Attch_4_CATHODIC PROTECTION SYSTEM (SACRIFICIAL ANODE).pdf

SECTION 26 42 14.00 10

CATHODIC PROTECTION SYSTEM (SACRIFICIAL ANODE)

PART 1 GENERAL

1.1 REFERENCES

1.1.1 The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. Unless other wise noted, the latest published version and/or revision shall be used.

1.1.1.1 ASTM INTERNATIONAL (ASTM)

a. ASTM B 418 Standard Specification for Cast and Wrought Galvanic Zinc Anodes

b. ASTM B 843 Standard Specification for Magnesium Alloy Anodes for Cathodic Protection

c. ASTM D 1248 Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and Cable

1.1.1.2 NACE INTERNATIONAL (NACE)

a. NACE SP0177 Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems

b. NACE RP0190 (Withdrawn 6-2002) External Protective Coatings for Joints, Fittings, and Valves on Metallic Underground or Submerged Pipelines and Piping Systems

c. NACE RP0193 External Cathodic Protection of On-Grade Carbon Steel Storage Tank Bottoms

d. NACE RP0274 High-Voltage Electrical Inspection of Pipeline Coatings

e. NACE RP0285 Corrosion Control of Underground Storage Tank Systems by Cathodic Protection

f. NACE SP0169 Control of External Corrosion on Underground or Submerged Metallic Piping Systems

g. NACE SP0286 Electrical Isolation of Cathodically Protected Pipelines

1.1.1.3 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA TC 2 Standard for Electrical Polyvinyl Chloride (PVC) Tubing and Conduit

1.1.1.4 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 70 National Electrical Code

1.1.1.5 U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

a. 40 CFR 280 Technical Standards and Corrective Action Requirements for

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FA2517-13-R-5000

Attachment 1 6 June 2014

Owners and Operators of Underground Storage Tanks (UST)

b. 49 CFR 192 Transportation of Natural and Other Gas by Pipeline: Minimum Federal Safety Standards

c. 49 CFR 195 Transportation of Hazardous Liquids by Pipeline

1.1.1.6 UNDERWRITERS LABORATORIES (UL)

a. UL 510 Polyvinyl Chloride, Polyethylene, and Rubber Insulating Tape

b. UL 514A Metallic Outlet Boxes

c. UL 6 Standard for Electrical Rigid Metal Conduit-Steel

1.2 SUBMITTALS

1.2.1 Government approval may be required on any of the following items. Items requiring submittals will be listed on the Submittal Register. Provide copes of all submittals per the requirements in Section 01 33 00, Submittal Procedures, or as listed on the Submittal Register.

1.2.1.1 SD-02 Shop Drawings

a. Drawings

(1) Copies of detail drawings consisting of a complete list of equipment and material including manufacturer's descriptive and technical literature, catalog cuts, results of system design calculations including soil-resistivity, installation instructions and certified test data stating the maximum recommended anode current output density and the rate of gaseous production if any at that current density. Detail drawings shall contain complete wiring and schematic diagrams and any other details required to demonstrate that the system has been coordinated and will function properly as a unit.

b. Contractor's Modifications

(1) Copies of detail drawings showing proposed changes in location, scope of performance indicating any variations from, additions to, or clarifications of contract 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 proper installation and performance of the system.

1.2.1.2 SD-03 Product Data

a. Equipment

(1) Within 30 days after receipt of notice to proceed, an itemized list of equipment and materials including item number, quantity, and manufacturer of each item. The list shall be accompanied by a description of procedures for each type of testing and adjustments, including testing of coating for thickness and holidays. Installation of materials and equipment shall not commence until this submittal is approved.

b. Spare Parts

(1) Spare parts data for each different item of material and equipment specified, after approval of detail drawings and not later than six (6) months prior to the date of beneficial occupancy. The data shall include a complete list of parts, special tools, and

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Attachment 1 supplies, with current unit prices and source of supply. One (1) spare anode of each type shall be furnished.

1.2.1.3 SD 06 Test Reports

a. Test and Measurements

(1) Test reports in booklet form tabulating all field tests and measurements performed, upon completion and testing of the installed system and including close interval potential survey, casing and interference tests, final system test verifying protection, insulated joint and bond tests, and holiday coating test. A certified test report showing that the anode to lead wire 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 three percent sodium chloride solution.

b. Contractor's Modifications

(1) Final report regarding Contractor's modifications. The report shall include pipe-to-soil potential measurements throughout the affected area, indicating that the modifications improved the overall conditions, and current measurements for anodes. The following special materials and information are required: taping materials and conductors; zinc grounding cell, installation and testing procedures, and equipment; coating material;

system design calculations for anode number, life, and parameters to achieve protective potential; backfill shield material and installation details showing waterproofing; bonding and waterproofing details; insulated resistance wire; exothermic weld equipment and material.

1.2.1.4 SD-07 Certificates

a. Cathodic Protection System

(1) Proof that the materials and equipment furnished under this section conform to the specified requirements contained in the referenced standards or publications. The label or listing by the specified agency will be acceptable evidence of such compliance.

b. Services of "Corrosion Expert"

(1) Evidence of qualifications of the "corrosion expert."

(a) The "corrosion expert's" name, NACE certification number and qualifications shall be certified in writing to the Government prior to the start of construction.

(b) Certification shall be submitted giving the name of the firm, the number of years of experience, and a list of not less than five (5) of the firm's installations three (3) or more years old that have been tested and found satisfactory.

1.2.1.5 SD-10 Operation and Maintenance Data

a. Cathodic Protection System

(1) Before final acceptance of the cathodic protection system, copies of operating manuals outlining the step-by-step procedures required for system startup, operation, adjustment of current flow, and shutdown. The manuals shall include the manufacturer's name, model number, service manual, parts list, and brief description of all equipment and their basic operating features. Copies of maintenance manual, listing routine maintenance procedures, recommendation for maintenance testing, possible breakdowns and repairs, and troubleshooting guides. The manuals shall include single-line diagrams for the

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FA2517-13-R-5000

Attachment 1 system as installed; instructions in making pipe-to-reference cell and tank-to-reference cell potential measurements and frequency of monitoring; instructions for dielectric connections, interference and sacrificial anode bonds; instructions shall include precautions to ensure safe conditions during repair of pipe or other metallic systems. The instructions shall be neatly bound between permanent covers and titled "Operating and Maintenance Instructions." These instructions shall be submitted for the Government's approval. The instructions shall include the following:

(a) As-built drawings, to scale of the entire system, showing the locations of the piping, location of all anodes and test stations, locations of all insulating joints, and structure-to-reference cell potential test points as measured during the tests required by Paragraph: TESTS AND MEASUREMENTS, of this section.

(b) Recommendations for maintenance testing, including instructions in making pipe-to-reference cell potential measurements and frequency of testing.

(c) All operating and maintenance instructions and nameplate data shall be in English.

(d) Instructions shall include precautions to insure safe conditions during repair of pipe system.

b. Training Course

(1) The proposed Training Course Curriculum (including topics and dates of discussion) indicating that all of the items contained in the operating and maintenance instructions, as well as demonstrations of routine maintenance operations, including testing procedures included in the maintenance instructions, are to be covered.

1.3 GENERAL REQUIREMENTS

1.3.1 The Contractor shall furnish and install a complete, operating, sacrificial anode cathodic protection system in complete compliance with NFPA 70, with all applicable Federal, State, and local regulations and with minimum requirements of this contract. In addition to the minimum requirements of these specifications, construction of gas pipelines and associated cathodic protection systems shall be in compliance with 49 CFR 192 and construction of hazardous liquid pipelines, including fuel pipelines, and associated cathodic protection systems shall be in compliance with 49 CFR 195 and construction and installation of underground fuel storage tanks and associated cathodic protection system shall be in compliance with 40 CFR 280. The services required include planning, installation, adjusting and testing of a cathodic protection system, using sacrificial anodes for cathodic protection of the Water, Fire Protection, Force Main, Gas lines, Liquid fuel and underground fuel storage tanks their connectors and lines under the slab or floor foundation. The cathodic protection system shall include anodes, cables, connectors, corrosion protection test stations, and any other equipment required for a complete operating system providing the NACE criteria of protection as specified. Insulators are required whenever needed to insulate the protected pipes from any other structure. Any pipe crossing the new piping shall have a test station. The cathodic protection shall be provided on metallic Water, Fire Protection, Force Main, Gas, Liquid Fuel Piping and underground Fuel Storage Tanks.

1.3.2 Services of "Corrosion Expert"

1.3.2.1 The Contractor shall obtain the services of a "corrosion expert" to supervise, inspect, and test the installation and performance of the cathodic protection system. "Corrosion expert" refers to a person, who by thorough knowledge of the physical sciences and the principles of engineering and mathematics, acquired by professional education and related practical

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Attachment 1 experience, is qualified to engage in the practice of corrosion control of buried or submerged metallic surfaces. Such a person must be certified by NACE International (NACE) as a NACE certified Corrosion Specialist or a NACE certified Cathodic Protection (CP) Specialist or be a registered professional corrosion engineer who has certification or licensing that includes education and experience in corrosion control of buried or submerged metallic piping and tank systems. The "corrosion expert" shall make at least 4 visits to the project site. Before materials are ordered and before the first visit, the "corrosion expert" shall review the requirements with the Installation Contractor , review and approve the equipment and materials to be used (Submittals), and review or prepare installation drawings for the cathodic protection required.

The first of these visits shall include obtaining soil resistivity data and acknowledging the type of pipeline coatings to be used. Using the information obtained the "corrosion expert" will furnish the contractor with a cathodic protection design that will provide cathodic protection to the required underground metallic piping and/or fittings. The "corrosion expert" shall review or prepare installation drawings for the required cathodic protection and review and approve the equipment and materials to be used (submittals). Once the submittals are approved and the materials delivered, the "corrosion expert" shall revisit the site to ensure the Contractor understands installation practices and laying out the components. The "corrosion expert" shall supervise installation of all cathodic protection. The third visit shall involve testing the static or unprotected potential of the structures that are to be protected and to connect the structure lead wire to the anode by way of the installed shunt after static potential measurements of each system are recorded. The "corrosion expert" shall verify the contractors installation procedures are in accordance with the plans and specifications. There shall be at least four weeks between the time the anodes are connected to the structure and the fourth visit to allow the protected structure to become polarized. The fourth visit shall involve final testing of the installed cathodic protection systems and training applicable personnel on proper maintenance techniques. The "corrosion expert" shall complete the final testing of all cathodic protection and conduct training course.

1.3.3 Contractor's Modifications

1.3.3.1 The specified system is based on a complete system with magnesium sacrificial anodes. The Contractor may modify the cathodic protection system after review of the project, site verification, and analysis, if the proposed modifications include the anodes specified and will provide better overall system performance. The modifications shall be fully described, shall be approved by the Government's representative, and shall meet the following criteria. The proposed system shall achieve a minimum pipe-to-soil "on" potential of minus 1000 millivolts with reference to a saturated copper-copper sulfate reference cell on the underground components of the piping or other metallic surface. The Contractor shall take resistivity measurements of the soil in the vicinity of the pipes and ground bed sites. Based upon the measurements taken, the current and voltage shall be required to produce a minimum of minus 1000 millivolts on potential between the structure being tested and the reference cell. This potential shall be obtained over 95 percent of the metallic area. The anode system shall be designed for a life of twenty-five (25) years of continuous operation.

1.3.4 Isolators

1.3.4.1 Electrical isolators are required to insulate the cathodically protected pipes from any other structure in accordance with NACE SPO286. Isolators on aircraft fueling systems shall be provided with lightning protection and a test station as shown.

1.3.5 Bond Wires

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1.3.5.1 For each cathodic system, the metallic components and structures to be protected shall be made electrically continuous. All joints except welded and screwed joints shall be bonded together.

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. The bond wires shall be number 8 AWG copper with underground insulation.

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 be included under this section. All tests shall be witnessed by the Government Inspector.

1.3.6 Surge Protection

1.3.6.1 Approved zinc grounding cells or sealed weatherproof lightning arrestor devices shall be installed across insulated flanges or fittings installed in underground piping as indicated on the drawings. The arrestor shall be gapless, self-healing, solid state type. Zinc anode composition shall conform to ASTM B 418, Type II. Lead wires shall be No. 6 AWG copper with high molecular weight polyethylene (HMWPE) insulation. The zinc grounding cells shall not be prepackaged in backfill but shall be installed as detailed on the drawings. Lightning arrestors or zinc grounding cells are not required for insulated flanges on metallic components used on nonmetallic piping systems.

1.3.7 Summary of Services Required

1.3.7.1 The scope of services shall include, but shall not be limited to, the following:

a. Close-interval potential surveys. Spacing shall not exceed 25 ft.

b. Cathodic Protection Systems.

c. System testing. Static potential test before anodes are connected to structure.

d. System testing, Final.

e. Interference testing.

f. Training.

g. Operating and maintenance manual.

h. Insulator testing and bonding testing.

i. Coating and holiday testing shall be submitted within 45 days of notice to proceed.

1.3.8 Nonmetallic Pipe System

1.3.8.1 In the event pipe other than metallic pipe is approved and used in lieu of metallic pipe, all metallic components of this pipe system shall be protected with cathodic protection. Detailed drawings of cathodic protection for each component shall be submitted to the Government for approval within 45 days after date of receipt of notice to proceed, and before commencement of any work or ordering any material.

1.3.8.2 Coatings

a. Coatings for metallic components shall be as required for metallic fittings. Protective covering (coating and taping) shall be completed and tested on each metallic component (such as valves, hydrants and fittings). This covering shall be as required for underground metallic pipe. Each

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Attachment 1 test shall be witnessed by the Government. Coatings shall be selected, applied, and inspected in accordance with NACE RP0190 and as specified in these specifications. The use of nonmetallic pipe does not change other requirements of the specifications. Any deviations due to the use of nonmetallic pipe shall be submitted for approval. Each fire hydrant, valve and/or coupling shall have two (2) coats of epoxy, 5 mil per coat, for a total dry film thickness of 10 mil. Damage to coating during transportation and/or installation shall be repaired in accordance with the manufacturer’s recommendations.

1.3.8.3 Tracer Wire

a. When a nonmetallic pipe line is used to extend or add to an existing metallic line, an insulated No. 8 AWG copper wire shall be thermite-welded to the existing metallic line and run the length of the new nonmetallic line. This wire shall be used as a locator tracer wire and to maintain continuity to any future extensions of the metallic pipe line.

1.3.8.4 Tests of Components

a. A minimum of two (2) tests shall be made at each metallic component in the piping system.

One (1) measurement shall be made directly over the anodes and the other test shall be over the outer edge of the component, but at the farthest point from the anodes. Structure and pipes shall be shown with the cathodic protection equipment. All components of the cathodic protection system shall be shown on drawings, showing their relationship to the protected structure or component. A narrative shall describe how the cathodic protection system will work. Testing at each component will be required. Metallic components requiring cathodic protection shall include but not be limited to the following:

(1) Pipes under the floor slab or foundations.

(2) PIV.

(3) Shutoff valves.

(4) Metallic pipe extended from aboveground locations.

(5) Each connector or change-of-direction device.

(6) Any metallic pipe component or section.

(7) Backflow preventor.

(8) Each fire hydrant.

1.3.9 Drawings

1.3.9.1 Detailed drawings shall be provided showing location of anodes, insulated fittings, test stations, permanent reference cells, and bonding. Locations shall be referenced to two (2) permanent facilities or mark points.

1.3.10 Electrical Potential Measurements

1.3.10.1 All potential tests shall be made at a minimum of 25 foot intervals witnessed by the Government. Submittals shall identify test locations on separate drawing, showing all metal to be protected and all cathodic protection equipment. Test points equipment and protected metal shall be easily distinguished and identified.

1.3.11 Achievement of Criteria for Protection

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Attachment 1

1.3.11.1 All conductors, unless otherwise shown, shall be routed to or through the test stations. Each system provided shall achieve a minimum pipe-to-soil potential of minus 1000 millivolt potentials with reference to a saturated copper-copper-sulfate reference cell on all underground components of the piping. Based upon the measurements taken, the current and voltage of the anodes should be adjusted as required to produce a minimum of minus 1000 millivolts potential between the structure being tested and the reference cell. This potential should be obtained over 95 percent of the metallic area. Testing will be witnessed by the Government.

Additional anodes shall be provided by the Contractor if required to achieve the minus 1000 millivolts potential. Although acceptance criteria of the cathodic protection systems are defined in NACE SP0169, for this project the potential of minus 1000 millivolts is the only acceptable criteria.

1.3.12 Metallic Components and Typicals

a. Metallic components: As a minimum, each metallic component shall be protected with at least one (1) magnesium anode. This number of anodes is required to achieve minus 1000 millivolts potential on the metallic area. As a minimum, the magnesium anode unpackaged weight shall be 17 pounds. The magnesium anodes shall be located at least five feet to the side of the metallic component and routed through a test station.

b. Fire Hydrants: Fire hydrant pipe components shall have a minimum of two (2) anodes. These magnesium anodes shall have an unpackaged weight of 17 pounds.

c. Pipe Under Concrete Slab: Pipe under concrete slab shall have a minimum of 3 magnesium anodes. Each of these magnesium anodes shall have an unpackaged weight of 17 pounds. Pipe under concrete slab shall have one (1) permanent reference electrodes located under the slab.

One (1) permanent reference electrode shall be located where the pipe enters the concrete slab.

All conductors shall be routed to a test station.

d. Valves: Each valve shall be protected with one (1) magnesium anodes. The magnesium anode shall have an unpackaged weight of 17 pounds.

e. Metallic Pipe Component or Section: Each section of metallic pipe shall be protected with 2 magnesium anodes. The magnesium anodes shall have an unpackaged weight of 17 pounds.

f. Connectors or Change-of-Direction Devices: Each change-of-direction device shall be protected with one (1) magnesium anodes. The magnesium anode shall have an unpackaged weight of 17 pounds.

1.3.13 Metallic Component Coating

1.3.13.1 Coatings for metallic components shall be as required for metallic fittings as indicated. This will include fire hydrants, T's, elbows, valves, etc. Coatings shall be selected, applied, and inspected in accordance with NACE RP0190 and as specified in these specifications.

PART 2 PRODUCTS

2.1 MAGNESIUM ANODES

2.1.1 A minimum of 3 anodes shall be installed on the Tank system. See Paragraph METALLIC COMPONENTS AND TYPICALS for additional anodes under slab.

2.1.2 Anode Composition

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Attachment 1

2.1.2.1 Anodes shall be of high-potential magnesium alloy, made of primary magnesium obtained from sea water or brine, and not made from scrap metal. Magnesium anodes shall conform to ASTM B 843 and to the following analysis (in percents) otherwise indicated:

Aluminum, max. 0.010 Manganese, max. 0.50 to 1.30 Zinc 0.05 Silicon, max. 0.05 Copper, max. 0.02 Nickel, max. 0.001 Iron, Max. 0.03 Other impurities, max. 0.05 each or 0.3 max. total Magnesium Remainder

2.1.2.2 The Contractor shall furnish spectrographic analysis on samples from each heat or batch of anodes used on this project.

2.1.3 Dimensions and Weights

2.1.3.1 Dimensions and weights of anodes shall be approximately as follows:

TYPICAL MAGNESIUM ANODE SIZE

(Cross sections may be round, square, or D shaped)

NOMINAL GROSS

NOMINAL APPROX. WT lb PACKAGED NOMINAL PACKAGE

WT. LBS. SIZE (IN) IN BACKFILL DIMENSIONS (IN)

3 3 X 3 X 5 8 5-1/4 X 5-1/4 X 8 5 3 X 3 X 8 13 5-1/4 X 5-1/4 X 11-1/4 9 3 X 3 X 14 27 5-1/4 X 20 12 4 X 4 X 12 32 7-1/2 X 18 17 4 X 4 X 17 45 7-1/2 X 24 20 2-1/2 X 2 ½ X 58 72 5-1/2 X 5-1/2 X 62 32 5 X 5 X 20-1/2 68 8-1/2 X 28 50 7 X 7 X 16 100 10 X 24

2.1.4 Packaged Anodes

2.1.4.1 Anodes shall be provided in packaged form with the anode surrounded by specially-prepared quick-wetting backfill and contained in a water permeable cloth or paper sack. Anodes shall be centered by means of spacers in the backfill material. The backfill material shall have the following composition, unless otherwise indicated:

Material Approximate Percent by Weight

Gypsum 75 Bentonite 20 Sodium Sulphate 5

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Attachment 1

Total 100

2.1.5 Zinc Anodes

2.1.5.1 Zinc anodes shall conform to ASTM B 418, Type II.

2.1.6 Connecting Wire

2.1.6.1 Wire Requirements

a. Wire shall be No. 12 AWG solid copper wire, not less than 10 feet long, unspliced, complying with NFPA 70, Type TW or RHH insulation. Connecting wires for magnesium anodes shall be factory installed with the place or emergence from the anode in a cavity sealed flush with a dielectric sealing compound. Connecting wires for zinc anodes shall be factory installed with the place of connection to the protruding steel core completely sealed with a dielectric material.

2.1.6.2 Anode Header Cable

a. Cable for anode header and distribution shall be No. 6 AWG stranded copper wire with type CP high molecular weight polyethylene, 7/64 inch thick insulation, 600-volt rating.

2.2 MISCELLANEOUS MATERIALS

2.2.1 Electrical Wire

2.2.2 Wire shall be No. 12 AWG stranded copper wire with NFPA 70, Type TW, RHW-USE or Polyethylene insulation. Polyethylene insulation shall comply with the requirements of ASTM D 1248 and shall be of the following types, classes, and grades:

2.2.3 High-molecular weight polyethylene shall be Type I, Class C, Grade E5.

2.2.3.1 Wire Splicing

a. Connecting wire splicing shall be made with copper compression connectors or exothermic welds, following instructions of the manufacturer. Single split-bolt connections shall not be used. Cover each connection with one (1) layer of 1/2 overlap rubber tape. Cover rubber tape with two (2) layers of l/2 overlap vinyl tape.

2.2.3.2 Structure Test Wires

a. Test wires shall be AWG No. 12 stranded copper wire with NFPA 70, Type TW or RHW or USE insulation.

2.2.3.3 Structure Wire Color Code

Anode or anode header cable Black Water pipe Blue Natural gas pipe Orange POL pipe White Underground tank White Reference electrode Yellow

Foreign or unprotected structure Red

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Attachment 1

2.2.3.4 Resistance Wire

a. Resistance wire shall be AWG No. 16 or No. 22 nickel - chromium wire.

2.2.4 Conduit

2.2.4.1 Rigid galvanized steel conduit and accessories shall conform to UL 6. Non-metallic conduit shall conform to NEMA TC 2.

2.2.5 Test Boxes and Junction Boxes

2.2.5.1 Boxes shall be outdoor type conforming to UL 514A.

2.2.6 Joint, Patch, Seal, and Repair Coating

2.2.6.1 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 1/2-inch thick. Coating compound shall be cold-applied coal-tar base mastic.

2.2.7 Backfill Shields

2.2.7.1 Shields shall consist of approved pipeline wrapping or fiberglass-reinforced, coal-tar impregnated tape, or plastic weld caps, specifically made for the purpose and installed in accordance with the manufacturer's recommendations.

2.2.8 Epoxy Potting Compound

2.2.8.1 The use of epoxy potting compounds for sacrificial anode cathodic protection systems is not required.

2.2.9 Test Stations

2.2.9.1 Stations shall be of the aboveground or flush-curb-box type and shall be the standard product of a recognized manufacturer. Test stations shall be complete with an insulated terminal block having the required number of terminals. The test station shall have an inside diameter of about 5 inches and be provided with a lockable cover and shall have an embossed legend, "C.P. Test."

A minimum of one (1) test station shall be provided each component of the pipe or tank. A minimum of six (6) terminals shall be provided in each test station. A minimum of two (2) leads are required to the metallic pipe or fitting from each test station. Other conductors shall be provided for each anode, other foreign pipe, and reference cells as required. Test stations may be constructed of nonmetallic materials. However, if nonmetallic materials are utilized, as a minimum, the materials shall be resistant to damage from ultraviolet radiation, contain good color retention qualities, contain high strength qualities, and be resistant to accidental or vandalistic impacts that might be normally encountered in the environment for which they are to be installed. The test stations shall be listed for the particular application for which they are to be utilized. The test station must have at least ¼ inch clearance between the body of the lid and the side of the test station.

2.2.10 Joint and Continuity Bonds

2.2.10.1 Bonds shall be provided across all joints in the metallic water lines or gas lines, across any

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Attachment 1 electrically discontinuous connections and all other pipes and structures with other than welded or threaded joints that are included in this cathodic protection system. Unless otherwise specified in the specifications, bonds between structures and across joints in pipe with other than welded or threaded joints shall be No. 8 AWG stranded copper cable with polyethylene insulation. Bonds between structures shall contain sufficient slack for any anticipated movement between structures. Bonds across pipe joints shall contain a minimum of 4 inch of slack to allow for pipe movement and soil stress. Bonds shall be attached by exothermic welding. Exothermic weld areas shall be insulated with coating compound and approved, and witnessed by the Government. Continuity bonds shall be installed as necessary to reduce stray current interference. Additional joint bonding shall be accomplished by the Contractor where the necessity is discovered during construction or testing or where the Government's representative directs that such bonding be done. Joint bonding shall include all associated excavation and backfilling. There shall be a minimum of two (2) continuity bonds between each structure and other than welded or threaded joints if the piping system is twelve inches in diameter or larger. The Contractor shall test for electrical continuity across all joints with other than welded or threaded joints and across all metallic portions or components. The Contractor shall provide bonding as required and as specified above until electrical continuity is achieved.

Bonding test data shall be submitted for approval.

2.2.11 Resistance Bonds

2.2.11.1 Resistance bonds should be adjusted as outlined in this specification. Alternate methods may be used if they are approved by the Government.

2.2.12 Stray Current Measurements

2.2.12.1 Stray current measurements should be performed at each test station. Stray currents resulting from lightning or overhead alternating current (AC) power transmission systems shall be mitigated in accordance with NACE SP0177.

2.2.13 Electrical Isolation of Structures

2.2.13.1 As a minimum, isolating flanges or unions shall be provided at the following locations:

a. Connection of new metallic piping or components to existing piping.

b. Pressure piping under floor slab to a building.

c. Isolation shall be provided at metallic connection of all lines to existing system and where connecting to a building. Additionally, isolation shall be provided between water, gas and forced main lines; and foreign pipes that cross the new lines within 10 feet. Isolation fittings, including isolating flanges and couplings, shall be installed aboveground or in a concrete pit.

Cradles and seals shall be of a type that is in regular factory production made for the purpose of electrically insulating the carrier pipe from the casing and preventing the incursion of water into the annular space.

2.2.13.2 Electrically Isolating Pipe Joints

a. Electrically isolating pipe joints shall be of a type that is in regular factory production.

2.2.13.3 Electrically Conductive Couplings

a. Electrically conductive couplings shall be of a type that has a published maximum electrical resistance rating given in the manufacturer's literature.

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2.2.13.4 Insulating Joint Testing

a. A Model 601 Insulation Checker, as manufactured by "Gas Electronics", or an approved equal, shall be used for insulating joint (flange) electrical testing.

2.2.14 Underground Structure Coating

2.2.14.1 This coating specification shall take precedence over any other project specification and drawing notes, whether stated or implied, and shall also apply to the pipeline or tank supplier.

No variance in coating quality shall be allowed by the Contractor or Base Construction Representative without the written consent of the designer. All underground metallic pipelines and tanks to be cathodically protected shall be afforded a good quality factory-applied coating.

This includes all carbon steel, cast-iron and ductile-iron pipelines or vessels. Coatings shall be selected, applied, and inspected in accordance with NACE RP0190 (withdrawn 6-2002) and as specified. If non-metallic pipelines are installed, all metallic fittings on pipe sections shall be coated in accordance with this specification section.

a. The nominal thickness of the metallic pipe joint or other component coating shall be 16 mils, plus or minus 5 percent.

b. Pipe and joint coating for factory applied or field repair material shall be applied as recommended by the manufacturer and shall be one of the following:

(1) Continuously extruded polyethylene and adhesive coating system.

(2) Polyvinyl chloride pressure-sensitive adhesive tape.

(3) High density polyethylene/bituminous rubber compound tape.

(4) Butyl rubber tape.

(5) Coal tar epoxy.

2.2.14.2 Field Joints

a. All field joints shall be coated with materials compatible with the pipeline coating compound.

The joint coating material shall be applied to an equal thickness as the pipeline coating.

Unbonded coatings shall not be used on these buried metallic components. This includes the elimination of all unbonded polymer wraps or tubes. Once the pipeline or vessel is set in the trench, an inspection of the coating shall be conducted. This inspection shall include electrical holiday detection. Any damaged areas of the coating shall be properly repaired. The Government shall be asked to witness inspection of the coating and testing using a holiday detector.

2.2.14.3 Inspection of Pipe Coatings

a. Any damage to the protective covering during transit and handling shall be repaired before installation. After field coating and wrapping has been applied, the entire pipe shall be inspected by an electric holiday detector with impressed current in accordance with NACE RP0274 using a full-ring, spring-type coil electrode. The holiday detector shall be equipped with a bell, buzzer, or other type of audible signal which sounds when a holiday is detected.

All holidays in the protective covering shall be repaired immediately upon detection.

Occasional checks of holiday detector potential will be made by the Government's representative to determine suitability of the detector. All labor, materials, and equipment necessary for conducting the inspection shall be furnished by the Contractor.

(1) Protective covering for aboveground piping system: Finish painting shall conform to the

SABER Specifications

FA2517-13-R-5000

Attachment 1 applicable paragraph of SECTION: 09 90 00 Paints and Coatings and as follows:

(a) Ferrous surfaces: Shop-primed surfaces shall be touched-up with ferrous metal primer.

Surfaces that have not been shop-primed shall be solvent-cleaned. Surfaces that contain loose rust, loose mil scale, and other foreign substances shall be mechanically-cleaned by power wire-brushing and primed with ferrous metal primer. Primed surface shall be finished with two (2) coats of exterior oil paint and vinyl paint. Coating for each entire piping service shall be an approved pipe line wrapping having a minimum coating resistance of 50,000 Ohms per square foot.

2.2.15 Resistance Wire

2.2.15.1 Wire shall be No. 16 or No. 22 nickel-chromium wire with TW insulation.

2.2.16 Electrical Connections

2.2.16.1 Electrical connections shall be done as follows:

a. Exothermic welds shall be "Cadweld", "Bundy", "Thermoweld", or an approved equal. Use of this material shall be in strict accordance with the manufacturer's recommendations.

b. Electrical-shielded arc welds shall be approved for use on steel pipe by shop drawing submittal action.

c. Brazing shall be as specified in Paragraph: Lead Wire Connections.

2.2.17 Electrical Tape

2.2.17.1 Pressure-sensitive vinyl plastic electrical tape shall conform to UL 510.

2.2.18 Permanent Reference Electrodes

2.2.18.1 Permanent reference electrodes shall be Cu-CuS04 electrodes suitable for direct burial.

Electrodes shall be guaranteed by the supplier for 20 years' service in the environment in which they shall be placed. Electrodes shall be installed directly beneath pipe, or metallic component and have a No. 12 AWG yellow wire long enough to extend to the test station without splicing.

2.2.19 Casing

2.2.19.1 Where a pipeline is installed in a casing under a roadway or railway, the pipeline shall be electrically insulated from the casing, and the annular space sealed and filled with an approved corrosion inhibiting product against incursion of water.

PART 3 EXECUTION

3.1 CRITERIA OF PROTECTION

3.1.1 Acceptance criteria for determining the adequacy of protection on a buried underground pipe, tank or metallic component shall be in accordance with NACE SP0169, NACE RP0193 or NACE RP0285 and as specified below.

3.1.2 Iron and Steel

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FA2517-13-R-5000

Attachment 1

3.1.2.1 The following method a. shall be used for testing cathodic protection voltages. If more than one method is required, method b. shall be used.

a. A negative voltage of at least minus 1000 millivolts as measured between the underground component and a saturated copper-copper sulphate reference electrode connecting the earth (electrolyte) directly over the underground component. Determination of this voltage shall be made with the cathodic protection system in operation. Voltage drops shall be considered for valid interpretation of this voltage measurement. Adequate number of measurements shall be obtained over the entire structure, pipe, tank, or other metallic component to verify and record achievement of minus 1000 millivolts. This potential shall be obtained over 95 percent of the total metallic area.

b. A minimum polarization voltage shift of 100 millivolts as measured between the underground component and a saturated copper-copper sulphate reference electrode contacting the earth directly over the underground component. This polarization voltage shift shall be determined by interrupting the protective current and measuring the polarization decay This means to interrupt the current flow from all anodes connected to the structure being tested. When the protective current is interrupted, an immediate voltage shift will occur. The voltage reading, after the immediate shift, shall be used as the base reading from which to measure polarization decay. Measurements achieving 100 millivolts decay shall be made over 95 percent of the metallic surface being protected.

c. For any metallic component, a minimum of two (2) measurements shall be made using subparagraph a., above, and achieving the on potential of minus 1000 millivolts. One (1) measurement shall be made over the anodes and one (1) measurement shall be made over the component and farthest away from the anode.

3.1.3 Aluminum

3.1.3.1 Aluminum underground component shall not be protected to a potential more negative than minus 1200 millivolts, measured between the underground component and a saturated copper-copper sulphate reference electrode contacting the earth, directly over the metallic component.

Resistance, if required, shall be inserted in the anode circuit within the test station to reduce the potential of the aluminum to a value which will not exceed a potential more negative than minus 1200 millivolts. Voltage shift criterion shall be a minimum negative polarization shift of 100 millivolts measured between the metallic component and a saturated copper-copper sulphate reference electrode contacting the earth, directly over the metallic component. The polarization voltage shift shall be determined as outlined for iron and steel.

3.1.4 Copper Piping

3.1.4.1 For copper piping, the following criteria shall apply: A minimum of 100 millivolts of cathodic polarization between the structure surface and a stable reference electrode contacting the electrolyte. The polarization voltage shift shall be determined as outlined for iron and steel.

3.2 ANODE STORAGE AND INSTALLATION

3.2.1 Anode Storage

3.2.1.1 Storage area for magnesium anodes will be designated by the Government. If anodes are not stored in a building, tarps or similar protection should be used to protect anodes from inclement weather. Packaged anodes, damaged as a result of improper handling or being exposed to rain, SABER Specifications

FA2517-13-R-5000

Attachment 1 shall be resacked by the Contractor and the required backfill added.

3.2.1.2 Anode Installation

a. Unless otherwise authorized, installation shall not proceed without the presence of the Government. Anodes of the size specified shall be installed to the depth indicated and at the locations shown. Locations may be changed to clear obstructions with the approval of the Government. Anodes shall be installed in sufficient number and of the required type, size, and spacing to obtain a uniform current distribution over the surface of the structure. The anode system shall be designed for a life of 25 years of continuous operation. Anodes shall be installed as indicated in a dry condition after any plastic or waterproof protective covering has been completely removed from the water permeable, permanent container housing the anode metal. The anode connecting wire shall not be used for lowering the anode into the hole. The annular space around the anode shall be backfilled with fine earth in 6 inch layers and each layer shall be hand tamped. Care must be exercised not to strike the anode or connecting wire with the tamper. Approximately 5 gallons of water may be applied to each filled hole after anode backfilling and tamping has been completed to a point about 6 inches above the anode.

After the water has been absorbed by the earth, backfilling shall be completed to the ground surface level.

3.2.1.3 Single Anodes

a. Single anodes, spaced as shown, shall be connected through a test station to the pipeline, allowing adequate slack in the connecting wire to compensate for movement during backfill operation.

3.2.1.4 Groups of Anodes

a. Groups of anodes, in quantity and location shown, shall be connected to an anode header cable.

The anode header cable shall make contact with the structure to be protected only through a test station. Anode lead connection to the anode header cable shall be made by an approved hydraulic crimp connector or exothermic weld and completely covered with one (1) layer of ½ overlap rubber tape. Cover rubber tape with two (2) layers of ½ overlap vinyl tape. The anode header cable shall start inside a test station and then by making a large loop shall extend to the end anode and then return to the same test station.

3.2.1.5 Welding Methods

a. Connections to ferrous pipe or metal tanks shall be made by exothermic weld methods manufactured for the type of [pipe] [tank] supplied. Electric arc welded connections and other types of welded connections to ferrous pipe and structures shall be approved before use.

CONNECTION TO METAL TANKS WILL BE TO LIFTING LUG ONLY .

3.2.2 Anode Placement – General

3.2.2.1 Packaged anodes shall be installed completely dry, and shall be lowered into holes by rope sling or by grasping the cloth gather. The anode lead wire shall not be used in lowering the anodes. The hole shall be backfilled with fine soil in 6 inch layers and each layer shall be hand-tamped around the anode. Care must be exercised not to strike the anode or lead wire with the tamper. If immediate testing is to be performed, water may be added only after backfilling and tamping has been completed to a point 6 inches above the anode. Approximately 5 gallons of water may be poured into the hole. After the water has been absorbed by the soil, backfilling and tamping may be completed to the top of the hole. Anodes shall be installed as specified or

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FA2517-13-R-5000

Attachment 1 shown. In the event a rock strata is encountered prior to achieving specified augered-hole depth, anodes may be installed horizontally to a depth at least as deep as the bottom of the pipe, with the approval of the Government.

3.2.3 Underground Pipeline

3.2.3.1 Anodes shall be installed at a minimum of 8 feet and a maximum of 10 feet from the line to be protected.

3.2.4 Installation Details

3.2.4.1 Details shall conform to the requirements of this specification. Details shown on the drawings are indicative of the general type of material required, and are not intended to restrict selection to material of any particular manufacturer.

3.2.5 Lead Wire Connections

3.2.5.1 Underground Pipeline (Metallic)

a. To facilitate periodic electrical measurements during the life of the sacrificial anode system and to reduce the output current of the anodes, if required, all anode lead wires shall be connected to a test station and buried a minimum of 24 inch in depth. The cable shall be No. 12 AWG, stranded copper, polyethylene or RHW-USE insulated cable. The cable shall make contact with the structure only through a test station. Resistance wire shall be installed between the cable and the pipe cable, in the test station, to reduce the current output, if required.

b. Lead wire-to-structure connections shall be accomplished by an exothermic welding process.

All welds shall be in accordance with the manufacturer's recommendations. A backfill shield filled with a pipeline mastic sealant or material compatible with the coating shall be placed over the weld connection and shall be of such size as to cover the exposed metal adequately.

3.2.5.2 Resistance Wire Splices

a. Resistance wire connections shall be accomplished with silver solder and the solder joints wrapped with a minimum of three (3) layers of pressure-sensitive tape.

3.2.6 Location of Test Stations

3.2.6.1 Test stations shall be of the type and location shown and shall be curb box, post or indoor mounted. Buried insulating joints shall be provided with test wire connections brought to a test station. Unless otherwise shown, other test stations shall be located as follows:

a. At each anode or when using a header cable at 300-foot intervals or less.

b. Where the pipe or conduit crosses any other metal pipe.

c. At both ends of casings under roadways and railways.

d. Where both sides of an insulating joint are not accessible above ground for testing purposes.

3.2.7 Underground Pipe Joint Bonds

3.2.7.1 Underground pipe having other than welded or threaded coupling joints shall be made electrically continuous by means of a bonding connection installed across the joint.

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FA2517-13-R-5000

Attachment 1

3.3 ELECTRICAL ISOLATION OF STRUCTURES

3.3.1 Isolation Joints and Fittings

3.3.1.1 Isolating fittings, including main line isolating flanges and couplings, shall be installed aboveground, or within manholes, wherever possible. Where isolating joints must be covered with soil, they shall be fitted with a paper joint cover specifically manufactured for covering the particular joint, and the space within the cover filled with hot coal-tar enamel. Isolating fittings in lines entering buildings shall be located at least 12 inches above grade of floor level, when possible. Isolating joints shall be provided with grounding cells to protect against over-voltage surges or approved surge protection devices. The cells shall provide a low resistance across isolating joint without excessive loss of cathodic current.

3.3.2 Gas Distribution Piping

3.3.2.1 Electrical isolation shall be provided at each building riser pipe to the pressure regulator, and at other locations as indicated on the drawings.

3.4 TRENCHING AND BACKFILLING

3.4.1 Trenching and backfilling shall be in accordance with Section 31 00 00 Earthwork.

3.5 TESTS AND MEASUREMENTS

3.5.1 Baseline Potentials

3.5.1.1 Each test and measurement will be witnessed by the Government. The Contractor shall notify the Government a minimum of five (5) working days prior to each test. After backfill of the pipe or tank, the static potential-to-soil of the pipe or tank shall be measured. The locations of these measurements shall be identical to the locations specified for pipe- or tank- to-reference electrode potential measurements. The initial measurements shall be recorded.

3.5.2 Isolation Testing

3.5.2.1 Before the anode system is connected to the pipe or tank, an isolation test shall be made at each isolating joint or fitting.