OPERATION AND MAINTENANCE MANUAL -...

OPERATION AND MAINTENANCE MANUAL

CATHODIC PROTECTION SYSTEM UNDERGROUNDFUELSTORAGETANKS

& PIPING

POL STATION FORT GREELY, ALASKA

OCTOBER 1998

Prepared for: U.S. Army, Alaska Directorate of Public Works Fort Greely, Alaska 99737

Prepared by: Central Environmental,lnc. 700 East 46'• Avenue Anchorage, Alaska 99503

Under the direction of:

Jacobs Engineering Group Inc. 4300 B Street, Suite 600 Anchorage, Alaska 99503

Total Environmental Restoration Contract Contract No. DACA 85-95-D-0018

Task Order No. 10

l I

OPERATION AND MAINTENANCE MANUAL

CATHODIC PROTECTION SYSTEM UNDERGROUNDFUELSTORAGETANKS

&PIPING

POL STATION FORT GREELY, ALASKA

OCTOBER 1998

Prepared for: U.S. Army, Alaska Directorate of Public Works Fort Greely, Alaska 99737

Prepared by: Central Environmental, Inc. 700 East 46'" Avenue Anchorage, Alaska 99503

Under the direction of:

Jacobs Engineering Group Inc. 4300 B Street, Suite 600 Anchorage, Alaska 99503

Total Environmental Restoration Contract Contract No. DACA 85-95-D-0018

Task Order No. 10

INDEX

DESCRIPTION PAGES

SECTION I

SECTION II

SECTION III

SECTION IV

SECTIONV

SECTION VI

SECTION VII

SECTION VIII

OBJECTIVES AND METHODS

RECT~RSURVE~LANCE

RECT~R TROUBLESHOOTING

MONTHLY RECTIFIER MAINTENANCE DATA SHEETS

A. B.

OPERATION FINAL SETTINGS DATA SHEETS

DET~S AND SPECIFICATIONS A. PROJECT SPECIFICATIONS B. RECTIFIER INSTRUCTION MANUAL C. MISCELLANEOUS PRODUCT DATA

Direct Burial Wire Installation (1 Sheet) Detail of Anode Installation ( 1 Sheet) Structure Connection (1 Sheet)

3

5

3 4

Conceptual Anode Lead Wire Routing (1 Sheet) Titanium Rods Coated with EC-600 STD (1 Sheet) Direct Burial Cable (2 Sheets) Rectifier (1 Sheet) Loresco SC3- Coke Breeze(4 Sheets) Magna Tee- Underground Warning Tape (1 Sheet) Bronze Alloy Ground Clamp (1 sheet)

PHOTO DOCUMENTATION 7

UNDERSTANDING CATHODIC PROTECTION 4

SECTION I OBJECTIVES AND METHODS

OB,{ECTIVE AND METHODS

OBJECTIVES

To acquaint Base personnel with the fundamentals of cathodic protection.

2. To enable Base personnel to conduct periodic monitoring on the new cathodic protection

systems to verify their continuous operation. The rectifier must be monitored and recorded

bimonthly (60 days) in accordance with Alaska Department of Environmental Conservation

(ADEC) guidelines. The testing ofthe system every third year, as required by ADEC, for proper

adjustment and operation must be by an ADEC "Certified Cathodic Protection Tester". If

changes in the rectifier output are greater than I 0%; determine if recent work has been done

which could have damaged one of the buried cables. Damage to buried cables must be repaired

by 100 % waterproof insulated splice kits with crimped connections.

Contact a National Association of Corrosion Engineers (NACE) "Certified Specialist" for system

assessment when system operation is greater than 10%.

METHODS

1. Monitor rectifier unit outputs to ensure continuous cathodic protection is maintained.

PRELIMINARY INFORMATION

A text pertaining to corrosion and cathodic protection fundamentals is included in Section VIII.

Cathodic Protection System Ft. Greely, Alaska

Page 1 of 1

Section I- Objectives and Methods

AKT-l07-05M310-J23-000I

····~

SECTION II

RECTIFIER SURVEILLANCE

RECTIFIER SURVEILLANCE

A. CRITERIA

1. Ensure the rectifier is operable and that output levels are within accepted target values.

B. EQUIPMENT

I. High-input impedance voltmeter with 0 to 1000 V AC and 0 to 1000 VDC scales.

The following meter is approved.

a. Beckman Model HD-100

b. Fluke Multimeter

C. PROCEDURE

I . Rectifier Surveillance

a. Twice a year record the rectifier voltage and amperage values as indicated by the

corresponding meters. These meters are mounted on the exterior panel board

within the rectifier cabinets.

b. Twice a year open the rectifier doors and ensure the unit is relatively clean and

free of debris.


Section II- Rectifier Surveillance

Page 1 of3

c. Twice a year the internal rectifier meters must be calibrated to ensure survey

accuracy. This is accomplished by measuring the output levels with a portable

voltmeter and comparing values with those registered on the permanent meters.

The voltage output is measured directly by reading across the output lugs with a

standard voltmeter in the 200 VDC scale. Current output is measured indirectly

by reading across the calibrated shunts provided within the rectifier with the same

portable voltmeter in the 200 MVDC scale. The rating of each shunt is embossed

on the shunt bar for converting mV to rnA.

Record any re-adjustment to the rectifier output in terms of the transformer tap settings. These

changes should only be made at the direction of a qualified corrosion engineer.

Data shall be obtained on a monthly basis to ensure proper operating status. All pertinent

rectifier data shall be recorded on the "Rectifier Maintenance" sheets provided in Section IV of

this manual. These forms shall be dated and signed, and any changes or unusual circumstances

that may have had an influence on the readings shall be noted in the "Remarks" column.

D. MALFUNCTION

A malfunction is indicated when output levels are outside the target values given on the rectifier

maintenance sheets. In the event an abrupt change in rectifier output level occurs or the rectifier

becomes inoperable, utilize the rectifier troubleshooting information contained within Section III

of this manual. If the problem persists, notify Corrpro Companies, Inc. at 1-800-829-8422.


Page 2 of3

Section II - Rectifier Surveillance

E. SUMMARY

The rectifier unit converts AC power to DC power which is supplied to the impressed current

anodes. This current is then discharged from the anodes, travels through the soil to the metallic

tank and pipe surfaces. The current then returns to the rectifier via the negative cables attached

to the tanks. Rectifier surveillance is required to ensure that the rectifier unit operates on a

continuous basis.


Section II -Rectifier Surveillance

Page 3 of3

SECTION III

RECTIFIER TROUBLESHOOTING

RECTIFIER TROUBLESHOOTING

Single Phase Unit

Adherence to a maintenance and periodic testing program as previously described will greatly

reduce the possibility of ultimate rectifier failure. However, failures may occur. The following

procedures are recommended to enable maintenance personnel to find and repair troubles rapidly

in order to maintain cathodic protection on the underground metallic structures.

1 . Precaution:

The following precautions should be observed when troubleshooting rectifiers:

a. Tum the rectifier off when handling components within the rectifier. Turn off the

circuit breaker at the AC panel board and at the rectifier cabinet.

b. Check the rectifier wiring diagram before starting to troubleshoot. (See Figure 1

and Table I.

c. Make certain that meters used in troubleshooting are properly connected. The

voltmeter should be connected across the points where the voltage is to be

measured while the ammeter should be placed in series with the circuit being

tested. A millivoltmeter should be connected across the terminals on the rectifier

shunt. Correct polarity must be observed when using DC instruments.

2. frocedures:

Most rectifier troubles are simple and do not require extensive detailed troubleshooting

procedures. Most common problems are: blown fuses, faulty meter, loose terminals, open anode


Section N -Rectifier Troubleshooting

leads, and lightning strike damage. These troubles are usually found by a simple visual

inspection of the rectifier.

For more difficult troubles, however, it is usually better to systematically isolate the rectifier

components until the defective part is found. This may be done as follows (see Figure 1 ):

a. Check to see whether voltage is being applied to the rectifier by placing the leads

from an AC voltmeter across the line side of the circuit breaker at points A

b. Check across the load side of the circuit breaker at points B to determine whether

it is defective. The voltage should be the same as that at points A.

c. With an AC voltmeter, check the transformer secondary windings (at points D

and E) to determine whether voltage is present. If the circuit breaker trips,

indicating a short circuit, the transformer may be isolated from the DC circuit by

removing the secondary tap changing link bars (D and E). If the circuit breaker

continues to trip, check for possible shorts within the transformer. If it no longer

trips, the short is not in the transformer, but either in the rectifier stack or in the

DC circuit.

Measure the AC voltage supplied to the rectifier stack (points G and F). This

voltage should be the same as that measured at the transformer secondary (points

D and E). If AC voltage is present at the transformer secondary but not at the

stack AC terminals, check the leads from the transformer to the stack as follows:

Place the AC voltmeter leads between point D on the transformer secondary and

point G on the stack. If no voltage is present, the lead between points E and G is


Section IV- Rectifier Troubleshooting

probably open. Verify by measuring the AC voltage between points E and F. If

voltage is present between these points, the open circuit is between points E and

G. If no voltage is present between these points, both leads are defective. Replace

the defective lead.

e. If the circuit breaker trips, the stack may be isolated from the rest of the DC

circuit by removing one of the DC leads at either point J or H. If the breaker

continues to trip, the stack is defective and should be replaced.

f. If the circuit breaker does not trip when a DC lead on the stack is removed but

does trip when it is connected, the short circuit is probably in the external

groundbed or structure leads. This may be verified by removing one of the

external leads from the rectifier and turning the rectifier on again.

g. If DC voltage is present at the stack but not at the rectifier output terminals, check

for loose connections or open leads between points J and the positive terminal or

between points H and the negative terminal. This may be done by measuring the

DC voltage between point J and the negative terminal or between point Hand the

positive terminal.

h. If DC voltage is present at the rectifier output terminals but no current is flowing,

there is an open circuit in one of the external DC leads.

i.. Faulty meters may cause the rectifier to appear defective when it is actually

operating. The meters may be checked with portable meters known to be

accurate.


Section IV -Rectifier Troubleshooting

Pag~ 3 o' '\

3. Troubleshooting Techniques:

Many rectifier problems have symptoms which are obvious; however, the obvious should never

be overlooked. Loose connections, signs of arcing, strange odors, etc., indicate troubles which

do not require elaborate test procedures to uncover. Some helpful troubleshooting techniques

are:

If no output voltage or current is present, the trouble and remedy may be:

a. Breaker tripped (or fuse blown):

(I) If apparently due to steady overload, reduce the output slightly.

(2) If the breaker trips repeatedly even with the output reduced, the cause may be a

short circuit in some component. Isolate the component as described before and repair or

replace.

(3) If the breaker trips occasionally for no obvious reason, the cause may be:

(i) Line voltage surges.

(ii) Intermittent short circuits. Isolate the component as described before. Check for loose brackets or connections. Check with ohmmeter while moving leads, etc. (Make certain power is turned off when using the ohmmeter).

b. No A C line voltage. Check the AC breaker. Do not overlook the possibility that

the AC panel board circuit breaker may have tripped.

c. Open circuit in some component or connection:

(i) Check all connections, fine and coarse transformer tap adjustments, and stack connections.


Page '~ c:: ~·


(ii) Rectifier stacks. Use an AC voltmeter to see if voltage is applied to the stacks. If so, they may be open-circuited and should be checked with an ohmmeter and possibly replaced.

d. Defective meters. Check the wires between the meters and the calibrated shunt

and output lugs. If the wires are intact but the problem persists replace the meter.

e. Defective transformer. If AC line voltage is applied to the primary but none is

present at the secondary, check to see whether there is an audible hum coming

from the transformer. If so, the primary is operating but the secondary is probably

open.

f. Circuit breaker. If the contacts do not close, they should be repaired or the

breaker replaced.



Page 5 of5

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SECTION IV

MONTHLY RECTIFIER MAINTENANCE DATA SHEETS

D C OUTPUT RECTIFIER DATE BY REMAIU{S

TAP SETTING

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SECTIONV

A. CATHODIC PROTECTION COMMISSIONING

B. OPERATION FINAL SETTINGS DATA SHEETS

C. SITEPLAN

A. CATHODIC PROTECTION COMMISSIONING

CATHODIC PROTECTION COMMISIONING

Results and Discussion

Corrpro Companies, Inc. has completed the commissioning and testing of the fuel facility. The

initial survey of the fuel farm indicated cathodic protection current from the above grade storage

tank cathodic protection system (AST). This current nullifies the base or native state potentials

on the UST and piping. The -0.850 millivolts criteria (Reference Spec. Section 16642, 3.l.l.a) is

the only criteria available with this condition. With the commissioning of the new system both

the AST and the UST are provided protection. In the event either system is not operating neither

AST nor UST will be completely protected. See data sheet titled "SURVEY DATA" (see Table

1) for pre/post commissioning data.

The electrical continuity of the AST with the UST and piping has drained the protection level

from the AST. The installation and commissioning of the UST cathodic protection has restored

necessary current to the AST. See data sheet titled "AST TANK" (see Table 2) for pre/post

commissioning data.

Conclusions

I. The fuel tanks (UST) and piping meet established criteria for effective cathodic

protection.


Section V - Commissioning &Data Sheets

Page 1 of 3

2. The piping is electrically continuous with the tanks and the facility's electrical conduit

system.

3 . The fuel tanks and piping are electrically continuous with the above grade tanks (AST)

through the valve pit piping.

4. The AST is benefiting from the new cathodic protection.

5. No stray currents were measured.

Recommendations

1. Both the AST and UST rectifier units must be monitored bimonthly (60 days) to satisfy

the ADEC regulations for UST and piping.

2. Re-survey, every three years, the cathodic protection levels and adjust as necessary as

required by the ADEC regulations.

Technical Approach

All data were acquired on-site using a high impedance multimeter. Structure-to-soil potentials

were obtained versus a Cu/CuS04 reference electrode. See Table 1 titled "SURVEY DATA" for


Page 2 of3

Section V -Commissioning &Data Sheets

pre/post commissioning data. The first column of data were acquired prior to commissioning the

new system. The second two columns of data present the "on" and "instant off" potentials for

the tanks and pipe. These data were obtained using the same techniques as reported above. The

potential difference between the "instant off potentials and the "mixed potentials" shows the

potential shift effected by the new anode groundbed.

Continuity Testing. Verification of electrical continuity was achieved by connecting a portable

reference electrode at a fixed location and measuring direct current voltage on all structures. The

data for the pipe and electrical conduit show identical "on" and "off readings indicating the two

structures are electrically continuous.

Stray Current Testing. Detection of stray current (see Table 3) was attempted by interruption of

the new rectifier. Indication of stray current is the positive shift associated with isolated

structured collecting negative current and discharging positive current. This test is conducted

using the structure-to-soil potentials obtained versus a Cu/CuS04 reference electrode.

Cathodic Protection System Ft. Greely. Alaska

Page 3 of3

Section V -Commissioning &Data Sheets

B. OPERATION FINAL SETTINGS DATA SHEETS

TABLE 1- SURVEY DATA

Test Station Mixed "OFF" "ON" "IR FREE" Identifier Location DC(mV) DC(mV) DC(mV)

UST 418 North ·0.838 ·1.250 -0.924 South -0.775 ·1.251 -0.906 East -0.806 ·1.140 -0.949 West -0.849 ·1.310 -0.892

UST 417 North -0.775 ·1.251 -0.906 South -0.746 ·0.930 -0.949 East -0.694 ·1.070 ·1.019 West -1.019 ·1.350 ·0.930

UST 416 North -1.125 ·1.360 ·1.125 South ·0.952 ·1.085 -0.952 East -1.072 ·1.266 ·1.072 West ·0.774 ·1.470 -0.972

UST 415 North -0.952 ·1.085 -0.952 South ·0.875 ·1.213 -0.875 East -1.072 ·1.266 -1.072 West -0.774 -1.470 -0.972

SPILL TANK #2 North -0.809 ·1.430 -0.899 South -0.766 ·1.370 -0.966 East -0.702 ·1.250 -1.380 West -0.748 ·1.070 -0.906

WASTE TANK #1 North ·0.842 ·1.460 -0.892 South -0.787 -1.440 -0.887 East -0.774 ·1.470 -0.972 West -0.702 ·1.250 -0.906

SPILL TANK #4 North -1.072 ·1.365 -0.978 South -0.876 -1.41 -0.876 East ·0.885 ·1.422 -0.885 West -0.942 ·1.431 ·0.942

SPILL TANK #3 North -1.012 -1.410 ·1.012 South -1.032 ·1.392 -1.032 East ·1.146 ·1.388 -1.146 West ·0.925 ·1.378 -0.952

BLDG. #617 PIPING @EXIT -0.774 ·1.029

NOTE: AST SYSTEM ON FOR ALL READING

TABLE 2-ASTTANK

NOTE: AST SYSTEM IS ON FOR ALL READING

TABLE 3- STRAY CURENT TEST

NOTE: AST SYSTEM IS ON FOR ALL READINGS. "IN" AND "OUT" INDICATE PIPING

C. SITEPLAN

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SECTION VI

DETAILS AND SPECIFICATIONS

A. PROJECT SPECIFICATIONS

B. RECTIFIER INSTRUCTION MANUAL- GOOD-ALL ELECTRIC

C. MISCELLANEOUS PRODUCT DATA Direct Burial Wire Installation (1 Sheet) Detail of Anode Installation ( 1 Sheet) Structure Connection (1 Sheet) Conceptual Anode Lead Wire Routing (1 Sheet) Titanium Rods Coated with EC-600 STD (1 Sheet) Direct Burial Cable (2 Sheets) Rectifier (1 Sheet) . Loresco SC3- Coke Breeze (4 Sheets) Magna Tee- Underground Warning Tape (1 Sheet) Bronze Alloy Ground Clamp (1 sheet)

A. PROJECT SPECIFICATIONS

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CATHODIC PROTECTION SYSTEM INSTALLATION SPECIFICATION

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FORT GREELY, ALASKA, CATHODIC PROTECTION BLD 618 SECTION 01090

SECTION 01090

SOURCES FOR REFERENCE PUBLICATIONS 06/95

1.1 REFERENCES

Various publications are referenced in other sections of the specifications to establish requirements for the work. These references are identified in each section by document number, date and title. The document number used in the citation is the number assigned by the sponsoring organization, e.g. UL 1 (1993; Rev thru Jan 1995) Flexible Metal Conduit. However, when the sponsoring organization has not assigned a number to a document, an identifying number has been assigned for convenience, e.g. UL's unnumbered 1995 edition of their Building Materials Directory is identified as UL-0 1 (1995) Building Materials Directory. The sponsoring organization number (UL 1) can be distinguished from an assigned identifying number (UL-1) by the dash mark(-).

1.2 ORDERING INFORMATION

The addresses of the organizations whose publications are referenced in other sections of these specifications are listed below, and if the source of the publications is different from the address of the sponsoring organization, that information is also provided. Documents listed in the specifications with numbers which were not assigned by the sponsoring organization should be ordered from the source by title rather than by number.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) 11 West 42nd St New York, NY 10036 Ph: 212-642-4900 Fax: 212-302-1286

.1\MERICAN PETROLEl.:"M INSTITUTE (API) 1220 L St., NW Washington, DC 20005 Ph: 202-682-8375 Fax: 202-962-4776

DOL 00014

Page 1

FORT GREELY, ALASKA, CATHODIC PROTECTION BLD 618 SECTION 01090

DOL 00014

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

2101 L St., 1'-.'W, Suite 300 Washington, DC 20037-1526 Ph:202-457-8474 Fax: 202-457-8473

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

P.O. Box 9146 Quincy, MA 02269 Ph: 800-344-3555 Fax: 617-984-7057

Page 3

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH (NIOSH)

Mail Stop C-13 4676 Columbia Parkway Cincinnati, OH 45226 Ph: 800-356-4676 To order pubs for which a fee is charged,

order from: Superintendent of Documents Government Printing Office Washington, DC 20402-9325 Ph: 202-783-3238 Fax: 202-275-7703

NATIONAL INSTITUTE OF STANDARDS A.ND TECHNOLOGY (NIST)

Publications and Programs Inquiries Room El28, Administration Building Gaithersburg, MD 20899 Ph: 301-975-3058 Order From: Superintendent ofDocuments U.S. Government Printing Office Washington, DC 20402 Ph: 202-783-3238

SECTION 01300

SUBNUTTALPROCEDURES 12/94

Table of Contents

PART 1 GENERAL ........................................................ 1 1.1 SUBNUTTAL CLASSIFICATION .................................... 1

1.1.1 Government Approved ...................................... 1 1.1.2 Information Only ........................................... 1 ................................................................ 1

1.2 APPROVED SUBNUTT ALS ......................................... 1 1.3 DISAPPROVED SUBNUTTALS ...................................... 2 1.4 WITHHOLDING OF PAYMENT ..................................... 2

PART 2 PRODUCTS (Not Applicable) .......................................... 2

PART 3 EXECUTION ...................................................... 2 3.1 GENERAL ...................................................... 2 3.2 SUBNUTT AL REGISTER (ENG FORM 4288) ........................... 3 3.3 SCHEDULING ................................................... 3 3.4 TRANSNUTTAL FORM (ENG FORM 4025) ............................ 3 3.5 SUBNUTTAL PROCEDURE ........................................ 3

3.5.1 Procedures ................................................ 3 3.5.2 Deviations ................................................ 3

3.6 CONTROL OF SUBNUTTALS ....................................... 4 3.7 GOVERNMENT APPROVED SUBNUTTALS ........................... 4 3.8 INFORMATION ONLY SUBNUTTALS ................................ 4 3.9 STAMPS ........................................................ 4

SECTION 01300

be given promptly to the Contracting Officer.

1.4 WITHHOLDil'l"GOFPAYMENT

Payment for materials incorporated in the work will not be made if required approvals have not been obtained.

PART 2 PRODUCTS (Not Applicable)

PART 3 EXECUTION

3.1 GENERAL

The Contractor shall make submittals as required by the specifications. The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections. Units of weights and measures used on all submittals shall be the same as those used in the contract drawings: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements.· Prior to submittal, all items shall be checked and approved by the Contractor's Quality Control (CQC) representative and each item shall be stamped, signed, and dated by the CQC representative indicating action taken. Proposed deviations from the contract requirements shall be clearly identified. Submittals shall include items such as: Contractor's, manufacturer's, or fabricator's drawings; descriptive literature including (but not limited to) catalog cuts, diagrams, operating charts or curves; test reports; test cylinders; samples; O&M manuals (including parts list); certifications; warranties; and other such required submittals. Submittals requiring Government approval shall be scheduled and made prior to the acquisition of the material or equipment covered thereby. Samples remaining upon completion of the work shall be picked up and disposed of in accordance with manufacturer's Material Safety Data Sheets (MSDS) and in compliance with existing laws and regulations.

3.2 SUBMITTAL REGISTER (ENG FORM 4288)

At the end of this section is one set of ENG Form 4288 listing itetns of equipment and materials for which submittals are required by the specifications; this list may not be all inclusive and additional submittals may be required. Columns "d" through "q" have been completed by the Government; the Contractor shall complete columns "a"

Page2

and "r" through "t" and submit the forms to the Contracting Officer for approval within 30 calendar days after Notice to Proceed. The approved submittal register will become the

I I I I I I I I

SECTION 01300

that each individual submittal is made on or before the Contractor scheduled submittal date shown on the approved "Submittal Register."

3.7 GOVERNMENT APPROVED SUBMITTALS

Upon completion of review of submittals requiring Government approval, the submittals will be identified as having received approval by being so stamped and dated. Four copies of the submittal will be retained by the Contracting Officer and one copy of the submittal will be returned to the Contractor.

3.8 mFORMATIONONLYSUBMITTALS

Normally submittals for information only will not be returned. Approval of the Contracting Officer is not required on information only submittals. The Government reserves the right to require the Contractor to resubmit any item found not to comply with the contract. This does not relieve the Contractor from the obligation to furnish material conforming to the plans and specifications; will not prevent the Contracting Officer from requiring removal and replacement of nonconforming material incorporated in the work; and does not relieve the Contractor of the requirement to furnish samples for testing by the Government laboratory or for check testing by the Government in those instances where the technical specifications so prescribe.

3.9 STAMPS

Stamps used by the Contractor on the submittal data to certify that the submittal meets contract requirements shall be similar to the following:

Page4

' . .....;...., .. Tfi,,<SMITTAL OF SIIOr UIIAWINGS, EOUirMENT DATA, MATEIIIAL. .tPLES, OR O"lE 0 NEW SUO~ MANUFACTUIIER'S CERTIFICATES OF COMPLIANCE 0 11ESUOM11.l AL._ lll .. d IMhllqlon• on ~~~~~':'_••U tide pri<Jf to lrohhtln~_!_~!...~""·'

;,CI•on I 1\EOU(;S T fOn APrnOVAL Of Ttn; fOLLOWING ITEMS fThit ttctlon will be lnhl•t•d by the conHHtotl

10: fi\OM:

CONTflACT NO. TI\ANSMITTAL NO,

--·---rnEVIOUS TflANS. NO.

. .,,.,, ... ' . '•' •'""'!~, . ·,:f[-~

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I'ECIFICATION SE.C, NO, (Co~t only ON tectlon wlthe.tch P110JECT TITLE /\NO LOCATION ••"•tnin•ll

::1 t-MfG. 011 CONTil. 0: CONTflACT nEFEflENCE ....

DOCUMENT - d ron CAT .• cunvE 0 liz c. 0

u z OEICnU"TION or ITEM C\JDMtneo OOAWtNO On

~ I= 6 USE :1: ITrfH. tlu. model numb•t.•tcJ onocuuue NO.

DnA WING !! 9 COOE srec. ~!;

... tS•• lntHut.llon No. ll 0 PAflA. NO, SHEET NO.

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1EMI\11KS 1 c•ttlfy th•t th• •bove tubmiUed lumt h•v• b••n ·~· "'•"""H 111 deull end.,. con«t •nd In Itt Itt conlonn· •nc• ¥Othh ttt• conuact dnwvlngs •nd tp•clflc:•tlont •-c:•pt •• oth•r""'l•• u•t•d.

NAME AND StONATUn£ OF CONTOACTOn

SUUQol'lll 1\rrtiOVIIL IICTION

INCLOSURES RETURN EO I Lin by lltm NoJ NAME, TillE /\NO SIGN/\ TUllE OF l\ffi10VIN~ NJTHCIIIIY 01\TE

''" 411·1·101 (UtiiUHUf1JANIOISOS l 0 0 tn. tr,opon•nt: UA£ N·t.lt'C) SJIE!o:T ur

SECTION 16642 CATIIODIC PROTECTION SYSTEM (Th1PRESSED CURRENT)

10/94 Table of Contents

PART 1 GENERAL ........................................................ 1 1.1 REFERENCES ................................................... 1 1.2 GENERAL REQUIREMENTS ....................................... 2

1.2.1 Contractor's Modifications .................................... 3 1.2.2 Insulators ................................................. 3 1.2.3 Anodes and Bond Wires ..................................... 3 1.2.4 Surge Protection ........................................... 3 1.2.5 Sacrificial Anodes .......................................... 3 1.2.6 Nonmetallic Pipe Systems .................................... 3 1.2. 7 Services of Corrosion Engineer ................................ 4

1.3 SUBMITTALS ................................................... 4

PART 2 PRODUCTS ....................................................... 6 2.1 IMPRESSED CURRENT ANODES ................................... 6

2.1.1 Bare High Silicon Cast-Iron Anodes ............................ 6 2.1.2 Bare Graphite Anodes ....................................... 6 2. 1.3 Canister Contained Anodes ................................... 6 2.1.4 Anode Connecting Cables .................................... 7 2. 1.5 Mixed Metal Oxide Anodes ................................... 7

2.2 RECTIFIERS AND AS SOCIA TED EQUIP:MENT ........................ 8 2.2.1 Rectifier Unit ............................................... 8 2.2.2 Cabinet Construction

....................................................... 10 2.2.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 2.2.4 Oil Itnmersed Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3 COKE BREEZE ................................................. 11 2.3.1 Calcined Petroleum Coke Breeze (Dry) ......................... 11 2.3 .2 Metallurgical Breeze (Processed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 MISCELLANEOUS MATERIALS ................................... 11 2.4.2 Deep Anode Ground Bed Casing .............................. 12 2.4.3 Anode Centering Device .................................... 12 2.4.4 Conduit ................................................. 12 2.4.5 Test Boxes and Junction Boxes ............................... 12 2.4.6 Polyethylene Insulation ..................................... 12 2.4. 7 Test Stations ............................................. 13 2.4.8 Calibrated Shunts .......................................... 13 2.4 .9 Sealing and Dielectric Compound ............................. 13 2. 4.11 Preformed Sheaths ........................................ 13 2.4.12 Epoxy Potting Compound .................................. 14 2.4.13 Backfill Shields .......................................... 14 2.4.14 Electrical Tape ........................................... 14

!! • ; "'- ~ -·c- - ~ c

- -- - ' - - -- --~~-

~??.:.j···

'· SECTION 16642 CATilODIC PROTECTION SYSTEM (IMPRESSED CURRENT) Page I .: ..

I SECTION 16642

I I

~.

I ' ~ , I I

CATIJ:ODIC PROTECTION SYSTEM (IMPRESSED CURRENT) 10/94

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI C80.1 (1990) Rigid Steel Conduit- Zinc Coated

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTMA53

ASTMD 1248

(1993a) Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless

. (1984; R 1989) Polyethylene Plastics Molding and Extrusion Materials

FEDERAL SPECIFICATIONS (FS)

FSHH-I-595

FS J-C-30

(Rev C) Insulation Tape, Electrical, Pressure-Sensitive Adhesive, Plastic

(Rev B) Cable and Wire, Electrical (Power, Fixed Installation)

.MILITARY SPECIFICATIONS (MS)

MS .MIL-I-1361 (Rev C; Notice 1) Instrument Auxiliaries, Electrical Measuring: Shunts, Resistors, and Transformers

NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE)

SECTION 16642 CA1RODIC PROTECTION SYSTEM (IMPRESSED CURRENT) Page 3

electrolyte to the pipe surfaces. The installation shall meet the specified protection criteria for a 25 year life.

1.2.1 Contractor's Modifications

The specified system is based on an impressed current system. The Contractor may modify the cathodic protection system after review of the project, site verification and analysis if the proposed modifications include the impressed current anodes and rectifiers and will provide better overall system performance. The modifications shall be fully described, shall be approved by the Contracting Officer and shall meet the following criteria. The proposed system shall achieve a minimum pipe-to-soil "Instant Off" potential of minus 0. 85 volts with reference to a saturated copper-copper sulfate reference cell on 100 percent of the underground components of the tanks and piping.

1.2.2 Insulators

Not in the scope of this project.

1.2.3 Anodes and Bond Wires

Anodes shall be installed in as shown in the plans. For each cathodic protection system, the metallic components and structures to be protected shall be made electrically continuous. This shall be accomplished by installing bond wires between the various structures. Bonding of existing buried structures may also be required to preclude detrimental stray current effects and safety hazards. Provisions shall be included to return stray current to its source without damaging structures intercepting the stray current. The electrical isolation of underground facilities in accordance with acceptable industry practice shall not be included under this section.

1.2.4 Surge Protection


1.2.5 Sacrificial Anodes

Not required.

1.2.6 Nonmetallic Pipe Systems


1.2.6.1 Coatings

SECTION !6642 CATHODIC PROTECTION SYSTEM (IMPRESSED CURRENT) Page 5

detail drawings and not later than one month prior to the date of beneficial occupancy. The data shall include a complete list of parts, special tools, and supplies, with current unit prices and source of supply. One spare anode and fuse of each type shall be furnished.

SD-04 Drawings

Contractor's Modifications; GA.

Six copies of detail drawings showing proposed changes in location, scope or performance indicating any variations from, additions to, or clarifications of contract drawings. The drawings shall show proposed changes in anode arrangement, anode size and number, anode materials and layout details, conduit size, wire size, mounting details, wiring diagram, method for electrically isolating each pipe, and any other pertinent information to the proper installation and performance of the system.

SD-08 Statements

Qualifications; GA.

Evidence of qualifications of the corrosion engineer.

SD-09 Reports

. Tests and Measurements; GA.

Test reports in booklet form tabulating field tests and measurements performed, upon completion and testing of the installed system and including close interval potential survey and interference tests, final system test verifying protection, insulated joint and bond tests, and holiday coating test. Each test report shall indicate the final position of controls. A certified test report showing that the connecting method has passed a 120-day laboratory test without failure at the place of connection, wherein the anode is subjected to maximum recommended current output while immersed in a 3 percent sodium chloride solution.

Contractor's Modifications; GA.

The following special materials and information are required: Rectifier and meters specifications; taping materials and conductors; testing procedures, and equipment; coating material; anode; grounding clamps, and leads.

SD-13 Certificates

Cathodic Protection System; GA.

'.··~·.· ....• · •. · •. •.•.··.·•.·· ... · •..•.. · .. ·•· •. ···•.•· ..

"'' •

•

SECTION 16642 CATHODIC PROTECTION SYSTEM (IMPRESSED CURRENT) Page 7

Not used.

2.1. 4 Anode Connecting Cables

Anodes shall have connecting cables installed at the factory. Each anode shall be accompanied by a reel of continuous cable having the length indicated. No spliced connections will be permitted.

2.1.5 Mixed Metal Oxide Anodes

Mixed metal oxide anodes shall be of the size indicated and shall conform to the following requirements.

2.1.5 .1 Conductive Material

The electrically conductive coating shall contain a mixture consisting primarily of iridium, tantalum, and titanium oxides. The average composition is generally a 50/50 atomic percent mixture of iridium and titanium oxides, with a small amount of tantalum. The resistivity, as tested by the manufacturer, shall be no more than 0.002 ohm-centimeter, and the bond strength shall be greater than 50 MPa to guarantee the current capacity life and the quality of the conductive ceramic coating. The adhesion or bond strength shall be determined by epoxy bonding a 2.54 mm diameter stud to the ceramic coating and measuring the load to failure (about 70 MPa) of either the epoxy or the interface between the coating and the substrate. The anode must be inert and the electrically conductive ceramic coating dimensionally stable. The ceramic coated anode shall be capable of sustaining a current density of I 00 ampere per square meter in an oxygen generating electrolyte at 66 degrees C (150 degrees F) for 20 years, to ensure the current capacity life. An accelerated current capacity life test shall be performed by the manufacturer on every lot of anode wire used to construct the anode as described. The mixed metal oxide coating shall be applied to the wire anode by a firm that is regularly engaged in and has a minimum 5 years experience in manufacturing and applying mixed metal oxide coatings to titanium anode substrates. The mixed metal oxide must be sintered to the titanium surface as to remain tightly bound to the surface when bent 180 degrees onto itself.

2.1.5 .2 Anode Life Test

The anode wire material shall sustain current densities of 1 00 ampere per square meter in an oxygen generating electrolyte for 20 years. The

· manufacturer shall cenify that a representative sample taken from the same lot used to construct the anode, has been tested and meets the following

SECTION 16642 CATHODIC PROTECTION SYSTEM (IMPRESSED CtJRRENT) Page 9

Rectifier unit shall consist of a transformer, rectifYing elements, transformer tap adjuster, output divided into three variable resistor (potentiometer) controlled circuits. Two circuits are equipped with three lugs each and one is equipped wiht four. There shall•be one analog de output voltmeter, one analog de output ammeter, one three position toggle switch for each meter, mechanical digital elapsed time meter, fuse holders with fuses for each de circuit, variable resistors, an ac power-supply circuit breaker, lightning arresters for both input and output, all wired and assembled in a weatherproof galvanized metal cabinet. The overall efficiency of the rectifier shall be not less than 65 percent when operated at nameplate rating and shall be capable of supplying continuous full rated output at an ambient temperature of 44 degrees C (112 degrees F) (112 degrees F) in full sunlight with expected life in excess of 10 years. The output current and voltage of the rectifier shall be as follows: Five amperes and 50 volts DC. A suitable model would be a Universal Rectifiers Model No. ASAI 50-5 AACFHPQ or a Good-all Electric Model No. CSA YSA 50-5 EGHNPZ, Z= AC mechanical digital elapsed time meter, Z= Large case size A3 to accommodate DC positive outputs, Z = Three each three ohm rotary rheostats, shunts, switching for reading amps and lugs in positive DC output leg per rectifier output detail, Z =Four each, DC negative output Jugs, or equal as approved by the Design Engineer.

2.2.1.1 Transformer

Transformer shall conform to UL 506.

2.2.1.2 Rectifiers

RectifYing elements shall be silicon diodes connected to provide full-wave rectification. Silicon diodes shall be protected by selenium surge cells or varistors against over-voltage surges and by current-limiting devices against over-current surges.

2. 2. 1.3 Meters

Meters shall be accurate to within plus or minus 2 percent of full scale at 27 degrees C (80 degrees F), and shall possess temperature stability above and below 27 degrees C (80 degrees F) of at least 1 percent per 5 degrees C (1 0 degrees F). Separate meters shall be 63.5 mm (2-112 inch) nominal size or larger.

2.2.1. 4 Circuit Breaker

A single-pole, flush-mounted, fully magnetic, properly rated nonterminal type circuit breaker shall be installed in the primary circuit of the rectifier supply transformer.

2.2.1.5 Fuses

SECTION 16642 CATEODIC PROTECTION SYSTEM (IMPRESSED CURRENT)

Not in the scope of this project

2.3 COKE BREEZE

2.3.1 Calcined Petroleum Coke Breeze (Dry)

Coke Breeze shall confo1111 to the following requirements:

2.3 .1.1 Electrical Resistivity

10 milliohm-meterto 20 milliohm-meter, (1.0 to 2.0 ohm-centimeter,) tightly compacted. · ·

100 milliohm-meter to 150 milliohm-meter, (10 to 15 ohm-centimeter,) loosely compacted.

2.3.1.2 Bulk Density

768 to 1184 kg per cubic meter (forty-eight to seventy-four pounds per cubic foot).

2.3 .2 Metallurgical Breeze (Processed)

Coke Breeze shall conform to the following requirements:

2.3 .2.1 Electrical Resistivity (Nominal)

100 milliohm-meter (1 0 ohm-centimeter) Max., tightly compacted.

Page 11

100 milliohm-meter to !50 milliohm-meter, ( 10 to 15 ohm-centimeter,) lightly compacted. 150 to 200 milliohm-meter, (15 to 20 ohm-centimeter,) loose.

2.3 .2.2 Bulk Density

608 to 672 kg per cubic meter (3 8 to 42 pounds per cubic foot).

2.4 MISCELLANEOUS MATERIALS

2.4.1 Electrical Wire

2.4 .1.1 Anode Connecting Wire

Anode connecting wire shall be No. 8 AWG stranded copper wire with type "Cathodic Protection" high molecular weight polyethylene insulation, 2. 8 mm (7/64 inch) thick, 600 volt rating, in accordance with NEMA WC 5. Cable-to-anode contact resistance shall be 0.003

SECTION 16642 CATHODIC PROTECTION SYSTEM (IMPRESSED CURRENT)

2.4.6.2 High Density Polyethylene

High density polyethylene shall be Type III, Class C, Grade E3.

2.4.7 Test Stations

Not used.·

2.4.8 Calibrated Shunts

Not used.

2.4.9 Sealing and Dielectric Compound

Sealing and dielectric compound shall be a black, rubber based compound that is soft, permanently pliable, tacky, moldable, and unbacked. Compound shall be applied as recommended by the manufacturer, but not less than 3.2 rnrn (1/8 inch) thick.

2.4.10 Protective Covering •

Except as otherwise specified, protective covering for underground metallic components including fittings shall be applied by hand.

2.4.1 0.1 Pipeline Metallic Components


2.4.1 0.2 Field Joints


2.4.10.3 Inspection ofPipe Coatings


2.4.10.4 Above Ground Piping System


2.4.11 Preformed Sheaths

Not used.

Page 13

-i;.

r SECTION 16642 CATHODIC PROTECTION SYSTEM (Th1PRESSED CURRENT) Page 15

shall be attached by listed and labeled electrical grounding clamps. Electrical grounding clamps shall be insulated with coating compound and approved by the Contracting Officer. Continuity bonds shall be installed as necessary to reduce stray current interference. Additional joint bonding shall be done where determined during construction or testing or as directed by the Contracting Officer. Joint bonding shall include excavation and backfilling. There shall be a minimum of 2 continuity bonds between each structure and other than welded or threaded joints. Electrical continuity shall be tested across joints with other than welded or threaded joints.

2.4.18.1 Resistance Bonds

Resistance bonds shall be adjusted for minimum interference while achieving the criteria of protection. Alternate methods may be used when approved.

2.4.18.2 Stray Current Measurements

Stray current measurements shall be performed on all underground structures within the influence of the cathodic protection system but not bonded to the system. Alternate methods may be used when approved. The stray current test report shall indicate location of test, type of structure tested, method of testing. ·

2.4 .19 Electrical Isolation of Structures


2.5 MAGNESIUM ANODES


2.6 LEAD WIRE CONNECTIONS

Lead wire to structure connections shall be made by a listed and labeled electrical grounding clamp of suitable size. Coatings shall be removed from the pipes at the point of connection. Pipe surface shall then be cleaned to bright metal. A backfill shield filled with a pipeline mastic sealant or material compatible with the coating shall be placed over the clamp and shall cover the exposed metal adequately.

PART 3 EXECUTION

3.1 CRITERIA OF PROTECTION

Acceptance criteria for determining the adequacy of protection on buried pipes and tanks shall be in accordance with NACE RPOl69 and as specified below.


3.2.1.2 Vertically Buried Bare Anodes

Not used.

3.2.1.3 Horizontally Buried Canister-Contained Anodes

Not used.

3.2.1.4 Vertically Buried Canister-Contained Anodes

Vertically buried canister-contained anodes shall be installed in vertical holes in the ground having depth, spacing, and locations shown. The holes in the ground shall be sufficiently larger in diameter than the canisters to facilitate easy lowering into the hole and backfilling. The space between the canister and the wall of the hole shall be completely backfilled with coke breeze backfill.

3.2.1.5 Cable Protection

Positive cable to the ground bed and negative cable to the pipes and tanks to be protected shall be buried a minimum depth of 750 mm (30 inches) except where above ground construction utilizing conduit is used. Cables shall be laid on an 80 mm (three inch) bed of clean sand and covered by an 80 mm (three inch) bed of clean sand.

3.2.1.6 Multiple Anode Systems

Not used.

3 .2.1. 7 Distributed Anode Systems

The anodes shall be in the POL facility at depths, spacing, and locations shown. The anodes shall be buried vertically.

3 .2.2 Deep Anode Ground Beds

Not used.

3.2.2.1 Anode Centering

Anodes shall be centered in the well by means of centering devices.

3 .2.2.2 Well Casing

Not used.


cables but no deeper than 15 em (six inches) below grade.

3 .2.2.1 0 Pavement Inserts


3.3 MAGNESillM ANODE INSTALLATION

Not used.

3.4 :MISCELLANEOUS INSTALLATION

. 3.4 .I Rectifier Installation

Mounting shall be as shown. wall mounting shall be equipped with a channel bracket, lifting eyes, and a keyhole at the top.

3.4.2 Wire Connections

3.4.2.1 Wire Splicing

Connecting wire splicing shall be made with copper compression connectors or exothermic welds, following instructions of the manufacturer. Split-bolt type connectors shall not be used. No splicing of anode conductors shall be permitted.

3.4.2.2 Steel Surfaces

Connections to ferrous pipe shall be made by the method as shown in section 2.6.

3.4.3 Pipe Joints


3.4.3.1 Electrical Continuity


3.4.3.2 Coating

Mechanical joints and fittings of either the electrically conductive or insulating type shall be coated with an underground type dielectric coating system. Where external electrical continuity bonds are installed across mechanical joints, bare or exposed metal, bare wire and exposed

'


the static potential-to-soil of the pipes and tank shall be measured. The locations of these measurements shall be identical to the locations specified for pipe and tank-to-reference electrode potential measurements.

3.5.2 Insulation Testing


3.5.2.1 Insulation Checker


3.5 .2.2 Cathodic Protection Meter

Not used.

3.5.3 Anode Output

Not used.

3.5.4 Electrode Potential Measurements

Upon completion of the installation and with the entire cathodic protection system in operation, electrode potential measurements shall be made using a copper-copper sulphate reference electrode and a potentiometer-voltmeter, or a direct current voltmeter having an internal resistance (sensitivity) of not less than 10 megohms per volt and a full scale of not more than 10 volts. The locations of these measurements shall be identical to the locations used for baseline potentials. The values obtained and the date, time, and locations of measurements shall be recorded. No less than 8 measurements shall be made over any length ofline or component.

3.5.5 Location of Measurements

3.5.5.1 Coated Piping or Conduit

For coated piping or conduit, measurements shall be taken from the reference electrode located in contact with the earth, directly over the pipe. Connection to the pipe shall be made at any means suitable for test purposes. Pipe to soil potential measurements shall be made at intervals not exceeding two times the depth of the structure below grade. The Contractor may use a continuous pipe to soil potential profile in lieu of interval pipe to soil potential measurements. Rectifier output shall be adjusted to result in all locations meeting the criteria for cathodic protection.

B. RECTIFIER INSTRUCTION MANUAL- GOOD-ALL ELECTRIC

3/94

INSTRUCTION MANUAL

Good-All Electric, Inc. 3725 Canal Drive

Fan Collins, CO U.S.A. 80524 30:J.I84-3080

FAX: 303-484-8649

RIC A CORRPRO COMPANY

SERIAL NO.----

INSPECTED----

DATE

BY

INTRODUCTION

Good-All rectifiers are sold and serviced by leading corrosion protection firms throughout the world. These firms have the

, . d 0 ... 11 d .; .... i facilities and oerscnne_ requ1re to des1gn, lns~a-- an ma~n~a-n your cor~osion Protective systems.

Stock of sub-assemblies and comoonents are maintained at our plant to enable "build to order" shipments to be made quickly. our skilled Engineering staff has years of field and design experience, and is well equipped to provide specialized rectifiers whenever the application war=ants the additional cost.

World-wide acceptanc·e of Good-All rectifiers is the result of rigid quality control as a basic part of the manufacturing process. Close attention to quality control of components, manufacturing processes and finished assemblies guarantee you the finest, most reliable rectifier in the world.

Corrosion of underground pipelines and other structures is a process which is continuous 24 hours per day, 365 days per year; therefore protection mus~ also be continuous to effectively combat corrosion. Correct selection, installation and operation of a cathodic orotection svs~e~ is i~oortant, as severe corrosion could result frCrn interrupcicns in prOtection. Reliability must be the chief crite.:-ia in the design of a cathodic protection installation. The Design Engineer can provide significant savings to his company in dollars and manpower by specifying Good-All rectifiers, which are backed by years of outstanding reliability history. We salute your good judgement in adding another Good~All rectifier to your system.

Rectifiers received in damageC condition should be accepted, a notation made on the freight bill and a claim made to the carrier. Concealed da::.ace should be reoorted to the carrier immediately. Any type danage should be reported to the carrier, all cartons or crates saved in original condition and claim made to the c·arrier. Permission must be granted by Good-All before the return of any rectifiers for repairs.

When requesting information or ordering parts for this rectifier unit, please specify the serial number and model number. Information 1s available from our distributors located in convenient areas about this country, Canada and over~eas, contact factory for location nearest you.

Rectifiers manufac~ured by Good-All are guaranteed against defects in design, 1-iork:::a:"lship or r.:aterial for a period of one yea:::as described in our ca~alog.

1

..

Nothing of an insulating nature should be applied to the case such as mastic, tar and etc.

If possible, place the unit in the shade. Mounting it on the North side of the pole will help. If the ambient temperature is extremely high, a sunshade is a good investment.

:3. Most codes require a fused, visible disconnect switch ahead of the rectifier. When working on the rectifier, make certain this s·>'~·itch is open, since voltage is p~esent en t~e line side of the circuit b=eake= even when it is turned off.

4. Lightning arresters are cheap insurance when the rectifier is located in a:::-eas of frequent thunder storms. The AC arreste:::- is best placed at the top of the service pole; but is effective even when placed inside the unit. AC and DC lightning arreste:::-s are standard equipment on all rectifie:::-s with silicon stacks.

5. The following precautions should be observed on every rectifier installation:

(A) The rectifier case should be connected to a ground rod driven at the location of the unit. There is a grouna~:1g lug en the cabinet for this purpose, usually on the pole-mount or leg.

(B) Make ce:::-tain before eneroizina the unit that the input voltage available is correct for the rectifier, as specified on the nameplate.

(C) Check the output connections for correct polarity.

(D) Do not install other equipment in the rectifier cabinet. This invalidates the rectifier guarantee, since the manufacturer has no control over the quality of the equipment added. The additional equipment might also interfere with the cooling of the rectifier.

(E) Make certain that the screens are not obstructed on air cooled cabinets. Do not place the Service Ma~ual en the bottom screen.

(:) On :~~=e phase manually adjusted units, make ce=~a~n all three sets o: adjustment taps are set alike.

3

Proper cooling of all the components in the rectifier is always a problem. Accumulations of dust, bird or insect nests, or anything of this type on the components or the screens can cause overheating and failure of the unit. Most rectifiers are ventilated through screens which have a maximum opening of l/8". This will prevent the entrance of most insects that can cause trouble; therefore, special care should be taken to see that no holes in the unit are left unplugged that could allow insects to enter the rectifier.

While the unit is t~rned off 1 the electrical watt-hour meter should be checked for creep. The creep in the meter can indicated either a faulty electric meter or electrical leakage of some kind in the wiring to the unit. This leakage might be in the actual wiring itself or, if, present, lightning arresters.

The unit should new be turned on and the meters in the rectifier checked using portable voltmeters and ammeters, known to be accurate. The accuracy of the meters can be checked by a DC voltmeter and by connecting a 50 millivolt meter to the shunt in the unit. This check is net necessary en each inspection; but should be performed at least once per year. Poor contacts in meter switches can also cause erroneous readings. This can be avoided by pushing the switch and taking readings until four identical consecutive readings are obtained. The Good-All meter switch is a sealed type, which will give many years of reliable operation.

The efficiency of the unit should then be checked. The efficiency of the unit is simply the ratio of the average DC output to the AC input times 100. The DC output is the DC volts times the DC amps.

% Efficiency = DC Volts ~ DC amos x 100 AC Watts

The input can be determined by connecting a wattmeter into the primary circuit of the rectifier, or, in most case, can be measured easier by counting the turns of the disc in the watt-hour meter and applying the following formula:

AC Watts = li A tl A l2QQ T

where K is the meter constant (shown on the dial face), N is the number of revolutions of the meter disc, and T is the time of measurement in seconds.

5

Circuit breakers can sometimes develop bad contacts; therefore, if the unit is completely inoperative, the potential across the load side of the circuit breaker should be checked before proceeding. If the rectifier is a single voltage rectifier, the load side of the circuit breaker will be connected to the primary of the transfor~er. If the unit is dual voltage rectifier, it is equipped with a voltage change-over panel; and since it has mechanical or pressure type contacts, this point should always be checked for open circuits.

The next checkpoint in the flow of power is the secondary of the transfo~er. The secondary AC voltage of the transformer is measured between the center studs on the vel tage change panel, and that amount of voltage bet•.;een these t·.;o points would be determined by the rating of the machine and the setting of the link bar adjustments. No voltage between these points could be caused by poor connections in the link bars.

The next component in the flow of power, is the rectifier stack which changes AC into DC. An assumption that a rectifier is inoperative or has no output may come as a result of no reading on the voltmeter or ammeter. However, one should not overlook the fact the voltmeter or ammeter itself could be at fault. Therefore, the meters should always be checked by substituting a portable meter, known to be good.

Some rectifiers may contain a filter in the DC output which is used in increase conversion efficiency andjor reduce interference. In most cases, this will be what is referred to as a single L section filter. This will consist of a choke connected in series with one of the DC leads and caoacitors connected between the positive and negative te=inals on "the output of the machine. (Se~ Page 11. for a typical circuit of a filter).

Many special features may be incorporated into the rectifier, such as secondary breaker protection, ala~ circuits, etc. "The best sources of circuit information are the lettered pages or added schematic diagrams in the rear of this Instruction Manual.

Insulation testers, such as Meggers or Vibra-grounds are preferred for high-potential circuit testing. However, if such is not available, a simple trouble light may be used.

As an example, if it is desired to check for a fault between the secondary of the transformer and case, disconnect the voltage adjustment link bars to isolate the secondary from the stacks. Then connect the trouble light between one of the hot AC primary lines coming into the unit and the secondary of the transformer. The hot line may be located by connecting the light between a line and ground. If it is a hot line, and the bulb is good, it will light. If there is no fault in the secondary, the light bulb will not glow.

7

4.

(2) If not, something farther ahead in the circuit is open.

Meter defective. a. Use accurate portable DC meters to check. b. Reolaces meters (or meter switches)

indicated. if

5. Transformer defective If AC line vel tage is applied to the primary, but none is measurable at the secondary, check to see if there is an audible hum coming from the transformer. a. If s,o, the primary is operating, but the

secondary is probably open. b. If not, the primary is probably open. c. Check the above conclusions by isolating the

transformer and checking the DC resistance of the windings with an ohmmeter. (l) Primary should have around l to 10 ohms

resistance. (2) Secondary should have 1 ohm or less. (3) If either of the resistances is cuite

high, the particular winding - is effectively an open circuit and the transformer will have to be repaired or replaced. Make sure that the high resistance is in the winding and not in some connection lug.

6. Circuit Breaker (or thermal overload protector) defective. If the contacts don't close, they should be repaired, or the breakers replaced.

B. If maximum DC output val tage obtainable at rated DC current is only about half what it should be, the trouble may be:

The machine is connected to rectifiers).

set low

for high line voltage but line (Dual-Input voltage

2. Half of the stacks are ooen-circuited in single phase machine, making the machine operate as a half-wave rectifier, instead of a full-wave rectifier.

3. Part of the stacks are open circuited in a threephase machine, making the machine operate as a single ~hasa rec~ifie:-, i::stead of a th:=ee-phase recti fie::-.

4. Stacks are aged badly.

9

STACK ~------~.-----------------------~--------~--------~-------n+

CAPACITORS

f\ISES

CHI"lKE

-11-

FOR CUSTOMER SERVICE

PLEASE RECORD THE PART NUMBER,

SERIAL NUMBER, & MODEL CODE OF

THIS UNIT AS PART OF YOUR

PERMANENT RECORD. PLEASE HAVE

THESE THREE ITEMS READILY

AVAILABLE WHEN CALLING FOR

SERVICE

THANK YOU!

AC RRF Af\ER !-'ANfl

I

~ N

'

CPS RECTIFIER

CPS

C-5

'7"JN' I I ! uuu u

C-7

B )UNO W!RE JJNCTION BOX

(EXIS1.) PUMP

HOUSE #61 7

_ ___/

OIL

SPILL COLLECTI')N TANK #4

----------1----

I

TRUCK FILL STAND

COLLECTION PAD

50.000 GAl.. TANKS

B-'

(EXIST.) WfLL

HOUSE

SPill. COLLECTION

TANK #3

2 ANODE LEADS

1 STRUCTURE lfAO p

C-2 CPS~

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l..EGEND

SEWER

FENCE

PUMP HOUSE POWER

VEHICLE DISPENSING ISLAND POWER

POWER REPORTED

CONTROL WIRING (REPORTED)

CPS CONNECTION WIRE

CATHODIC SYSTEM ANODE OR BOND POINT DESIGNATION

CPS ANODE

CPS BOND

PHO I 0 LOCA fiON

NOT TO SCALE

CATHODIC PROTECTION SYSTEM SITE PLAN FORT GREELY, ALASKA

~:>f?OJ. MGF>

G. SEVIYSOIJ DRAWFT.BY:-S.f3.K.

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WARNING! ELECTRICAL EQUIPMENT Direct all installation and servicing to properly trained and qualified personnel. Failure to correctly install or service this electrical equipment may expose you to dangerous voltage points or other risks resulting in injury or death.

Refer to the manual for further instructions.

INSTALLATION INSTRUCTIONS INSPECTION Inspect the packaging as well as the inside .and outside of the rectifier for shipping damage. DO NOT attempt to install or operate damaged equipment.

Inspect and tighten any hardware or wiring that may have come loose during shipment.

INSTALLATION - THE ENCLOSURE MUST BE PROPERLY GROUNDED Be sure AC voltage and phase correspond to the AC rating of the unit. That rating is on the serial number label on the inside of the front door. If the rectifier has dual ratings, be sure the Hi/Low voltage change buss bar is set for the input voltage.

Anodes should be· wired to the ( +) terminal; Structure to the (-) terminal.

Zero the DC meter(s) (analog only).

Set voltage taps on the lowest settings (A-1). 3-phase models must have each phase set to the same coarse and fine position. For startup of Automatic rectifiers, see manual.

If oil cooled, be sure oil is to fill line and that NEMA grade 10C uninhibited oil is used.

If air cooled, be sure there are no obstructions blocking air vents, louvers, or screen.

START-UP Turn AC circuit breaker to "ON" and check output via DC meters. If breaker trips or overheating is observed, turn breaker off and refer to manual for troubleshooting.

Adjust taps up one step at a time until desired DC current or voltage is obtained. DO NOT EXCEED RATED OUTPUT OF RECTIFIER!

For further information, refer to the enclosed manual.

REC. lNSTRl'CflOI<S 002 (11,97)

C. MISCELLANEOUS PRODUCT DATA

DIRECT I!IUAIAL W1RE INSTAl t AnON

BACKFll..L AND TAMP IN

SPECIFICATION~

A- 7S MM !3'1

WARNING TAPE AS F'ER SPECIFICATlO

SOIL.

/

-E CAN BE ENCL.OSC:OtN CO!-mNUOUS

NOTE: . L A.no<k and ltn.lc.t.uTe leads may be i:csuDaJ in the .wee tre:nc:h with ~ k:ads. It u not ~ab.-is:lble to insu.ll ?0"""=" or cathodic prot=ion system leads in the aame tr=h with ~ or SEP 11 •q? 1 A• ........ .

. : --.

DETAIL OF ANODE INSTAl I A'JlON

AHOOE CENTERING OCYIC:lr--~ AS PER Sf'ECif'IC-''TlON

A"'CCE OO'T)< AS I"!:R ~'TX>H •z' eEI.OW eoT'1"0M Of'" T...- _.....,

~·---- spr._c.l.Al rzrn c...veoN 5ACKFU...!.. AS PER SPECIF1C:A110N

a I AUCTURE CONNI!CT10N

'c::o.&.T COfo'IPI..E:I"EO CONNECTlOH WITH SPf:CIFlE:D SEAW'NT

NO'l'ES: I ~H "1'0 PIP£ AND E::XCA.VA'TE:TO

PEI'IMIT IHST"AL.J..A-notO OF STRUC'T\JRE LEAD.

l! lltEJo40'w'E. ~ FROM s:TE 01'" CONNECTIOH "1'0 BARE: SHIH'I' Sl"EEl.. IN nE: AREA OF"~ CUUo4P CONTACT wm; "THE PIPE •

.c SEAL c...a.MP AHO BARE METAL AS SP'ECIFlE:D.

. '_.:,··

CONDUCTOR· .• .-.

. ' . .. . . .....

-·· .. ·.·. '• \· ·.· .. ·

~ ., .

:- ··· .

·, .

•·:

I' ' "-

D -x---- -----}~-- --- x--·- --~x- -x-~-~x---

NOlL

(lyp.)

Anode cuiJic 'oulir~<J~ orH lcnulivo. Aduol routes will be field determined.

--------- 0.4;;;; 9;·--~K""K,_--,----------- ---··----- -------------- .. -

CORRf)IW COMfl ANIES, INC. iiiSGHW-ii1-- 1M .. Diil ___ ----- -· --

SJ.ti[ r CW![LAND • A llJ\NTA • CIIICAGO

IIOlJSTON • NEW ORlEANS • Sf AntE f'IIILAOfl PHIA • SAN fRANCISCO . ..,

---·.. . --------'-"""·--

NONE I '~ 1

Conceptuo I 1\node Lead Wire [~outing

tfp EITEOi Anode Techno:ogte:: (:;.·1,;;.:

Febr..oary 19. 1998

Alicia Self Corrpro Compames Inc. 11524 Mukilteo Speedway Suite 101 Mukilteo, WA 98275

Re: t/8' x. 48" Titanium Rods Coated with EC-600 STD Mixed Metal Oxide Coating

Dear Al1cia:

The referenced anode material nae; a rating of 0.8 amps in coke breeze fer a 20 year life. Sin~ the anode has a surface area of 0.1 3 square feet. the calculated current cens1ty is 6.1 amps oer square foot. This rating was developed by perfcrm:ng accelerated life tes1s in coke breeze. The enc::osec graphs show the results at the accelerateo hfe tests. Current Density is p:otted on the X axis and life is plated on the Y axis m un•ts of~ .000 hours. 3oth ax.es are pJotteo in Jog scale.

For an anooe to last 20 years, the equivalent life Is 175,200 hours or 175.2 x 1,000 hours. The nor1zcmalline near the top of the grapn represents this target c1 175,200 hours or 20 years of lifetime. 'l1e EC-600 STD coating is shown as 1 00% leading on the graphs. The graphs show that at the ooerating cu:-rent density of 6.1 amps per square foot, rne equivalent lifetime IS well aoove the target of 175,200 hours.

If you nave eny questions or would like to discuss, please contact me at (440)28!5. ::351.

Enclosures

HMWPE Direct Burial Cable

Multi-Purpose Cathodic Protection Cable Selecting the right cable for con.'1ecting anodes, power supplies, a-'1d structures is an important part of any cathodic protection design. Harco makes this selection process easy by offering a cable manufactured speciiically for the cathodic protection industry. It is composed of copper wire which is covered by high molecular weight polyethylene (HMWPE). The copper wire is stranded and annealed to pennit extra flexibility. Because the polyethylene on the cable is approximately twice as thick as on conventional HMVVPE wire, it serves as both elect.rical ii1sulator and mechanical cover for the conductor. This provides Harco' s cathodic protection cable with outstanding dielectric strength and moisture resistance. During L'1stallation the cable can withstand considerable mechanical abuse without risk of damage to the copper electrical conductor. The polyethylene cover is also chemically resistant and protects against most organic and inorganic sub-

stances.

Harco's HMWPE cable is manufactured according to strict quallty control standards. The polyethylene coating is made to meet American Society for Testing Materials Standard D -1248 for plastic molding and e>:truded materials In addition, routine tests are performed to ensure that the cable possesses certain mechanical and electrical properties.

Typical Applications HMVVPE cable is offered in a variety of sizes. It can be used as a header cable on cathodic protection systems or to make anode lead or negative return connections The thick polyethylene cover permits direct burial of the cable in native soils or submersion in fresh water The cable ex.'lib1ts superior flexibility a:1d ca:1 be be:lt Wlthout risk of notch propagation lt is not recommended for use m envuonments containing chlorine. hydrochlonc acid, or petroleum hydrocar-

bons.

Ordering Procedure Harco 's HMWPE cable is readily stocked in a range of wire sizes and is available for immediate shipping. To order the right cable for your particular application, indicate that you need Harco HMWPE cable and specify the lineal feet and wire size desired. An example is provided to help illustrate this process.

Ordering Procedure Example

ITEM EXAMPLE

Quantity (Lineal Feet) 2.000 It

Wire Size #4AWG

Wire Type HMWPE -

(

WIRE SIZE

AWG lmm~

14 12.5)

12 (4)

10 16)

~ 8 (10)

6 116)

4 '(25)

2 . 135)

1 145)

1/0 (50)

2/0 (70)

4/0 1:20)

HMWPE Direct Burial Cable

COPPER CONDUCTORS~

11

~ J

-'-- HIGH MOLECUlAR WEIGHT POLYETHYLENE

HMWPE Order Information NUMBER INSULATION NOMINAL

OF THICKNESS 0.0. STRANDS in (mm) in lmm)

7 0.11 12794) 0.299 17 59)

7 0.11 12.794) 0.31 (7.87)

7 0.11 12.794) 0.34 18.64)

7 0.11 (2794) 0.36 19.14)

7 0.11 12.794) 0.41 110.41)

7 C.ll (2 794) 046 (11.68)

7 0.11 (2.794) 0.52 113.21)

19 0.125 13.175) 0.59 114.99)

19 0.125 (3.175) 0.63 (16.00)

19 0.125 (3.175) 0.67 117.02)

19 0.125 (3.175) 0.78 (19.81)

HARCO MUKILTEO 7929 44TH AVE W. SUITE F MUKILTEO WA 98275

ATTN: ALICIA - REFERENCE: PO~ 6455 & JOB~ 650-0090

GOOD-ALL ELECTRIC INC MEDINA, OHIO CATHODIC PROTECTION RECTIFIER QUOTE PREPARED BY BOB KOZICKIE

QUOTATION NO 975972

PHONE 330-722-5102 FAX 330-722-2110 DATE 10-23-1997 =:===~=======:==============================~:=========~~==========x;= Fb_,-, Nt.

SAYSL*50-5***EGNPZ = OTY = 1

Custom Air Cooled Rectifier - Silicon Stack AC !nout = 120/208/240VAC; Single Phase; 60HZ I-nput Current = 3.09/1.78/1.55 Amps CASE SIZE AND WEIGHT = A3 286#

Option E = Option G = Option H = Option N = Option p = Option s =

CONTINUOUS READ METERS EFFICIENCY FILTER - IMPROVES EFFICIENCY UP TO 15% 25 TAPS ON TRANSFORMER STANDARD LIGHTNING PROTECTION ON BOTH IN AND OUT HOT DIPPED GALVANIZED CASE - ETCHED AND 11 GAUGE CABINET

SPECIAL CASE FINISH AC ELAPSED TIME METER

POWDER COATED WHITE

OPTION Z( ) = OPTION Z( 072) = OPTION Z( ) = THREE EACH THREE OHM ROTARY RHEOSTAT SHUNTS, SWITCHING

FOR READING AMPS AND LUGS IN POSITIVE DC OUTPUT LEG PER RECTIFIER OUTPUT DETAILS.

OPTION Z( ) = FOUR EACH DC NEGATIVE OUTPUT LUGS

----------------------------------------------------------------------GOOD-ALL ELECTRIC WILL NOT ACCEPT ANY DELIVERY PENALTY CHARGES OR LIQUIDATED DAMAGE CHARGES ON ANY ORDER. PRICE AND DELIVERY QUOTED ARE VALID FOR 60 DAYS; FOB MEDINA, OHIO 44256 ESTIMATED SHIP DATE: 12 WEEKS AFTER RECEIPT OF ORDER (Please confirm shipping schedule at time of order) TERMS ARE NET 30 W!TH APPROVED CREDIT *** VISA/MASTERCARD PURCHASES AVAILABLE FOR YOUR CONVENrENCE ***

REGARDS - 808 KOZ!CKIE

., •••

"- . _-__ , -.. - ... -.--

C. E. Equipment Company, Inc./ LORESCO International, Inc.

PO.Bax 1089 Hattiesburg, MS 39403

(601) 544-7490 Fa: (601) 544-7531

F.AX TRANSMISSION COVER SHEET

Dt#e: May 20, I 998

To: Cmt:r4l Errvtmnmtal/Lis11. Biskup

Fta Nll: 907-561-0178

Rt: Infomultion on WRESCO Type SC-3

Snckr: Dtbunth R W'NAt/Assistlvlt Offia Mll1ltzpr

YOU SHOULD RECEIVE I+ PAGE(S), INCLUDING THIS COVER SHEET. IF YOU DO NOT RECEIVE ALL THE PAGES, PLEASE CALL (601) 544-7490.

Resistivity on LORESCO Type SC-3 is less than one temh of ohm em and 150 PSI.

THIS CARBON IS CALCINED

INIMUM TEMPERATURE OF

UNDER VERY EXACTING AND

STANDARDS. THIS STEP

SEMI-GRAPHITIZED

WITH EXCELLENT

TO FURTHER

_CONDUCTIVITY,

SURFACES OF THE INDIVIDUAL

RTICLES ARE MODIFIED TO

ANCE THE CONTACT

THIS BREAK·

THROUGH IN

·SURFACE

ALTERATION

ENSURES

MAXIMUM

ELECTRONIC

CURRENT

TRANSFER WITH POSITIVE ANODE

::~~NT ACT .iiiUdiN A SPECIALLY

FORMULATED SURFACTANT IS ADDED

TO REDUCE PARTICLE SURFACE

_TENSION FOR COMPACT SETTLING

UNDER WATER.

HAS A BULK DENSITY

FOOT. THE

CARBON CONTENT IS GREATER

BY WEIGHT. THE BULK

AND HIGH FIXED Cj\.~-B01f'

c ou ~~_E.o.-w-rnr·;:~~ ---_A_?.!iU.RE·n··cow RESISTIVITY MEDIUM

ALLOWS FOR LONGER GROUNDBED

LIFE AT A LOWER OPERATING COST.

---

.087 6.4 15.70 640

6" 14.3 6.99 1430

, a• .349 25.5 3.93 2550

.545 39.8 2.51 3980

.784 57.2 1.75 5720 <"'""--

Installation

~ :~cc,··<_,;, .. ':r,{ ;~.;t&;;i;•·~~~; ~·········· lORESCO.SC·~f; DUE".fi:l: LTS~.

'ousT-FREE MANUFACTURE.. IS

SIMPLE TO !NSTA~L BY

EITHER MIXLNG AND PUMPING oR' BY POURI.NG,. WITH DEEP•

ANODE SYSTEMS! PUMPING

FROM THE BOTTOM UP IS' 'ccX• REc()MMENDED·:·· LoREsc'cr sc:::3· HAS' SUPERB PUMPING'_-·

QUALITIES DUE TO THE

ADDITION OF SURFACTANT$ AND WHEN AGITATED IN

WATER. TAKES ON THE CHARACTERISTICS OF HEAVY

MUD. A RECOMMENDED MIX IS

SEVEN GALLONS OF WATER PER

ONE-HUNDRED POUNDS. AFTER INSTALLING SC•3, ALLOW

TWENTY-FOUR HOURS SETTLING

TIME BEFORE ENERGIZING.

THE MODIFIED SURFACE OF

THE CARBON PARTICLES

COUPLED WITH THE ACTION OF

THE SURFACTANT& IN SC•3 WILL ACHIEVE POSITIVE ELECTRICAL CONTACT BY

SETTLING. VIBRATING OR

COMPACTING IS NOT

NECESSARY.

Material OesCPiption

<.·:·~.· ,

' ·'-"'<"':•'•l:i."' ;··;_,.·.-.-.. >,+~--t.·~--~:"5-~<.-; ,,_ -. ., .... _, .. ·:;; ,?,•~~:

Specilicatiuns -·--':'." :''""~,_--

- ~ Butt2~DENS!TY ,:"}4 . PER CUBIC FOOT

~- PREDOMiNANTLY ROUND

PARTtCLES

~ · ALL·•~ART I CLES. SUR FACE

MODI FlED" FOR 'MiXIMUM:

ELECTRICAL CONDUCTrVrTY

~ PARTICLE S !ZiNG: To BE DUST FREE WITH A MAXIMUM PARTICLE sizE ·aF lMM-

~: ·M;N;MUM CALcrf.tkiON

~

~

~

TEMPERATURE OF BASE•·

MATERIALS IS 1250° C

BASE MATERIALS ARE

CALCINED UNDER ISO 9002 QUALITY CONTROL

SURFACTANT& ARE ADDED TO

ASSIST PUMPING AND

SETTLING

No DE-DUSTING OILS ARE USED DURING THE

MANUFACTURE OF BASE

PARTICLES

·'

Shipping Data

LORESCO SC•3 IS SHIPPPED IN ONE-HUNDRED POUND UNIT

WITH POLYETHYLENE INNER

LINERS AND A WOVEN POLYPROPYLENE OUTER_LINER

SC•3 MAY BE STORED,OUTS FOR LIMITED PERIODS:. (NOT

TO EXCEED FOUR-HUNDRED

HOURS OF SUNLIGHT).

PALLETS ARE AVAILABLE WIT TWENTY-FIVE UNITS PER

PALLET. PROVE!'! EXPORT

PACKAGING IS AVAILABLE.

SC•3Works

LORESCO SC•3 REPRESENTS TECHNOLOGY DEVELOPED

EXCLUSIVELY FOR HIGH

CURRENT CATHODIC

PROTECTION INSTALLATIONS.

SC•3 WILL SATISFY ALL FUNCTIONING REQUIREMENTS

FOR A PREMIUM EARTH

CONTACT BACKFILL. SPECIFY

LORESCO SC•3. IT WORKS.

FIXED CARBON: 99.54%

ASH: 0.41%

MOISTURE: 0.05%

·VoLATILES: 0% (950° C)

LORESCO SC•3 IS A SURFACE MODIFIED.

BLENDED, AND SIZED CARBON BACKFILL WITH SURFACTANT$.

P. o. Box 1089 Hattiesburg, MS 39403 USA

Phone 601.544.7490 Fax 601.544.7531

'

'" -·- •.a · - ........ I """'lliiiiil._l:: 'P.r'ld~rground .War-ning Tapa

Magna Tee® The standard detedable product used for locution and ~ warning protection for underground lines. • Multl·loyor Cllllstrvclfon offers permanllftce of message,

stnagth 1111d focm&ifity. • No ink extends to rht tdgo of rho rape providing the strongt~r bond between layers to prevent delamination.

• Bold biCKk letters indude menage and inslallatfon rocommendallan.s.

• Silvor !oil shows through on llle !rani and 1M bade lor a:mUaat dig·in visibility.

Use wirhsl I~ pcmibk rut# bury as das• Ia tilf surfDc. a fii'IKiicrzl •

• . WATI:R UDUTY TAPE- MAGNAT£C

STOCK lt.m No. '- W!c:' .. ~ X L.e~ _Me~ .. 3,-0'2, 2' :0:. 1000:' CAUTJON WATER LINE BELOW 31ooin:! J .. 1. 10CO' CAUT!ON WATE~ UNE BELOW ,,-0:24 s· x ~coo· CALFTlON WATER LINE SELOW 3,·WU4 2":x.~OCO' CAU710N WATE~ LINE 6E!..O\o\' 31..052 2' X 1000' CAUT10N SEWER LINE 9ELOW 31·053 ' ~ ~ oc~· CAU71CN SEWER LINE 3E:.cw 11.0S.5 a·· ;s; ~COC' CAV.iON SEWE~ LINE SELOW 11·100 :;·· .x 'COO' CAUTrON RECI..A!MEC WATER

3E!-OW 0C NOT :JR1NK 3,~122 Z' ;s; 'CCC' CAL.:T!CN .ec~CE MAIN BS.!_OW

:USTOM lem No. w~_:;_Ler:g~ c;·O!or Pl<;: O:y.

Mill21 2.' .X 1000' 6i-.:e/sihter Sulk '1TQ3i J"xtCOO' G~eer1l$1lver Sullo:

GAS UTILITY TAPE • MAGNATEC TOCK

llvm No. Wi~_., X lsl"!gtl'! Message --~,40 2·x:oco· CAUTION GAS LINE 3ELOW

•14.1 3' X ~000' CAVifCN GAS L.INE BELOW ·143 e· x 1ooo· CAU!ION GAS LJNE BELOW

31~G144 z·· .x tOCO' CAV710N GAS LJNE SE~CW 3HJS7 z· x 1oco· C.:..IJTICN 0!\. LINE SELOW

I JSTOM rtem No. Wie:h x Length Color Pk<g. Oty. MT"Y2, 2" X 1000' Ve!lowl;ilver Bulk I "YJ, :r x 1coo· Yl!Uow/silver Sulk l 'Y61 s· x toao· Yeliowlsilvsr Bulk

Cott:ir

Blueisil~r

91uaJsilver 9Jue/s-1iver Slt.ie!sliver

Greent9Jive· Greer:/s;/ve: GrHn/sJivl!!lr

?.,r:l!Ghtilver

":'ar.lsli"'!•

Mi~-- or::er 72 '-0

Color

YeUowiSJl"--.re~

Yeuow/Siiver Ye!!owisilver Yei!ow/srl'f!lr

Orange/Sliver

Mir:. Or::sr

72 48 24

:)'' lndv. wt Pkg. Qty. _Pl<g. Los.: ' ' ., 5.0 6 JO.S ·,.,.

• ., ..

7.0 4 30.5 14 0 2 30.5

........ "

5.0 1"-4 725 ·'

5.0 6 30.5 . •' 7.0 " JC . .S :-:·

140 2 30 5 70 " 3C.S

5.0 6 30.5 '

!r:dv. 'N":. Myl!iple

5.0 72 1.0 48 ..

:_.-__ ., .. v~- <,. . .

'. !nav WL Pl<g. C.~. Pkg. Los.

5.0 6 30.5 ..

7.0 4 30.5 14.0 2 30 5 50 ,.. 725 5.0 6 305

lr:::01. Wt. Mu!~ple . .....,) 5.0 72 7.0 4a ,~_o 24

I~-.-

'

n

--

V'

~tround Fittings , · *

Bronze Alloy Ground Oamp

Use: Ground clamps for bare copper conductor. can be used on water pipes, conduits, or pipe electrodes. Made of Cast Bronze Alloy 85·5-S-5 copper. For insulated or bare conductor wire, Copper AWG lt2 through #1 0. Camp Is reversible. Installed as per the National Electrical Code Article 250· Groundln9. Meetl or exc~eds the requirements of UL 4S7 and NEMA FB-1. Conforms to Federal Specification W-F-4060. Type S. Class 7. Sl)'le S ..

< .• ,; ~:;; r .. ;. ::.·. Calalos urc No. ·r Tnade ..

• Nim.l.er 7114 795- . Si:tc 'l.... .. '· ! . l'' ar--··"' .$C·1J 25001 t ~;,1.":-<iC-~ • · 25002 • 1-!'"·2" Gi:-4 ~ 2so04 2-IS•~4'

·G'c-6·"· 25006 '4-~.;:6. l.~ . .. ·:.: ~ .. :u ..:.

Ca~rluo Quanlily

25 Bulk Bulk Bulk

GC·l tilrough GC-4 UL File No. E88878

Dimensions (inches) ~-L"'-~-r:·. '; ; ~·~ .~ ; .. Cru. No.. A ::· B, C

f'1.,,~ ~ • .' ·~ ·; ..-. GC-1.VA 2.28 t.Q..~3 .. : 0.70-1.89 :G,t-2~~~~ 3.62 ~cr~·~-~ .11.38·2.97 ,GC.~"' :

1l 6.38 t· Q:33 ~ 2.73-5.94

,~s:s.;•.<:l 8.50 r_J-1.o.:;i.2.66-7.75 -.:o..-'"o .. ,, ii a:~~ ,J.

Bronze Alloy Ground Rod Clamp Bron::e Screws for Direct Burio.l

T A

j_ -11--B----\r-

Use: To terminate bare copper conductor directly to ground rod. Suitable for direct burial applications.

Made of cast Bronze Alloy 85·5·5·5 copper. Installed as per the National Electrical Code Artide 251lGroundlng. Meetl or exceeds the · requirementl of UL 467. CSA C22 2 No. 18-1992. and NEMA FB-1. Conforms to Federal Specification W-F-406D. Type 5, Class 7. Sl)'le s.

A

1.22 1.41 1.47

Wtre Ro.nge

#2 through #10 •S through 11/~ #B through 1110

®

SECTION VII

PHOTOGRAPHS

PHOTO 1: TYPICAL CABLE TRENCH

· WITH EXISTING POL PIPING

PHOT02: TYPICAL CABLE TRENCH

WITH SAND GEO AND CABLE LEADS

PHOT03: CLOSE DET AL PHOTO

CABLE LEADS WITH COLOR CODING. WHITE MARKED CABLES ARE STRUCTURE LEADS

RED/YELLOW MARKED CABLES ARE ANODE LEADS

PHOT04: TYPICAL ABOVEGROUND STRUCTURE

PIPE CLAMP CONNECTION

PHOTOS: TYPICAL UNDERGROUND STRUCTURE CLAMP

CONNECTION WITH PIPE WRIPINGS.

PHOT06: TYPICAL BACKFILLCABLE TRENCH WITH TRACEABLE MARKER TAPE

"CATHODIC PROTECTION CABLE BURIED BELOW".

PHOTO?: RECTIFIER AND STRUCTURE LEAD

JUNCTION BOX.

SECTION VIII

UNDERSTANDING CATHODIC PROTECTION

UNDERSTANDING CATHODIC PROTECTION

To have an effective cathodic protection maintenance program it is important that personne I

responsible for monitoring understand the basic principles on how the systems work. This

section of the manual is devoted to giving these persons a better understanding of why metals

corrode and how cathodic protection achieves corrosion control.

When metals are made they must first be recovered from the environment in their natural state.

An example of this is that iron is mined in the form of iron-oxide (what we call rust). This oxide

is then processed through refining and heating to form steel. The steel is then molded into

pipelines and other structural configurations. When this steel is placed in the environment,

however, it immediately begins to release energy and reverts back to it's original state, rust. The

process by which the steel reverts to rust is known as corrosion.

When steel corrodes it releases the energy it acquired when it was refined. This energy is

released in the form of electrical current discharged into the soil or water.

The release of energy is the result of reactions the steel has with the surrounding environment.

For instance, a pipeline may corrode due to differences in soil compaction and moisture where

the line passes under a road or stream because of varying oxygen levels, or when it is connected

to other metals such as copper. Each small amount of energy released causes iron particles to

leave the pipe's surface. These particles accumulate and eventually form visible rust nodules.


Section VIII- Understanding Cathodic Protection

Page I of 4

To control corrosion, the release of electrical energy from the metal's surface must be stopped.

This can be accomplished in a number of ways which includes coatings and cathodic protection.

Coatings are commonly used to, in essence, separate the metal from the environment. Thus, the

metal cannot react or corrode. No coating is perfect however, and small flaws exist or develop

later. These flaws, commonly called holidays, are the result of damage during transportation,

installation and burial of the pipeline, as well as imperfect applications. Since the metal is

exposed, corrosion will be initiated at each of these flaws once the line is buried.

To control corrosion at coating flaws and on bare structures, cathodic protection is commonly

applied. Cathodic protection is a method in which an electrical DC current is applied to the

metal surface from the soil or water. When this applied current equals or exceeds the current

leaving the metals surface, corrosion is stopped. The current is applied from an expendable

anode placed in the soil or water in the proximity of the structure protected.

All cathodic protection systems pass current through the soil or water from anodes connected to

the structure that is to be protected. Two basic types of cathodic protection are employed.

Sacrificial anode material, such as magnesium or zinc, is used to create a galvanic cell. Such

anodes are selfenergized and are connected directly to the structure to be protected. When the

anodes are connected they begin to corrode and discharge current into the soil which is received

by the pipeline. These anodes are usually used where it is desirable to apply small amounts of

current to achieve corrosion control. This usually limits their use to well coated, electrically

isolated structures.


Section VIII -Understanding Cathodic Protection

Page 2 of4

The other basic method employs anodes energized by a direct current power supply known as a

rectifier. This method, commonly referred to as "impressed current", employs relatively inert

anodes (graphite, high-silicon cast iron, platinized niobium, titanium oxide) connected directly to

the positive terminal of the rectifier. The structure being protected is then connected to the

negative terminal to complete the electrical circuit. DC current is then forced from the anodes to

the structure. These systems are generally used where large amounts of current are required.

such as extensive pipeline networks, storage tanks and condensers.

The selection of cathodic protection equipment to be used in any given application is also of

utmost importance. A wide variety of rectifiers are available, including air-cooled, oil-

immersed, and automatic units. The range of voltage and amperage output is almost infinite.

Selection should be based on the particular requirements of the "project", as determined by

thorough, comprehensive engineering efforts.

Anodes which serve to distribute the direct current into the earth or water are manufactured from

various metals. Graphite, high-silicon cast iron, platinum, magnesium, aluminum, and zinc

alloys are commonly used. Each material has its own particular application, and the evaluation

of their use is commonly a determining factor in the success or failure of a cathodic protection

system.

Some cathodic protection systems use dielectric flanges to electrically isolate the pipelines

protected. By isolating the pipelines, all of the cathodic protection current is received by the

intended line. If the pipeline were not isolated, a portion of the current would be intercepted by



Page 3 of 4

other nearby metallic structures such as ground cables and rebar. In some instances, especially

power stations and chemical plants, the amount of current intercepted can be greater than the

amount that actually reaches the piping to be protected. Therefore, generally large amounts of

current are required to overcome the other structures and protect the shorted pipeline. Usually

pipelines and other structures that are not isolated require an impressed current system. Galvanic

anodes do not have the capability to supply sufficient current when the lines are shorted or

poorly coated.

Through proper engmeermg practices, material and system selection, and installation and

maintenance procedures, cathodic protection can extend the useful life of any structure being

protected.



Page 4 of4

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