Attachment 07-United Facilities Criteria Cathodic Protection-14 Jan 2019.pdf

UFC 3-570-01

28 November 2016

Change 1, 14 January 2019

UNIFIED FACILITIES CRITERIA (UFC)

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

CATHODIC PROTECTION

Change 1, 14 January 2019

UNIFIED FACILITIES CRITERIA (UFC)

CATHODIC PROTECTION

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND

AIR FORCE CIVIL ENGINEER CENTER (Preparing Activity)

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location 1 14 Jan 2019 Paragraphs 1-2, 1-4, 1-7, 2-2 and 2-3

This UFC supersedes UFC 3-570-02A, dated March 2005 and 3-570-02N dated January 2004.

Change 1, 14 January 2019

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Refer to UFC 1-200-01, DoD Building Code (General Building Requirements), for implementation of new issuances on projects.

AUTHORIZED BY:

GEORGE O. LEA, P.E. JOSEPH E. GOTT, P.E.

Chief, Military Engineering Branch Chief Engineer U.S. Army Corps of Engineers Naval Facilities Engineering Command

EDWIN H. OSHIBA, SES, DAF MICHAEL McANDREW Deputy Director of Civil Engineers DCS/Logistics, Engineering & Force Protection

Director, Facilities Investment and Management Office of the Deputy Under Secretary of Defense (Installations and Environment)

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UNIFIED FACILITIES CRITERIA (UFC)

NEW SUMMARY SHEET

Document: UFC 3-570-01, Cathodic Protection

Superseding: UFC 3-570-02A, Cathodic Protection, March 2005 UFC 3-570-02N, Electrical Engineering Cathodic Protection, Jan 2004

Description: This UFC provides general design guidance for cathodic protection (CP) systems. This UFC applies to all Army, Navy, and Air Force service elements and contractors.

Reasons for Document:

• Update the format of the manual (more of a policy and guidance manual instead of a technical cookbook on design) and unify UFC 3-570-02A and UFC 3-570- 02N.

• Incorporate policy, guidelines, and procedures previously identified in Engineering Technical Letters and Interim Technical Guidance Documents.

• Provide additional guidance to the Project Design Engineer (PDE) in managing CP design contracts and guidance on commissioning of CP systems.

• Incorporate information regarding new technologies and update obsolete technical information.

Impact:

• Clarifies policy where CP must be provided. Provides more guidance to the PDE managing a CP Architect-Engineer (A-E) design contract to help improve designs. Previously, the manual only described technical requirements for the actual designers. Helps ensure CP provided where necessary and properly designed to ensure economical long-term facility/structure life cycle cost.

Unification Issues

• \1\Para 2-2 Structures for which CP is Mandatory. Navy has relaxed this for some structures and requires these structures to be evaluated for CP requirements.

• Para 2-3 Navy has relaxed the mandatory requirement that DoD CP systems reviewers be certified. /1/

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TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 PURPOSE AND SCOPE

1-2 APPLICABILITY

1-3 GENERAL BUILDING REQUIREMENTS

1-4 REFERENCES

1-5 GLOSSARY

1-6 CYBERSECURITY

1-7 RECONCILIATION WITH OTHER UNIFIED FACILITIES CRITERIA

CHAPTER 2 CATHODIC PROTECTION SYSTEMS POLICY

2-1 INTRODUCTON

2-2 STRUCTURES FOR WHICH CP IS MANDATORY

2-2.1 POL Facilities and Structures

2-2.2 Underground Storage Tank System

2-2.3 Natural Gas Pipe Lines

2-2.4 Waterfront Structures

2-2.5 Buried or Submerged Steel Utility Piping

2-2.6 Ductile or Cast Iron Utility Piping

2-2.7 Potable Water Storage Tanks

2-2.8 Fire Protection Water Storage Tanks

2-3 OTHER STRUCTURES FOR WHICH CATHODIC PROTECTION MUST

BE EVALUATED

2-4 PROTECTIVE COATINGS SPECIFICIED IN CONJUNCTION WITH

CATHODIC PROTECTION

2-5 ISOLATION OF COPPER WATER PIPES FROM FERROUS PIPES

2-6 CP PROJECT PLANNING

2-6.1 General CP Requirements

2-6.2 Environmental/Site Concerns

CHAPTER 3 DESIGN REQUIREMENTS

3-1 INTRODUCTION

3-2 APPLICABLE CODES AND REGULATIONS

3-3 SYSTEM DESIGN

3-3.1 Two types of CP systems

3-3.2 Field Surveys and Tests

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3-3.3 Availability of AC Power (ICCP Systems)

3-3.4 Environmental/Site Concerns

3-3.5 Electrical Continuity

3-3.6 Identification of Other Structures in the Area

3-3.7 Electrical Isolation

3-3.8 Connecting Electrical Wires and Cables

3-3.9 Connections and Splices

3-3.10 Hazards Associated with Cathodic Protection

3-3.11 Special Requirements

3-3.12 Easement Issues

3-3.13 CP System Protection Criteria

3-3.14 System Maintainability

3-3.15 Design Submittals

3-3.16 Design Build

3-4 DESIGN FOR CONSTRUCTABILITY

3-4.1 Identification of Issues During Design Field Survey

3-4.2 Prevention of Damage to Existing Structures/CP System Components. . 24

3-4.3 Commissioning

CHAPTER 4 CATHODIC PROTECTION SYSTEM COMPONENTS

4-1 INTRODUCTION

4-2 GALVANIC ANODE SYSTEMS

4-2.1 Anodes

4-2.2 Backfill

4-2.3 Connecting Wires

4-3 IMPRESSED CURRENT SYSTEMS

4-3.1 Anodes

4-3.2 Backfill

4-3.3 Anode/Structure Lead Wires and Header Cables

4-3.4 Deep Anode Bed Design

4-3.5 Rectifiers and Other DC Power Supplies

4-4 OTHER COMPONENTS

4-4.1 Electrical Continuity and Isolation

4-4.2 Connections and Splices

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4-4.3 Test Stations

4-4.4 Permanent Monitoring Electrodes and Probes

4-5 SPECIAL TECHNOLOGICAL CONSIDERATIONS

4-5.1 Remote Monitoring

4-5.2 Pre-engineered CP for Underground Storage Tanks

4-5.3 Aboveground (on-grade) Storage Tanks

4-5.4 CP Systems for Reinforcing Steel in Concrete

4-5.5 Water Storage Tanks

4-5.6 Hot Water Storage Tanks

APPENDIX A REFERENCES

APPENDIX B BEST PRACTICES

B-1 CATHODIC PROTECTION PLANNING

B-1.1 Project Documentation

B-1.2 Corrosion Control/CP System Assistance

B-2 CP SYSTEM DESIGN CONTRACT PROCESS

B-2.1 Project Documentation

B-2.2 Developing A-E Scope of Work

B-2.3 What Information to Provide A-E

B-2.4 Deliverables – What to Expect from the A-E

B-2.5 Common Problems/Lessons Learned with A-E Designs

B-3 CP SYSTEM DESIGN DOCUMENTATION

B-3.1 DESIGN BASIS

B-3.2 DESIGN DRAWINGS

B-3.3 Specifications

B-3.4 Common Problems/Lessons Learned with Design Documents

B-4 TYPES OF CP SYSTEMS

B-4.1 GALVANIC CP SYSTEMS

B-4.2 IMPRESSED CURRENT SYSTEMS

B-5 GENERAL DESIGN PRINCIPLES

B-5.1 DESIGN APPROACH

B-5.2 DESIGN PARAMETERS AND CONSIDERATIONS

B-5.3 GENERAL CATHODIC PROTECTION DESIGN PROCESS

B-6 TYPICAL DESIGN CALCULATIONS

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B-6.1 Calculate Structure Surface Area to be Protected

B-6.2 Calculate Cathodic Protection Current Requirements

B-6.3 Determine CP System Circuit Resistance

B-7 OTHER CP SYSTEM COMPONENT DESIGN CONSIDERATIONS

B-7.1 Connecting Wires

B-7.2 Connections and Splices

B-7.3 Bonds and Insulating Joints

B-7.4 Test Stations - Location and Function

B-8 DESIGN PRACTICES THAT FACILITATE OPERATION AND

MAINTENANCE

B-8.1 As Built Drawings

B-8.2 Locate Equipment Where Readily Maintainable

B-8.3 Test Stations

B-8.4 Markers and Labeling

B-8.5 Test Access

B-8.6 Permanent Reference Electrodes (PRCs)

B-8.7 Electrical Resistance Probes

B-8.8 Coupon Test Station System

B-8.9 Anode Current Output

B-8.10 Electrical Isolation Testing

B-8.11 Remote Monitoring

B-8.12 GPS Synchronizable Interruption

B-9 LESSONS LEARNED AND OTHER PRECAUTIONS FOR CP SYSTEM

DESIGN

B-9.1 Common Problems and Design Deficiencies

B-10 SPECIALIZED CP TECHNOLOGY AND CONSIDERATIONS

B-10.1 Deep Anode Beds

B-10.2 Pre-engineered Cathodic Protection for Underground Storage Tanks

B-10.3 CP Systems for Reinforcing Steel in Concrete

B-10.4 Interior of Potable Water Tanks

B-10.5 Hot Water Storage Tanks

B-11 CP SYSTEM COMMISISONING

B-11.1 System Commissioning Procedures

B-11.2 System Commissioning FAQs

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APPENDIX C GLOSSARY

APPENDIX D EXAMPLE CATHODIC PROTECTION DESIGN DETAILS

FIGURES

Figure 3-1 Schematic Illustration of a GCP System Figure 3-2 Schematic Illustration of a ICCP System Figure 4-1 Schematic of a typical deep well anode bed Figure 4-2 Small Solar Powered CP System. Solar Panels Shown in Picture on Left.

Battery Bank and Control Center Shown on Right

Figure 4-3 Bond Wire Installed Between Two Electrically Isolated Pipe Sections Figure 4-4 Exothermic Weld of CP System Wiring to the Structure Figure 4-5 Mechanical Connection of Wiring to the Structure

Figure 4-6 STI-P3® Tank Figure 4-7 Titanium Mesh Anodes Fastened to a Concrete Beam

Figure 4-8 Discrete Zinc Anode (Wrapped in Green Mesh) in Concrete Deck Repair.

Device with Yellow Lead Wire is a Permanent Reference Electrode

Figure 4-9 Discrete Zinc Anodes in Fiberglass Jacket for Pile Installation Figure 4-10 Photos Showing “Before” and “After” Installation of Integrated Pile Repair

Systems

Figure B-3 Wenner Four Electrode Method Schematic Figure B-4 Wenner Four Electrode Method for Measuring Soil Resistivity Figure B-5 Measuring Soil Resistivity in a Soil Box Figure B-6 Typical Ground Flush Mount Test Station

Figure B-7 Above Grade Test Stations. PVC Pipe Mount on the Left, Pole Mount in the Center, and Wall Mount on the Right

Figure B-8 Resistors in an Above Grade Terminal Box Figure B-9 Flush Mounted Current-Potential Test Station Figure B-10 Pipe Mounted Test Station. Figure on Right is a Close-Up of the Test

Station “Head” or Terminal Board

Figure B-11 Wall/Pole Mount Type Test Station Figure B-12 Rectifiers Located for Ease of Maintenance Figure B-13 Test Station Marker for Flush Mount Test Station Figure B-14 Small Flush Mounted Test Station with Too Many Large Sized Wires

Figure B-15 Example of an ER Probe Figure B-16 Probe with Encapsulated Connector Figure B-17 Pre-Assembled Conduit System, Probe, and PRC for Submerged Use.. 101 Figure B-18 Anode Junction Box Figure B-19 Interference on Pipeline in Vicinity of a DC Powered Rail System

Figure B-20 Interference on Foreign Pipelines in the Vicinity of a CP System Figure B-21 Placing Anodes to Minimize Interference Figure B-22 Centralizers Installed on High Silicon Cast Iron Anodes Figure B-23 Anode Column Vent Pipes Run Outside of Anode Junction Box Figure B-24 Severe Corrosion of Cast Iron Cover on the Anode Well Head Box Caused

By Chlorine Gas Vented into the Box Figure B-25 STI-P3® Tank

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Figure B-26 Titanium Mesh Anodes Fastened to a Concrete Beam Figure B-27 Discrete Zinc Anode (Wrapped in Green Mesh) in Concrete Deck Repair.

Device with the Yellow Lead Wire is a Permanent Reference Electrode Figure B-28 Discrete Zinc Anodes in Fiberglass Jacket for Pile Installation

Figure B-29 Photos Showing “Before” and “After” Installation of Integrated Pile Repair and CP Systems

Figure B-30 Typical Lifejacket Installation Figure B-31 Concrete Demolished Around Entire Pile to Permit Installation of a Bar

Welded to Each Rebar to Establish Electrical Continuity

Figure B-32 Octagonal Shaped Buoy Design Figure B-33 Umbrella-like Anode Support Structure Design Figure B-34 CP System for a Vertical Hot Water Tank with a Man-Way Access Opening.

Figure B-35 CP System Rectifier and Anode Condulet Fitting on Side of Water Tank.

Figure B-36 Close up of Condulet Fitting Showing Anode Rod Extending Out of the

Storage Tank Figure B-37 Reference Electrode Placed in Contact with Moist Wadding Temporarily

Placed Inside of the Capillary Tube Monitoring Port

Figure D-1 Example GCP Anode Installation Detail Figure D-2 Example ICCP Anode Installation Detail Figure D-3 Example Deep Anode Installation Detail Figure D-4 Example GCP Anode Detail

Figure D-5 Example Seawater GCP Anode Detail

Figure D-6 Example ICCP Oil Cooled Rectifier Detail Figure D-7 Example Anode Junction Box Detail Figure D-8 Example Flush Mount Test Station Detail Figure D-9 Example Flush Mount Bond Test Station Detail

Figure D-10 Example Soil Access Test Station Detail

Figure D-11 Example Dielectric Insulation Flange Detail Figure D-12 Example Exothermic Weld Detail Figure D-13 Example Electrical One-Line Schematic Diagram

TABLES

Table 1-1. UFC Documents Requiring Reconciliation of CP System Requirements and Criteria

Table B-1. General CP System Cost Guidelines

Table B-2. Advantages/Limitations of GCP Systems Table B-3. Advantages/Limitations of ICCP Systems Table B-4. Current Density Requirements for Cathodic Protection of Bare Steel Table B-5. Common Problems with GCP System Designs

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CHAPTER 1 INTRODUCTION

1-1 PURPOSE AND SCOPE.

This UFC provides policy and design requirements for cathodic protection (CP) systems. This document provides the minimum design requirements, and must be utilized in the development of plans, specifications, calculations, and Design/Build Request for Proposals (RFP).

UFC 3-501-01, Electrical Engineering, provides the governing criteria for electrical systems, explains the delineation between the different electrical-related UFCs, and refers to UFC 3-570-01 for Cathodic Protection requirements. Refer to UFC 3-501-01 for design analysis, calculation, and drawing requirements.

1-2 APPLICABILITY.

Compliance with this UFC is mandatory for Department of Defense (DoD) facilities located on or outside of DoD installations, whether acquired by appropriated or non-appropriated funds, or third party finance and constructed.

\1\For Navy projects, third party financed and constructed projects are not required to meet this UFC’s requirements except for provision and extension of Navy-owned or Government-owned systems and infrastructure that are extended to the third party's site. /1/

1-3 GENERAL BUILDING REQUIREMENTS.

UFC 1-200-01, General Building Requirements, provides applicability of model building codes and government-unique criteria for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, sustainability, and safety.

Use this UFC in addition to UFC 1-200-01 and the UFCs and government criteria referenced therein.

1-4 REFERENCES.

Appendix A contains a list of references used in this document. The publication date of the code or standard is not included in this document. In general, the latest available issuance of the reference is used.

\1\For Navy projects, the reference date is set by the contract or RFP date. /1/

1-5 GLOSSARY.

Appendix C contains acronyms, abbreviations, and terms.

1-6 CYBERSECURITY.

All control systems (including systems separate from an energy management control system), remote monitoring units, and automated data collection units must be planned, Change 1, 14 January 2019 designed, acquired, executed and maintained in accordance with UFC 4-010-06; and as required by individual Service Implementation Policy.

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1-7 RECONCILIATION WITH OTHER UNIFIED FACILITIES CRITERIA.

The CP requirements and criteria in this document will be reconciled with CP requirements and criteria in other UFCs so that the required criteria are located in a single location; the other UFCs and criteria documents will refer to UFC 3-570-01. In the event there is a conflict between these criteria and other criteria in another document, these criteria govern. The documents listed in Table 1-1 are known to be affected by the requirements and criteria in this document.

Table 1-1. UFC Documents Requiring Reconciliation of CP System Requirements and Criteria

DOCUMENT TITLE

UFC 3-230-01 Water Storage, Distribution and Transmission UFC 3-460-01 Design: Petroleum Fuel Facilities

UFC 3-460-03

Operation and Maintenance: Maintenance of Petroleum Systems

UFC 3-570-06

Operation and Maintenance: Cathodic Protection Systems

UFC 4-150-07

Maintenance and Operation: Maintenance of Waterfront Facilities

UFC 4-151-10 General Criteria for Waterfront Construction UFC 4-152-01 Design: Piers and Wharves

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CHAPTER 2 CATHODIC PROTECTION SYSTEM PLANNING

2-1 INTRODUCTON.

In accordance with DoD Instruction 5000.67, Prevention and Mitigation of Corrosion on DoD Military Equipment and Infrastructure, consider corrosion prevention and control (CPC) as an integral part of the design, construction, sustainment, restoration and maintenance of all DoD infrastructure. Utilize CP systems to reduce corrosion of buried or submerged metallic structures, thus reducing the probability of failure and concomitant environmental, operational, safety, and economic repercussions.

Petroleum, oil and lubricant (POL) systems, waterfront structures, and utility systems have been found to be the most critical facilities in terms of a combination of risk from corrosion, the need for continuous direct support of base operations, and the life cycle cost effectiveness of utilizing appropriate corrosion control systems.

CPC requirements development, pre-design surveys, system designs, and acceptance surveys must be accomplished under the supervision of one of the following individuals:

• NACE International certified Corrosion Specialist or Cathodic Protection Specialist with a minimum of five years of experience in the applicable CP system being designed.

• Where the qualification requirements are more restrictive or more stringent than any one of the above requirements, an appropriately certified person as required by applicable state/local laws, regulations, or requirements (primarily for underground storage tanks).

2-2 STRUCTURES FOR WHICH CP IS MANDATORY.

Regardless of soil or water corrosiveness, provide both CP systems and protective coatings for the following buried or submerged metallic structures:

• Petroleum, Oil, and Lubricants (POL) pipelines

• Underground POL/gas storage tanks, piping, and ancillary items

• Underground hazardous substance storage tanks

• Natural Gas and Propane Pipelines, including metallic components of non-metallic lines

• Fire protection water storage tanks

• Interior of all steel water distribution storage tanks, including the interior of elevated tank risers

• Oxygen Pipelines

• Other facilities with hazardous products as identified by the major commands, major claimants, or other competent authorities

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\1\For Army and Air Force projects, CP for the following structures and systems is mandatory. For Navy projects, the following structures and systems are not considered mandatory by this UFC, but may be mandatory by specific system UFC or other documents. Evaluate these structures for CP by the paragraph titled Other Structures for Which Cathodic Protection must be Evaluated:

• Oil/water separators and all associated metallic fittings in contact with soil

• New Waterfront Structures

• Piping or water lines used with fire protection water storage tanks, including metallic components of non-metallic lines (i.e., PIV’s, fire hydrants, change of direction devices, valves, metallic sections under building slabs and elsewhere, etc.)

• Metallic water distribution pipelines (including steel, ductile and cast iron pressurized piping) buried under concrete slabs (building foundations, runways, taxiways, parking aprons, wharf decks, and similar)

• Metallic components of force mains

• Sewage lift stations (all metallic components in contact with soil or liquids)

• Underground heat distribution and chilled water piping in metallic conduit/1/

2-2.1 POL Facilities and Structures.

Provide CP systems along with other corrosion control measures such as protective coatings and materials selection for all POL liquid fuel pipelines and storage facilities following the provisions of Code of Federal Regulations (CFR) Title 49 Chapter 1, Part 195, Transportation of Liquids by Pipeline, and CFR Title 40 Chapter 1, Part 112, Oil Pollution Prevention. Overseas installations must comply with the requirements of the Host Nation standards, DoD Overseas Environmental Baseline Guidance Document (OEBGD), and related specific Area Governing Standards. Coordinate CP system design with other POL related requirements in UFC 3-460-01.

2-2.2 Underground Storage Tank System.

Provide CP systems along with other corrosion control measures such as protective coatings and materials selection for all steel underground storage tank (UST) systems in accordance with CFR Title 40 Part 280, Technical Standards and Corrective Action for Owners and Operators of Underground Storage Tanks. By definition, the underground storage tank system includes the storage tank and associated piping. In addition, comply with State and Local government laws that may dictate additional or more stringent requirements. Overseas installations must comply with the requirements of the Host Nation standards, DoD OEBGD, and related specific Area Governing Standards. Ensure that UST CP systems are designed by a certified CP Specialist.

2-2.3 Natural Gas Pipe Lines.

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Provide CP systems along with other corrosion control measures such as protective coatings and materials selection for all metallic natural gas pipelines in accordance with the provisions of CFR Title 49 Chapter 1, Part 192, Transportation of Natural and Other Gas by Pipeline.

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2-2.4 Waterfront Structures.

Provide CP systems in conjunction with other protective measures such as proper material selection, protective coatings, and encasement, for the following submerged metallic waterfront structural systems:

• Steel sheet pile bulkheads along the waterfront or waterway

• Steel bearing piles for piers and wharves

• Steel fender piles for piers and wharves

• Submerged mooring components

Specify the proper type and size of galvanic or impressed current anodes to meet the desired CP system life. Do not specify magnesium anodes as the primary CP system for structures immersed in salt water.

2-2.5 Buried or Submerged Steel Utility Piping.

For all other steel utility piping, provide CP systems and bonded protective coatings on buried or submerged steel utility piping in which the electrolyte (soil or water) resistivity is less than 30,000 ohm-cm at the installation depth at any point along the piping installation.

2-2.6 Ductile or Cast Iron Utility Piping.

For all other ductile or cast iron utility piping and fittings, provide CP systems and protective coatings on buried or submerged new ductile or cast iron pipe in which the electrolyte resistivity is less than 30,000 ohm-cm at the installation depth at any point along the piping installation. Do not use unbonded protective coatings such as loose polyethylene wraps. Additionally, provide joint bonding for all ductile and cast iron installations. For non-metallic pipe with ductile or cast iron fittings, provide CP systems and protective coatings on buried or submerged new ductile or cast iron fittings in which the electrolyte resistivity is less than 30,000 ohm-cm.

\1\For Navy projects, the use of unbonded protective coatings, such as loose polyethylene wraps, is not prohibited. /1/

2-2.7 Potable Water Storage Tanks.

Provide CP and protective coatings for the interior submerged surfaces of potable water storage tanks, including bolted panel tanks in accordance with National Sanitation Foundation (NSF) Standard 61. Include requirements in the contract specifying that the contractor is responsible for providing an interior coating system and ensuring that the coating system is compatible with an impressed current CP (ICCP) system, if specified, and NSF Standard 61. For bolted panel storage tanks, require the contractor to ensure all panels of a bolted panel storage tank are electrically continuous.

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2-2.8 Fire Protection Water Storage Tanks.

Fire protection water storage tanks are mission critical facilities and must be properly protected against corrosion. Provide an ICCP system for the interior submerged surfaces of all fire protection water storage tanks, including bolted panel tanks. When the backfill beneath an on-grade tank is corrosive, provide an ICCP system for the exterior bottom of the on-grade tank. Include requirements in the contract specifying that the contractor is responsible for providing an interior coating system and ensuring that the coating system is compatible with the ICCP system. For bolted panel storage tanks, require the contractor to ensure all panels of a bolted panel storage tank are electrically continuous.

\1\For Navy projects, allow ICCP or sacrificial anode (GCP) systems for fire protection water storage tanks. /1/

2-3 OTHER STRUCTURES FOR WHICH CATHODIC PROTECTION MUST

BE EVALUATED.

Evaluate the economic feasibility of providing CP systems for the following buried or submerged systems:

• Gravity sewer lines

• Existing steel waterfront structures

• Reinforcing steel in concrete

• New or existing cast or ductile iron potable water lines (unless installed under a concrete slab) in soils with resistivity greater than 30,000 ohm-cm along its entire length

• Exterior bottom of on-grade steel water storage tanks

• Buried hydraulic elevator cylinders

• Other buried/submerged metallic structures not covered above

Installation of CP systems on these types of structures must be based on life-cycle economics. The overall corrosion protection system must include a combination of CP systems, protective coatings, proper material selection, encasement, or other methods.

CP system requirements determined by non-DoD personnel (e.g., A/E’s, private contractors, private consultants, etc.) must first be reviewed by a DoD qualified Corrosion Engineer or DoD NACE International certified cathodic protection specialist who subsequently recommends government approval prior to implementation.

\1\For Navy projects, delete the requirement that all CP system requirements be reviewed by a DoD Qualified Corrosion Engineer or DoD NACE International certified cathodic protection specialist. When available, DoD qualified CP personnel must be used for review. /1/

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2-4 PROTECTIVE COATINGS SPECIFICIED IN CONJUNCTION WITH

CATHODIC PROTECTION.

Protective coatings to be applied to a new metallic structure in conjunction with CP must have the minimum characteristics as described in NACE International SP0169 and the appropriate UFGS. Coordinate the coating type and requirements with the CP system being specified. Utilize the appropriate protective coating UFGS and supplement the UFGS requirements, as necessary, with the minimum coating characteristics indicated in NACE International SP0169, Control of External Corrosion on Underground or Submerged Metallic Piping Systems. Do not delete the CP requirements simply because it is not compatible with a particular coating.

2-5 ISOLATION OF COPPER WATER PIPES FROM FERROUS PIPES.

Dielectrically isolate copper water service lines from ferrous pipe in accordance with the requirements in NACE International SP0286, Electrical Isolation of Cathodically Protected Pipelines, unless not economically practicable. Where not practicable, design the CP system to include protection of both the copper and ferrous piping.

2-6 CP PROJECT PLANNING.

2-6.1 General CP Requirements.

Include CP system requirements as a separate line item in project documentation for the construction of new or the repair/upgrade of existing metallic structures as required by paragraphs 2-1 and 2-2. Cathodic protection systems are often not included in a project design because they are not appropriately identified in the project planning documents. Addition of these requirements later in the process often results in funding problems and other delays. Coordinate CP system requirements with the appropriate service CP subject matter expert or Major Command Corrosion Engineer. Refer also to the best practices in Appendix B.

2-6.2 Environmental/Site Concerns.

Identify environmental and site concerns. Prepare proper environmental Categorical Exclusions (CATEX), or if necessary, Environmental Impact Assessments (EIA) documentation prior to project execution. Refer also to paragraph 3-3.5.

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CHAPTER 3 DESIGN REQUIREMENTS

3-1 INTRODUCTION.

This chapter identifies CP system technical design requirements and defines the data that must be developed to establish engineering design bases and to evaluate the proper type of CP system(s) to be provided.

3-2 APPLICABLE CODES AND REGULATIONS.

In addition to the policy in Chapter 2, ensure that the CP system design complies with the legal requirements in any of the applicable codes, regulations, and other documents:

• CFR Title 40 Chapter 1, Part 112, Oil Pollution Prevention

• CFR Title 40 Part 280, Technical Standards and Corrective Action for Owners and Operators of Underground Storage Tanks

• CFR Title 49, Chapter 1, Part 192, Transportation of Natural and Other Gas by Pipeline

• CFR Title 49, Chapter 1, Part 195, Transportation of Liquids by Pipeline

• Department of Defense, Overseas Environmental Baseline Guidance Document and the appropriate regional/country Final Governing Standards.

• State or locality laws and regulations with more stringent CP requirements than the Federal laws and regulations.

Design agents doing Air Force designs will also comply with the requirements in Air Force Instruction 32-1054, Corrosion Control.

3-3 SYSTEM DESIGN.

Design CP systems in accordance with the policy in Chapter 2, applicable codes and regulations in paragraph 3-2, and the requirements of this section. Refer also to the best practices and lessons learned in Appendix B.

3-3.1 Two types of CP systems.

Select the CP system type, sacrificial anode (GCP) or ICCP, based on feasibility and cost. An economic analysis may be necessary to determine the system with the best life-cycle cost. In general, systems with small stable current requirements (0.5 Amp or less per 100 linear feet of structure) are more likely to be protected using sacrificial anode type systems. Those structures with larger current requirements (1 amp or more per 100 lineal feet of structure), or where the current requirements vary considerably with time, are more likely to require ICCP systems.

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3-3.1.1 Galvanic (Sacrificial) Anode Systems.

A galvanic (sacrificial) anode CP system is essentially a controlled electrochemical cell.

Figure 3-1 illustrates such a system. The structure becomes the cathode in the electrochemical cell, and corrosion that would have occurred on the structure being protected is mitigated due to the corrosion of the anode. The anode is consumed in the process but can usually be replaced when consumed. Anode life of 10 to 15 years is common, although lifetime can be limited by other factors such as mission requirements or mechanical damage.

Figure 3-1 Schematic Illustration of a GCP System

The structure and ancillary components intended for protection by sacrificial anodes must be electrically continuous. Conversely, other buried metals electrically continuous with the structure to be protected, but are not intended to be protected by the CP system, must be electrically isolated from the protected structure.

3-3.1.2 Impressed Current Systems.

Impressed current CP systems are also essentially controlled electrochemical cells.

However, in the ICCP system, a supply of direct electrical current is used to develop the potential difference between the anode and the structure being protected as Figure 3-2 illustrates. The direct current source supplies current from the anode through the electrolyte to the surface of the structure being protected. Like sacrificial anodes, ICCP anodes are also consumed, although typically at a much lower consumption rate.

Anode life of 20 to 25 years is common; although similar to GCP systems, lifetime can be limited by other factors such as mission requirements or mechanical damage.

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Figure 3-2 Schematic Illustration of an ICCP System

As with GCP systems, the structure and ancillary components intended for protection by ICCP systems must be electrically continuous. Conversely, other buried metals electrically continuous with the structure to be protected, but are not intended to be protected by the CP system, must be electrically isolated from the protected structure.

3-3.2 Field Surveys and Tests.

Conduct a field survey to determine site conditions required to adequately design a CP system. Perform specific investigations and field tests at the proposed installation site(s) to evaluate as a minimum:

• Electrolyte corrosivity (resistivity, pH, etc.)

• CP system current requirements

• Suitable anode bed locations, including geological concerns

• Available electrical power

• Location of rectifiers

• Overall terrain around the structure (location of test stations)

• Easement issues for structures located off station

• Possible environmental concerns

• Constructability issues (physical and operational)

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• Location of existing nearby CP systems and potential stray current concerns. Review of a published Base Corrosion Control Plan.

• Security restrictions that may impact cost

• Communication with local Corrosion Coordinating Committees for structures located off station

3-3.3 Availability of AC Power (ICCP Systems).

During the site survey, determine the availability of alternating current (AC) power at the site as the cost of installing new AC power service may be an important factor in determining whether a sacrificial or ICCP system is the more practical solution for the specific application. Where practicable, locate the ICCP rectifier nearby a building with available AC power and comply with applicable fire safety codes.

Design required electrical service in accordance with UFC 3-501-01. The electrical service design must be accomplished under the supervision of a registered professional electrical engineer.

3-3.4 Environmental/Site Concerns.

Consider the numerous environmental and safety concerns that may significantly impact the selection of CP system type, materials specified, system component installation procedures and controls, design document preparation, and the overall cost of the project. Consult with environmental and safety personnel during the early stages of design to identify the concerns and allow ample time for the designer to address these concerns. The following are some examples:

3-3.4.1 Hazardous Material.

Identify existing hazardous material at the proposed project site. These should be identified in the required environmental documents.

3-3.4.2 Archaeological/Historic Preservation Requirements.

Identify archaeological/historic preservation requirements and limitations at the proposed project site. This should also be identified in the required environmental documents.

3-3.4.3 Federal, State and Local Regulations.

Review and comply with Federal, state and local regulations that may affect the CP system installation. Some states have specific regulations regarding the design and installation of CP systems for underground storage tanks.

3-3.4.4 Mercury-Containing Anodes.

Avoid specifying mercury-containing aluminum alloy anodes. Consult with local/state regulators regarding concerns about the use of zinc anodes in certain situations.

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3-3.4.5 Water Storage Tanks.

Specify anodes and other related components in water storage tanks that comply with National Sanitation Foundation/American National Standards Institute (NSF/ANSI) Standard 61.

3-3.4.6 Issues That May Impact Construction/Installation.

Address issues that may impact the construction/installation process, particularly, the drilling or excavation for installation of the anodes:

• Address requirements and specify procedures and controls when hazardous material is encountered.

• Address requirements and specify procedures and controls when drilling into the ground water table. Specify controls for preventing cross contamination of ground water aquifers.

• Specify construction site controls to prevent pollution of the environment.

• Specify safety requirements applicable to the site and specific installation.

Review the appropriate UFGS sections for environmental and safety requirements to ensure the applicable concerns are addressed. Provide design documents to the base/DoD installation environmental and safety personnel for review to ensure the requirements are properly addressed.

3-3.5 Electrical Continuity.

Determine locations and provide bonding to ensure electrical continuity of all buried metallic structures that are intended to be protected by the CP system. All electrically discontinuous section(s) of the structure(s) to be protected must be properly bonded into the system to ensure adequate protection. Common causes of electrical discontinuities include:

• Dresser couplings.

• Mechanical pipe section connections such as found in ductile iron pipe.

• Plastic valves and fittings.

• Non-metallic sections of pipeline (new, existing or future installation).

• Improper bonding (or lack of bonding) on joints, flanges or previously installed dielectric isolation unions or flanges.

If electrical discontinuities cause the pipeline system to be too fragmented, and continuity bonding is not feasible, consider providing multiple smaller separate CP systems for the electrically discontinuous sections of structure. Some isolated sections of pipelines may be small enough to use a GCP system, but the designer must consider possible interference problems on these sections.

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3-3.5.1 Tracer Wires on Plastic Pipe.

When plastic pipe is used to replace or extend existing pipe, exothermically weld an insulated No. 8 American Wire Gage (AWG) copper wire to the existing steel pipe and run the wire along the full length of the plastic pipe for continuity and locator tracing purposes. As this may not always be technically feasible; alternatively, install tracer wires/tapes/devices directly above the plastic pipe at a depth that will be detectible by current detection equipment and technologies.

3-3.6 Identification of Other Structures in the Area.

Locate existing or planned Tburied or submerged structures. Determine if the other structures will impact or be impacted by the planned CP system. Identify the location of such structures in the design documents for interference testing during commissioning.

Locate new CP anode beds to minimize the possibility of interference, while providing the best current distribution possible. Although resistivity is an important factor in anode bed location, the location of other structures in the area is just as important.

3-3.6.1 Pipeline Crossings.

For a new pipeline installation, require/specify a minimum clearance of twelve inches between all pipelines lines at crossings. If practicable, specify 24 inches of clearance.

Indicate that direct contact between crossing or adjacent pipelines must be avoided.

Also where practicable, specify installation of insulating mats between pipelines at crossings if substantial earth currents are detected in the area or if a newly coated line is crossing a poorly coated or uncoated line.

3-3.6.2 Cathodic Protection Interference.

Stray currents, also called interference, result from external electromotive forces and can greatly accelerate corrosion. Stray current corrosion can be caused by voltage gradients (current flow) resulting from DC transit systems, HVDC Transmission systems, DC welding, telluric earth currents, and CP systems. The amount of corrosion caused is directly proportional to the amount of DC current flowing in the electrolyte.

Steel corrodes at a dissolution rate of about 20 pounds per ampere-year. CP systems can impress large amounts of current from their anodes, through the electrolyte, to the cathode. When a metallic structure not connected to or not intended to be protected by the CP system (referred to as the “foreign” structure) is immersed in the same electrolyte in the vicinity of the protected structure, it is subjected to stray current corrosion because of the electromotive force being applied through that electrolyte, and can undergo extremely severe corrosion without proper mitigation.

Provide test stations with provisions for bonding at all crossings for stray current interference testing and mitigation. Specify any additional appropriate methods and procedures to mitigate stray currents. Contact the users (owners, if not government owned) of the existing pipelines and inform them of the planned project. As any solutions to problems at pipeline crossings require cooperative efforts, effective

Change 1, 14 January 2019 coordination is essential. Identify coordination points of contact on the design drawings, particularly if non-government owned structures are impacted. For off base locations, Corrosion Coordinating Committees have been established in many areas to facilitate coordination of such efforts.

3-3.7 Electrical Isolation.

Determine locations and provide electrical isolation from buried metallic structures that are not intended to be protected by the CP system. Electrical isolation is essential to minimizing current requirements for both GCP and ICCP systems and ensuring the intended structure can be adequately protected. Also provide insulating joints to isolate sections of structures so that each section can be protected separately when necessary (e.g. a pipeline with multiple road crossings). For POL pipelines, provide surge arrestors across the electrical isolation device per UFC 3-460-01.

3-3.8 Connecting Electrical Wires and Cables.

Specify proper selection of cable size and type of insulation for ampacity, mechanical strength and electrically safe, reliable system operation. Use only copper cables in any CP installation. The DC output connecting cables used between the various components of CP systems are vital to the proper performance of the system. Any break in the primary circuit will result in failure of the system. Breaks in the auxiliary connections such as those used to test the system will also result in difficulties in proper adjustment and inspection of the system. See also paragraphs 4-2.4 and 4-3.3.

3-3.9 Connections and Splices.

Wire splices and connections are a source of undesirable circuit resistance and are a weak point in the reliability of the system as they often fail due to either corrosion or mechanical damage. Wire splices are not permitted in the following situations:

• Submerged GCP and ICCP anode lead wires or anode header cables

• Buried individual GCP and ICCP anode lead wires. Provide anodes with lead wires of sufficient length to reach an anode junction box/test station

• Buried sections of anode header cables unless specific site conditions or mission requirements prohibit the installation of an anode junction box/test station

• Buried sections of structure lead wires/header cables in highly corrosive environments

Keep connections to an absolute minimum and specify types of connections that have low resistance, high reliability, and good resistance to corrosion. See also paragraph 4- 4.2.

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3-3.10 Hazards Associated with Cathodic Protection.

3-3.10.1 Explosive Hazard Concerns.

Design both ICCP and sacrificial anode CP systems to comply with the regulations governing the hazardous area where flammable liquids or explosive gasses may be present. Such areas include, but are not limited to:

• Fuel storage farms

• Fuel terminals and fueling areas

• Refineries

• Ammunition depots

• Manholes (sewer gas)

Cathodic protection rectifiers used in such applications must be special oil-immersed explosion-proof types, or must be located outside of the hazardous area. In addition, all connections must be made in explosion-proof housings, and electrical conduits entering the housings properly sealed.

3-3.10.2 Bonding for Electrical Safety.

Provide electrical bonding points to prevent static discharge as required for safety where ships, vehicles, or aircraft are fueled or loaded. Any voltage gradient in the soil can result in a potential difference between structures located at different points, resulting in dangerous arcing. Cathodic protection systems are one source of such voltage gradients. Normal electrical bonding methods used in such circumstances is sufficient to mitigate this hazard. Voltage gradients caused by CP systems can also cause arcing during pipeline repairs when the pipeline is severed. Specify that a temporary bond be provided across the area to be cut to prevent this hazard before cutting a pipeline.

3-3.10.3 Installation Work near High Voltage Power Lines.

Installation work around high voltage power lines constitute a safety hazard from either direct contact with the power lines or induced voltage from these power lines. If the potential for such occurrences exists at the project site, then include provisions in the design documents addressing these concerns during construction.

3-3.10.4 Induced Alternating Current Concerns.

Alternating current (AC) can be induced on underground or aboveground components of CP systems, as well as large structures being protected in the vicinity of AC electrical transmission lines. This is particularly true if the structure is well coated or isolated from the ground, and the probability and intensity of induced current increases the more the pipeline is oriented parallel to the AC transmission lines. Pipelines using the same right-of-way as the AC transmission lines are particularly susceptible to induced AC

Change 1, 14 January 2019 voltages. In addition to causing corrosion damage, these voltages can be dangerous to personnel who may come in contact with the structure or CP system.

Identify the location of the AC transmission lines during the design of CP systems and assess the effects of induced currents. Where practicable, avoid placement of CP system components and test stations in areas where induced currents may exist.

Provide the appropriate combination of safety features to mitigate the effects of induced current for equipment that must be located within induced current areas and prevent electric shock to maintenance personnel such as.

• Electrical test stations and cabinets with a lockable dead front

• Gradient control mats around pipeline appurtenances engineered to provide safe (15 volts or less) touch-and-step voltages during both load and fault conditions

• Grounding systems for pipeline appurtenances and nearby independent isolated metallic structures

• Distributed galvanic anodes connected to the pipeline as part of the grounding system

• High resistivity crushed stone around pipeline appurtenances (use in conjunction with grounding/gradient control system)

Include induced current safety precautions and test procedures in the specifications for CP system commissioning field surveys or other electrical tests in the vicinity of AC transmission lines

3-3.10.5 CP Systems Near Communication Equipment.

Electrical filters are used to both increase the efficiency of the rectifier by reducing alternating current ripple and to reduce interference with communications equipment.

Efficiency filters can increase the efficiency of single-phase bridge type rectifiers by 10 to 14 percent and their use must be based upon a first cost versus operating (power) cost basis. Efficiency filters are not commonly used with three-phase rectifiers as the alternating current ripple in these units is inherently lower.

Specify noise interference filters where operational requirements mandate their use.

Verify requirements with the user during the design survey. Where necessary, retrofit noise interference filters into an existing rectifier when noise problems are encountered and are significantly affected by turning the unit on and off.

3-3.11 Special Requirements.

Identify any special requirements in the proposed CP system description such as the need for remote monitoring units, automated data collection units, unique structure or procedural features that may impact the CP system design, operation, or maintenance.

Refer to paragraph 4-5 and the best practices in Appendix B. These special requirements will impact the construction cost.

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All control systems, remote monitoring units, and automated data collection units must be planned, designed, acquired, executed and maintained in accordance with DoD Instruction 8500.01 and DoD Instruction 8510.01, and as required by individual Service Implementation Policy.

3-3.12 Easement Issues.

Easements are usually not an issue since most projects are located on-installation where easements are not necessary. In the case of CP systems for distribution pipelines and other structures located off-installation, identify easement issues as early as possible during the design process if not already addressed during the planning stages. Obtaining easements can be a long legal process; therefore, should be identified as early as possible before the start of construction. Involve installation real estate personnel for assistance.