Anode type and model number.
 Anode mass and dimensions.
 Nominal and maximum anode output current capacity.
 Material composition.
 Cable material specification and construction details.
 Test data and certificate of compliance.
 2 Year Spares.
 Inspection Plan.
Page 5
03.1.2. Supply (including all related/required accessories):
Supply of all items required for the system is included in the scope and is not
limited to the items mentioned below:
 Supply of Sacrificial anodes (as per the proposed design) for offshore
steel tubular piles, with all other accessories required to install and
commission the system.
 Complete job including design, supply of equipment and its installation

(including under water works, if any) is in contractor’s scope.
 Supply of all cables, lugs, AJB’s, CJB’s TBs and all other required
accessories.
 Current control for all anodes to be provided as a separate line item.
 Technical drawings (For approval and as built with associated cables and
junction boxes, cable routing and existing CP).
 Boarding, lodging, meals, transport, water are in the scope of the

contractor.
03.1.3. Installation, Testing, and Commissioning of System:
Contractor is responsible for installation, testing and commissioning of

complete system including the items mentioned below:
 Cabling work.
 Excavation, back filling, hard barricades, safety signs etc.
 Commissioning and testing of complete system will be done in two
phases.
 Initial phase will be done when all equipment has been installed.
 Another final test will be conducted after 14 days.
 Project acceptance will be given only if final test results meet the
specifications.
03.2. EVTL:
 Existing available drawings.
 Work permit for job.
 Lay down area will be provided.
Page 6
04. EXISTING DATA:
The existing data available for the said jobs is mentioned in the attached
annexure.
Annexure-I: Existing Data of Sacrificial Anodes for Jetty Piles.
05. GENERAL TERMS AND CONDITIONS:

 Contractor proposal should include methodology and detailed plan for
the activity and can visit the site informing the PoC before placing bid.
 Contractor will adhere to the safety guidelines, EVTL SHE Policy and
Emergency response plan of EVTL.
 Complete Items, tools, boat, consumables, and miscellaneous items

required for the job will be contractor’s responsibility.
 Contractor will be responsible to complete the job as per agreed plan

and timelines with EVTL.
 Completion of job will be subjected to the final approval and verification

by EVTL engineer.
 Single Phase Electricity will be provided by EVTL, wherever and

whenever is feasible for EVTL.
 All consumable, tool tackles, PPEs, manpower and other required

resources for the activity will be provided by contractor.
 Contractor will designate a supervisor who shall be responsible to

ensure the safe execution of the job at site.
 All PQA passes and permissions/permits are to be assured by the

Contractor.
 EVTL will prefer the usage of non-sparking (brass) tools on site due to
flammable and hazardous site.
 Contractor to give Warranty on the life of anode in years they will serve.
Failure of anode before said period in warranty will make the contractor
liable for rehabilitation of the system again at Contactors cost.
Page 7
 Diesel Driven Vehicles will only be allowed in the premises, to be
arranged by the contractor for movement of people and shifting of
material.
 Contractor to provide all relevant quality certificate of the material

provided or used in the project.
 All material to be verified by EVTL before being used and installed.
06. QUALITY ASSURANCE:

 Final report to be submitted within 30 days.
 Develop inspection and test plans that include all the principal stages of
the CP System material procurement, installation, and commissioning.
 Technical data sheets.
 All vendor documents and certifications incl QA/QC, FAT documents.
 Installation and maintenance manuals.
 Job completion report.
 Warranty: 3 years.
Page 8
07. RFP COORDINATOR:
The point of contact for the OWNER. All communication between the Bidder
and the OWNER upon release of this RFP shall be made with the RFP
Coordinator, as follows:
Technical Bibi Zainab

Coordinator
E-Mail Address [email protected]
Mailing Address Engro Vopak Terminal Ltd.

Plot # OZ/I/P-81. South Western Zone, Berth # 13, Port Qasim,
Karachi, Pakistan.
Telephones (92 21) 34730121-3, 34730356
Phone Number +92-333-3071339
Commercial Uzma Tarique

Coordinator
E-Mail Address [email protected]
Mailing Address Engro Vopak Terminal Ltd.

Plot # OZ/I/P-81. South Western Zone, Berth # 13, Port Qasim,
Karachi, Pakistan.
Telephones (92 21) 34730121-3, 34730356
Phone Number +92-300-2009198
Fax Number +92-21-34730113
Any other communication will be considered unofficial and non-binding on the

OWNER. Bidders are to rely on written statements issued by the RFP Coordinator.
NOTE: SGS REPORT ATTACHED
Page 9
APPENDIX - E
EVTL ANODES INSTALLATION

DETAILS
APPENDIX - F
EVTL PILES FOR ANODES

INSTALLATION
Anodes
No. of
S. No. Job Description 2016 2017 2018 No. of
piles
59 1.Pile NO.59,Tresstle Area,Steel Pile Filled By RC 1001 980 940 2 2
68 10.Pile NO.68 O,Jetty Head,Steel Pile Filled By RC 938 938 904 9 9
71 31.Pile NO.71 E,Breasting Dolphins Steel Pile 1002 945 912 2 12
72 32.Pile NO.71 F,Breasting Dolphins Steel Pile 1000 928 910 4 24
73 46.Pile NO.73 R,Mooring,Steel Pile 1007 1001 930 10 40
74 47.Pile NO.74 A ,Walkway,Steel Pile 1003 1004 927 32 32
101 165
Uf: 0.85
EVTL Jetty Piles CP Survey (SGS Team) Con(kg/A.y): 5.4 Cd (A/m2): 0.12 Life (y): 20
SGS SGS
Required Required
Reading Reading Diameter Length Area Required
S.No. Location Piles# alloy mass anodes
(-mV) (-mV) (m) (m) (sq.m) current (A)
(kg) (No.)
April 22 Sep 22
1 Trestle 58A 670 670 0.610 12.7 24.3 2.921 371.1 1.0
2 area 58B 643 670 0.610 12.7 24.3 2.921 371.1 1.0
3 Piles 59A 692 711 0.610 12.7 24.3 2.921 371.1 1.0
4 59B 693 641 0.610 12.7 24.3 2.921 371.1 1.0
5 Jetty R69 785 750 0.610 12.7 24.3 2.921 371.1 2.0
6 Head S69 810 756 0.610 12.7 24.3 2.921 371.1 2.0
7 Piles T69 785 809 0.610 12.7 24.3 2.921 371.1 2.0
8 Fenders 72A 747 710 2.300 36 260.1 31.215 3966.1 6.0
9 71F 814 725 1.420 36 160.6 19.272 2448.7 4.0
10 72D 758 817 2.300 36 260.1 31.215 3966.1 6.0
Total anodes for 10 No. piles: 26.0
'AZI-CD-H2 anodes, weight 200 kg, 1600x220 mm
Top, CD 5.5
seabed, CD -11
above seabed, m 16.5
Toe, CD -30.5
In seabed, m 19.5
APPENDIX - G
SKETCH OF TYPICAL SEA

CROSSECTION FOR REFERENCE
APPENDIX - H
DRAWINGS
APPENDIX - I
INDUS DIVERS INSTALLATION

PROCEDURES &
UNDERWATER IMAGES
DIVING OPERATION REPORT
ANODE INSTALLATION PROJECT
ENGRO VOPAK JETTY
15TH November 2023
Prepared by Engr. Muhammad Taha
Page 1 of 12
continued
Contents
1. Executive Summary ..................................................................................................................... 3
2. Operation Details ........................................................................................................................ 3
2.1 Date and Time ........................................................................................................................... 3
2.2 Location..................................................................................................................................... 3
2.3 Weather and Sea Conditions ..................................................................................................... 3
3. Team Members ........................................................................................................................... 3
4. Operation Procedure .................................................................................................................. 4
4.1 Pre-Ops Meetings / Visits .......................................................................................................... 4
4.2 Pre-Dive Briefing ....................................................................................................................... 4
4.3 Assessment Dive ....................................................................................................................... 4
4.4 Anode Installation Process ........................................................................................................ 5
4.7 Safety / Rescue .......................................................................................................................... 6
5. Challenges ................................................................................................................................... 6
5.1 Anode and Pile Curvature Mismatch ......................................................................................... 7
5.2 Limited Visibility During Low Water Periods ............................................................................. 7
5.3 Inaccessibility of Piles During Low Water .................................................................................. 7
5.4 Interruptions Due to Vessel Berthing and Casting..................................................................... 7
6. Visual Inspection of Piles ............................................................................................................. 7
7. Conclusion and Future Recommendation ................................................................................... 8
Appendix A ......................................................................................................................................... 9
Appendix B ....................................................................................................................................... 12
Page 2 of 12
continued
1. Executive Summary
Anodes installation was required at Engro Vopak jetty for which Nuricon Petroservices, a
cathodic protection expert, was contracted. For the underwater installation, Indus Divers, a
professional diving company, was subcontracted. A total of 26 anodes were installed, provided
by Nuricon Petroservices, on piles under the Engro Vopak jetty. The specific piles for installation
were identified by Engro and Nuricon Petroservices.
International diving practices were followed throughout the operation, with additional
consideration of safety protocols provided by Engro Vopak. A dedicated rescue boat remained
on-site to deal with any emergencies, ensuring the safety of all team members.
The outcome of the operation was successful, with all anodes being installed as planned. This
marks a significant achievement in the maintenance and longevity of the jetty structure,
ensuring its continued safe and efficient operation.
For future operations, it is recommended to conduct a visual inspection of the remaining piles
to validate the health of the anodes on these piles. This proactive measure can help ensure the
continued effectiveness of the cathodic protection system.
2. Operation Details
2.1 Date and Time
The operation was carried out from October 28, 2023, to November 13, 2023.
2.2 Location
The operation took place at the Engro Vopak Jetty, located in Port Qasim.
2.3 Weather and Sea Conditions

The weather during the operation period was generally good and clear. Average
temperature during this period was around 27°C and wind speed varied from no wind to
around 20 km/h.
The underwater current was moderate to high, which impacted the diving conditions. The
visibility underwater was low during low water, which posed challenges for the divers.
3. Team Members
# Name Designation
1 Cdr (R) Agha Murtaza Mirza CEO
2 Engr Muhammad Taha Project Lead
3 Engr Rehan Ahmed Siddique Senior Engineer
4 Ismail Manager Finance
5 Amjad Admin
6 Obaidullah Dive Supervisor
7 Muhammad Siddiq Technical Supervisor
8 Ghulam Muhammad Lead Diver
9 Rizwan Ullah Diver
10 Avinash Diver
11 Zainul Abideen Diver
12 Mateeullah Diver
13 Abdul Wahab Diver
14 Noman Diver
15 Shaman Diver
16 Sadiq Sama Dive Technician
Page 3 of 12
continued
# Name Designation
17 Rana Muhammad Imran Dive Technician
18 Rafique Helper
19 Iqbal Helper
# Name Company
1 Bibi Zainab Engro Vopak
2 Muhammad Zubair Engro Vopak
3 Maqsood Temuri Nuricon Petroservices
4 Kashif Sarwar Nuricon Petroservices
5 Jawwad Hussain Nuricon Petroservices
4. Operation Procedure
4.1 Pre-Ops Meetings / Visits

A series of meetings were held where the management, diving, and technical supervisors
of Indus Divers, Nuricon Petroservices, and Engro Vopak met to discuss the methodology
and safety protocols for installation. Also, site visits were conducted to ascertain the
working environment. Anodes were inspected during a visit which revealed that plates
were already welded to the anode. The plates already had a curvature which was confirmed
by Nuricon Petroservices to perfectly fit the piles’ curvature.
Also, the diving and technical supervisors met the safety team of the Engro Vopak Terminal.
They were briefed on the working procedures and safety measures. Their complete
satisfaction was ensured when Indus Divers’ higher management showcased that the
safety protocols of Indus Divers fully align with the safety standards of Engro Vopak.
4.2 Pre-Dive Briefing

Before the operation, the Dive Supervisor ensured that all pre-mobilization preparations
were in place. This included a comprehensive dive briefing, equipment inspection,
displaying warning flags, assigning dive team responsibilities, implementing safety
precautions, and preparing for the dive.
The safety team of Engro Vopak inspected the safety protocols of all the diving and safety
equipment including the generator, cables, welding plant, chain block, etc. Documentation
including method statement, emergency response plan, risk assessment, and calibration/
testing certificates before the start of the project were also reviewed.
A safety orientation was also conducted by Engro Vopak for the diving team to get
acquainted with the safety protocols of the terminal. Further each day ops started with a
toolbox talk to ensure all safety measures were in order.
4.3 Assessment Dive

An assessment dive was organized on 22nd October 2023 to verify the sea condition,
fouling, and silting on piles, and the status of old anodes. The results of the assessment
dive were communicated to all stakeholders. See Appendix A for details.
Page 4 of 12
continued
4.4 Anode Installation Process

The anode installation process involved:
a. Marking the Piles

Engro Vopak and Nuricon Petroservices teams identified the piles where anode
installation was required.
b. Assessing the Position

The position for installation of the anodes on each pile was confirmed by Nuricon
Petroservices’s team onboard. Refer to Table 2 Summary of Anode Installation.
c. Cleaning of Piles
The cleaning was done on only the area where the top and bottom plates of each anode
were to be welded. It was done using a custom-designed stencil.
d. Positioning the Anode

A specialized arrangement was fabricated at Indus Divers’ engineering workshop to
ensure the safe lowering of 200 kg anodes from the boat to the defined position on the
piles.
e. Installation of Anode
The anodes were secured at the position followed by proper welding. The plate and pile
were welded together on all four sides with a small wedge in between wherever
required. Details of the installation can be seen in Table 1 Details of Anode Installation.
f. Photography
Pre and post installation photographs of each anode were taken as proof of the secure
installation of anodes on each pile. Appendix B
The following table details the anodes installed on the piles.
# Date Pile Name No. of Anodes Welded

1 29-10-2023 74C – A 1
2 30-10-2023 74C – B 1
3 31-10-2023 73Q 1
4 01-11-2023 73Q 3
5 02-11-2023 58 – A 2
6 03-11-2023 58 – B / 59 – B 2 (1 / 1)
7 04-11-2023 59 – A / 59 – B 2 (1 / 1)
8 06-11-2023 72A 3
9 07-11-2023 72A 3
10 08-11-2023 69R – A / 69R – B 2 (1 / 1)
11 09-11-2023 70V / 69V 2 (1 / 1)
12 10-11-2023 68V 1
13 11-11-2023 60 – B / 60 – A 2 (1 / 1)
14 13-11-2023 60 – A 1
Table 1 Details of Anode Installation
Page 5 of 12
continued
The following table summarizes the Anode installation.
HEIGHT FROM
# Pile Name No. of Anodes Welded
GROUND (FT)
1 58 3 (A-2 / B-1) 3
2 59 3 (A-1 / B-2) 3
3 60 3 (A-2 / B-1) 2
4 68V 1 4.5
5 69R 2 (A-1 / B-1) 4
6 69V 1 5.5
7 70V 1 6
8 72A 6 3 5 / 12 3
9 73Q 4 5 / 7 (2)
10 74C 2 (A-1 / B-1) 5
Table 2 Summary of Anode Installation
4.7 Safety
Safety documents including the Emergency Response Plan, risk assessment, and safe
working practices for the project were shared and approved by Engro Vopak. Following the
approval Diving Safe Practices (LNG terminal specific) were shared by Engro Vopak which
were incorporated in the Indus Divers safety SOPs.
Prior to the start of the project a detailed safety meeting was organized. Higher
management, safety team and supervisors from Indus Divers, Nuricon Petroservices, and
Engro Vopak were the participants. Indus Divers briefed all the participants on the plan of
work, methodology, and safety protocols to be followed for the project. After rigorous
assessment by Engro Vopak safety team, go-ahead for project commencement was
accorded.
The Dive Supervisor briefed all the personnel involved in the job on the agreed of work,
methodology, and safety protocols. Indus Divers ensured all safety standards of Engro
Vopak were followed.
During operations safety inspectors visited the site randomly. Their guidelines were
carefully attended to and adopted.
4.8 Rescue
As part of Engro Vopak safety requirement, a rescue boat was provided. It was a high speed
and maneuverable boat dedicated for rescue operations. The rescue boat remained at site
for the complete duration of work. The boat was equipped with a first aid kit, diver’s
recovery stretcher, life jackets, throwable rescue buoys, communication equipment, PPEs,
emergency lights, marking buoys, toolbox, and safety lines.
Also, a dedicated Rescue Team of professional divers was on board to deal with any
emergency.
5. Challenges
During the operation, the team encountered several challenges. However, with careful
planning and problem-solving, Indus Divers was able to overcome these obstacles and
successfully complete the operation with the support of Nuricon Petroservices and Engro
Vopak.
Page 6 of 12
continued
5.1 Anode and Pile Curvature Mismatch

A discrepancy where the curvature of the anode plates did not align perfectly with the
curvature of the piles was encountered.
Solution: Small wedges were ingeniously used to bridge the gap between the plate and
pile, securing them together with robust welding. Additional welding passes were executed
to reinforce the strength of the weld joint, ensuring a secure and durable installation.
5.2 Limited Visibility During Low Water Periods

The low water periods posed a challenge due to significantly reduced visibility, constraining
our operational timeframe.
Solution: Schedules were strategically prepared to ensure maximum operations during

high water periods, optimizing visibility and operational efficiency.
5.3 Inaccessibility of Piles During Low Water

Certain piles were in shallow water. These piles were inaccessible during low water periods,
posing a potential hindrance to our workflow.
Solution: A flexible approach was adopted, prioritizing work on more accessible piles that
had relatively more depth. This ensured the uninterrupted progress of the operation
despite the challenging conditions.
5.4 Interruptions Due to Vessel Berthing and Casting

Vessel berthing and casting operations intermittently halted our operations. Additionally,
certain piles became inaccessible due to the vessel occupying the jetty.
Solution: Proactive planning with the support of the Engro Vopak team was done by
scheduling the operations around the vessel's schedule, focusing on unblocked piles. For
piles under the vessel berthing area, anode installations were scheduled during periods
when vessel movement was not anticipated. Even holidays were worked to best utilize the
time. This strategic planning enabled us to work around the vessel schedule and ensure the
successful installation of all anodes.
6. Visual Inspection of Piles

During the operations, it was recommended by Indus Divers that a visual inspection of piles not
considered for new anode installation should be done for future reference.
The opportunity was taken and Engro Vopak in coordination with Nuricon Petroservices requested
for a visual inspection of 7 more piles. The services were given free of cost.
The following table summarizes the observations of the diver:
# Pile Name Observation

1 61 Only small parts of the anode were seen on the pipe. Marine
fouling on the pile, anode, and pipe was observed.
2 62 40-50% of the anode was consumed. Marine fouling on the
pile, anode, and pipe was observed.
3 63 60-70% of the anode was consumed. Marine fouling on the
4 68 (A & B) 50-60% of the anode was consumed. Heavy marine fouling on
the pile, anode, and pipe was observed.
Page 7 of 12
continued
5 69O 70-80% of the anode was consumed. Marine fouling on the

6 74C (A & B) 70-80% of the anode was consumed. Heavy marine fouling on
the pile, anode, and pipe was observed.
7 74F 10-20% of the anode was consumed. Light marine fouling on
the pile, anode, and pipe was observed. Also, fishing net was
entangled.
7. Conclusion and Future Recommendation

The operation to install anodes on the piles under the Engro Vopak jetty was successfully
completed, which was a result of teamwork by Engro Vopak, Nuricon Petroservices, and Indus
Divers. The two-way communication and transparency between each stakeholder were the key
to success. Despite facing several challenges, including a mismatch in the curvature of the
anodes and piles, poor visibility during low water periods, and interruptions due to vessel
berthing and casting, Indus Divers was able to devise effective solutions and ensure the smooth
execution of the operation. It was all courtesy of professional support by Engro Vopak.
Our team demonstrated exceptional adaptability, problem-solving skills, and commitment to

safety throughout the operation. The successful installation of all anodes not only fulfilled the
objective of this operation but also contributed to the maintenance and longevity of the jetty
structure.
Moving forward, we recommend conducting a visual inspection of the remaining piles to

validate the health of the anodes on these piles. This proactive measure can help ensure the
continued effectiveness of the cathodic protection system.
We would like to express our gratitude to all team members, the representatives of Engro Vopak
and Nuricon Petroservices for their support, cooperation, and dedication throughout this
operation. We look forward to future operations where we can apply the valuable lessons
learned from this experience.
Page 8 of 12
continued
Appendix A
Page 9 of 12
continued
Engro Vopak Jetty Assessment Dive Report

Prepared by: Engr. Muhammad Taha
Date: 22.10.2023
Client: Nuricon Petroservices / Engro Vopak
Project: Anode Installation Project
Executive Summary:
This report presents the findings and future directions resulting from the assessment dive
conducted at the Engro Vopak Jetty in preparation for the Anode Installation Project. The
assessment was done in the presence and guidance of Nuricon Petroservices team. The
primary objective of the assessment dive was to evaluate the condition of the piles, sea
conditions, and depths in the area. This information shall allow Indus Divers to plan the
installation of the anode more effectively and efficiently. The following is a comprehensive
analysis of the assessment and key recommendations for the project.
I.Assessment Findings:
The assessment dive at Engro Vopak Jetty revealed the following crucial findings:
Measured Depth Charted Depth

# Pile Name
(m) (m)
1 72A 14 12
2 74C 7.5 5.5
3 69R 9 7
4 73Q 5 3
5 58 6 4
6 59 6 4
7 60 6 4
Additional findings include:

a. Piles are covered with marine growth.
b. Piles are coated and painted.
c. Old anodes were observed approximately 5 – 3ft above the seabed.
II.Future Directions:
To prepare for the Anode Installation Project, the following future directions have been
established:
1. Indus Divers shall prepare the necessary arrangements to lower anodes from
the boat to the designated installation height.
2. Marine fouling, paint, and coating must be removed to ensure effective
anode-to-pile contact.
3. The removal of fouling, paint, and coating will be conducted exclusively in the
anode installation area where plates will be welded.
4. It shall be done using a fine polishing pad and specialized scrappers.
5. Each anode must be tagged based on the pile to which it will be installed.
6. Engro is responsible for delivering anodes to Indus Divers on the boat.
7. Anodes will be lowered using adjustable clamps installed on the piles.
8. An additional adjustable clamp shall be installed below the designated
installation area to provide a secure platform for divers.
Page 10 of 12
continued
Conclusion:
The assessment dive at Engro Vopak Jetty has provided valuable insights and clear directions
for the Anode Installation Project. The identified findings and future directions ensure the
project’s smooth execution and success. By adhering to these guidelines, we will facilitate
effective anode installation and long-term protection of the jetty’s piles.
Page 11 of 12
continued
Appendix B
Engro Anode Installation
Page 12 of 12

Final Dossier For JT CP Secrificial Anode Replacement

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Final Dossier For JT CP Secrificial Anode Replacement

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FINAL DOSSIER FOR JT CP SACRIFICIAL

ENGRO VOPAK TERMINAL LTD.

NURICON PETROSERVICES (PVT.) LTD.

CLIENT: ENGRO VOPAK TERMINAL LIMITED

PROJECT: JETTY CP SACRIFICIAL ANODE REPLACEMENT

P.O. NO.: 3040002248

P.O. DATE: 29-MAY-2023

REPORT BY: MAQSOOD TEMURI-LEAD DESIGNER

REPORT SUBMIITED BY: NURICON PETROSERVICES (PVT.) LTD.

ENGRO:07/047 00 19-DEC-2023 MZT KS FINAL EVTL 1

01. DEFINITIONS AND ABBREVIATIONS ................................................................................ 3

Client Engro Vopak Terminal Limited, Port Qasim

Project Specific Drawings and Specifications from Client:

EVTL RFP : Rehabilitation of Cathodic Protection system

Doc. No. CHEC-EPTL-DW-96- : Detail of Anode Plan: Sheet 1 & Sheet 2 in a

Doc. No. CHEC-EPTL-DW-96- : Fender Detail.

PDF File : Piles for anodes installation 2 pages.

BS 7361 Part 1 : Code of Practice for Land and Marine

06. POTENTIAL PROFILES FROM 2016 TO 2018:

Design & Replacement / installation of Sacrificial Anodes at Jetty Piles in line

2016 2017 2018

EVTL Jetty Piles CP Survey (SGS Team)

SGS Reading (-mV) SGS Reading (-mV)

Table 2: Pile Potentials and Diameters:

27-Mar-23 Pile Dia.

 Accreditation: Cathodic Protection System shall be designed by a NACE

 Need for electrical isolation of metallic structure electrically continuous

 CP Criteria shall be defined according to NACE SP0169

 A minimum polarized potential of -850mv with respect to CSE and AgCl

 A pre-design site survey shall be performed and following to be taken into

 The number and location of soil resistivity readings shall be determined

 Anode ground beds shall be as per the standards mentioned in NACE.

 Rectifiers should be sized to provide 125% of maximum design voltage

 Each rectifier unit shall be complete with instrument cabinet, enclosure,

 Enclosures shall be NEMA 4X.

 Detailed execution schedule.

2. It is advisable to plan anodes replacements in a relatively shorter span of

3. During the execution of this project it was required to measure the

0.Pile NO.58 A/B,Tresstle

1.Pile NO.59 A/B,Tresstle

Total anodes installed 26

TEST & INSPECTION REPORT

Invoice No.: YJ2023082S PO No.: ENGRO:07/047/2023

Welding 200KGS/200KGS Qualified Qualified

The chemical composition of the aluminum anodes and the manufacturing

quality found to be qualified, suitable to use.

Inspection: WU Siyu Date: 13-July 2023

Invoice No.: YJ2023082S PO No.: ENGRO:07/047/2023

Drawing No.: A-Al-TSTC-1600-193.5-001

Inspection: WU Siyu Date: 14-July 2023

02. PROJECT OVERVIEW:

02.1. JETTY PILES CP REHABLITATION:

Design & Replacement / Installation of Sacrificial Anodes at Jetty

2016 2017 2018

SGS Reading(-mV) SGS Reading (-mV)

 Accreditation: Cathodic Protection System shall be designed by a NACE

 Need for electrical isolation of metallic structure electrically continuous

 CP Criteria shall be defined according to NACE SP0169.

 A minimum polarized potential of -850mv with respect to CSE and AgCl