26 42 14.00 10.pdf

Bldg. SAS3455 ARFF V-22 Osprey Fire Trainer Pad, MCAS New River Version 2 - 05/26/21

SECTION 26 42 14.00 10

CATHODIC PROTECTION SYSTEM (SACRIFICIAL ANODE)

08/ 09, CHG 1: 11/ 19

PART 1 GENERAL

1.1 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

ASTM B418 (2016) Standard Specification for Cast and Wrought Galvanic Zinc Anodes

ASTM B843 (2018) Standard Specification for Magnesium Alloy Anodes for Cathodic Protection

ASTM D1248 (2016) Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and Cable

NACE INTERNATIONAL (NACE)

NACE SP0185 (2007) Extruded Polyolefin Resin Coating Systems with Soft Adhesives for Underground or Submerged Pipe

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA TC 2 (2020) Standard for Electrical Polyvinyl Chloride (PVC) Conduit

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

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

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

UNDERWRITERS LABORATORIES (UL)

UL 6 (2007; Reprint Sep 2019) UL Standard for Safety Electrical Rigid Metal Conduit-Steel

UL 510 (2020) UL Standard for Safety Polyvinyl Chloride, Polyethylene and Rubber Insulating Tape

SECTION 26 42 14.00 10 Page 1

UL 514A (2013; Reprint Aug 2017) UL Standard for Safety Metallic Outlet Boxes

1.2 SUBMITTALS

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-02 Shop Drawings

Drawings

Six 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, installation details, and any other details required to demonstrate that the system has been coordinated and will function properly as a unit. All drawings shall be submitted in .pdf and AutoCAD (.dwg) formats.

Contractor's Modifications

Six copies of detail drawings showing proposed changes in location, scope of performance indicating any variations from, additions to, or clarifications of contract drawings or specifications. . 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, m ethod for electrically-isolating each pipe, and any other pertinent information to proper installation and performance of the system. All drawings shall be submitted in .pdf and AutoCAD (.dwg) formats.

SD-03 Product Data

Equipment

Within 30 days after receipt of notice to proceed, an itemized list of equipment and materials including itemnumber, 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 commerce until this submittal is approved.

Spare Parts

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

SD-06 Test Reports

SECTION 26 42 14.00 10 Page 2

Tests and Measurements

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 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.

Contractor's Modifications

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

SD-07 Certificates

Cathodic Protection System

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

Services of "Corrosion Expert"

Evidence of qualification of the "corrosion expert."

a. The "corrosion expert's" name and qualifications shall be certified in wiring to the Contracting Officer 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.

SD-10 Operation and Maintenance Data

Cathodic Protection System

Before final acceptance of the cathodic protection syste, six 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

SECTION 26 42 14.00 10 Page 3 description of all equipment and their basic operating features.

Six copies of maintenance manual, listing routine maintenance procedures, recommendation for maintenance testing, possible breakdowns and repairs, and troubleshooting guides. The manauls shall include single-line diagrams for the system as installed;

instructions in making pipe-to-reference cell and tank-to-reference cell protential 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 metalllic systems. The instructions shall be neatly bound between permanent covers and titled "Operating and Maintenane Instructions." These instructions shall be submitted for the Contracting Officer'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 potentials as measured during the tests required by Paragraph: TESTS AND MEASUREMENTS, of this section. As-built drawings shall be submitted in .pdf and AutoCAD (.dwg) formats.

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

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

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

Training Course

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 maintenence instructions, are to be covered.

1.3 GENERAL REQUIREMENTS

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 . The services required include planning, installation, adjusting and testing of a cathodic protection system, using sacrificial anodes for cathodic protection of the Gas lines, their connectors and lines below ground. 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 pipes from any other structure. Any pipe crossing the gas pipe shall have a test station. The cathodic protection shall be

SECTION 26 42 14.00 10 Page 4 provided on Gas pipes.

1.4 QUALITY ASSURANCE

1.4.1 Services of "Corrosion Expert"

The Contractor shall obtain the services of a "corrosion expert" to Design, 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 experience, is qualified to engage in the practice of corrosion control of buried or submerged metallic surfaces.

a. Such a person must be accredited or certified by the National Association of Corrosion Engineers (NACE) as a NACE Accredited Corrosion Specialist or a NACE certified Cathodic Protection (CP) Specialist or be a registered professional engineer who has certification or licensing that includes education and experience in corrosion control of buried or submerged metallic piping and tank systems, if such certification or licensing includes 5 years experience in corrosion control on underground metallic surfaces of the type under this contract.

b. The "corrosion expert" shall make at least 3 visits to the project site. The first of these visits shall include obtaining soil resistivity data, acknowledging the type of pipeline coatings to be used and reporting to the Contractor the type of cathodic protection required. Once the submittals are approved and the materials delivered, the "corrosion expert" shall revisit the site the ensure the Contractor understands installation practices and laying out the components. The third visit shall involve testing the installed cathodic protection systems and training applicable personnel on proper maintenance techniques. The "corrosion expert" shall supervise installation and testing of all cathodic protection.

c. Submit evidence of qualifications of the "corrosion expert" . The "corrosion expert's" name and qualifications shall be certified in writing to the Contracting Officer prior to the start of construction. 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.

1.4.2 Isolators

Isolators are required to insulate the indicated pipes from any other structure. Isolators shall be provided with lightning protection and a test station as shown on the shop drawings. .

1.4.3 Anode and Bond Wires

A minimum of 5 magnesium anodes with an unpackaged weight of 9 pounds shall be provided uniform distances along the metallic pipe lines. A minimum of 3 test stations shall be used for these anodes. These anodes shall be in addition to anodes for the pipe under concrete slab and casing requirements. For each cathodic system, the metallic components and structures to be protected shall be made electrically continuous. This shall be accomplished by installing bond wires between the various

SECTION 26 42 14.00 10 Page 5 structures. Bonding of existing buried structures may also be required to preclude detrimental stray current effects and safety hazards. Provisions shall be included to return stray current to its source without damaging structures intercepting the stray current. The electrical isolation of underground facilities in accordance with acceptable industry practice shall be included under this section. All tests shall be witnessed by the Contracting Officer.

1.4.4 Surge Protection

Approved zinc grounding cells or sealed weatherproof lightning arrestor devices shall be installed across insulated flanges or fittings installed in underground piping and indicated on the shop drawings. The arrestor shall be gapless, self-healing, solid state type. Zinc anode composition shall conform to ASTM B418, Type II. Lead wires shall be number 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 shop drawings. Lightning arrestors or zinc grounding cells are not required for insulated flanges on metallic components used on nonmetallic piping systems.

1.4.5 Nonmetallic Pipe System

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 Contracting Officer for approval within 45 days after date of receipt of notice to proceed, and before commencement of any work.

1.4.5.1 Coatings

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 fillings). This covering shall be as required for underground metallic pipe. Each test shall be witnessed by the Contracting Officer. Coatings shall be selected, applied, and inspected in accordance with NACE SP0185 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.

1.4.5.2 Tracer Wire

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 thermit-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 pipe line.

1.4.6 Drawings

Detail 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.

SECTION 26 42 14.00 10 Page 6

1.4.7 Electrical Potential Measurements

All potential tests shall be made at a minimum of 10 foot intervals witnessed by the Contracting Officer. 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.

1.4.8 Achievement of Criteria for Protection

All conductors, unless otherwise shown, shall be routed to or through the test stations. Each system provided shall achieve a minimum pipe-to-soil "instant off" potential of minus 850 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 adusted as required to produve a minimum of minus 850 millivolts "instant off" potential between the structure being tested and the reference cell. This potential should be obtained over 95 percent of the metallic area. This must be achieved without the "instant off" potential exceeding 1150 millivolts. Testing will be witnessed by the Contracting Officer. Additional anodes shall be provided by the Contractor if required to achieve the minus 850 millivolts "instant off". Although acceptance criteria of the cathodic protection systems are defined in NACE SP0185, for this project the "instant off" potential of minus 850 millivolts is the only acceptable criteria.

1.4.9 Metallic Components and Typicals

a. Metallic components: As a minimum, each metallic component shall be protected with two (2) magnesium anodes. This number of anodes is required to achieve minus 850 millivolts "instant off" potential on the metallic area and at the same time not provide overvoltage above 1150 millivolts "instant off." As a minimum, the magnesium anode unpackaged weight shall be 9 pounds. The magnesium anodes shall be located on each 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 havr an unpackaged weight of 17 pounds.

c. Pipe Under Concrete Slab: Pipe under concrete slab shall have a minimum of 2 magnesium anodes. These magnesium anodes shall have an unpackaged weight of 9 pounds. Pipe under conctete slab shall have 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 1 magnesium anodes.

The magnesium anode shall have an unpackaged weight of 9 pounds.

e. Metallic Pipe Component or Section: Each section of metalic pipe shall be protected with 2 magnesium anodes. The magnesium anodes shall have an unpackaged weight of 9 pounds.

f. Connectors or Change-of-Direction Devices: Each change-of-direction device shall be protected with 2 magnesium anodes. The magnesium anode shall have an unpackaged weight of 9

SECTION 26 42 14.00 10 Page 7 pounds.

1.4.10 Metallic Component Coating

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 SP0185 and as specified in these specifications.

1.5 DELIVERY, STORAGE, AND HANDLING

Storage area for magnesium anodes will be designated by the Contracting Officer. 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, shall be resacked and the required backfill added.

1.6 EXTRA MATERIALS

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

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

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 the minimum requirements of this contract.

a. 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 .

b. The services required include planning, installation, adjusting and testing of a cathodic protection system, using sacrificial anodes for cathodic protection of the Gas lines, 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.

c. Within 30 days after receipt of notice to proceed , submit 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. Insulators are required whenever needed to insulate the pipes from any other structure. Any pipe crossing the gas pipe shall have a test station. The cathodic protection shall be provided on Gas pipes.

d. Submit proof that the materials and equipment furnished under this

SECTION 26 42 14.00 10 Page 8 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.

e. Before final acceptance of the cathodic protection system, submit 6 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.

f. Submit Six copies of maintenance manuals, listing routine maintenance procedures, recommendation for maintenance testing, possible breakdowns and repairs, and troubleshooting guides. The manuals shall include single-line diagrams for the 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 Contracting Officer's approval. The instructions shall include the following:

(1) 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 s as measured during the tests required by paragraph TESTS AND MEASUREMENTS of this section .

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

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

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

2.1.1 Contractor's Modifications

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.

a. Submit Six copies of detail drawings showing proposed changes in location, scope of performance indicating any variations from, additions to, or clarifications of contract specifications or drawings. The drawings shall show proposed changes in anode arrangement, anode size and number, anode materials and layout details, conduit size, wire size, mounting details, wiring diagram, method for electrically-isolating each pipe, and any other pertinent information to proper installation and performance of the system. The modifications shall be fully described, shall be approved by the Contracting Officer 's Representative , and shall meet the following

SECTION 26 42 14.00 10 Page 9 criteria.

b. The proposed system shall achieve a minimum pipe-to-soil "instant off" potential of minus 850 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 t ake 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 850 millivolts "instant off" 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.

c. Submit final report regarding Contractor's modifications. The report shall include pipe-to-soil 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.

2.1.2 Summary of Services Required

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

a. Close-interval potential surveys.

b. Cathodic Protection Systems.

c. System testing.

d. Casing corrosion control.

e. Interference testing.

f. Training.

g. Operating and maintenance manual.

h. Insulator testing and bonding testing.

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

2.1.3 Tests of Components

A minimum of four (4) tests shall be made at each metallic component in the piping system. Two (2) measurements shall be made directly over the anodes and the other two (2) tests 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

SECTION 26 42 14.00 10 Page 10 describe how the cathodic protection system will work and provide testing at each component. Components requiring cathodic protection shall include but not be limited to the following:

a. Pipes under the floor slab or foundations.

b. PIV.

c. Shutoff valves.

d. Metallic pipe extended from aboveground locations.

e. Each connector or change-of-direction device.

f. Any metallic pipe component or section.

g. Backflow preventer.

h. Culvert.

2.1.4 Electrical Potential Measurements

All potential tests shall be made at a minimum of 10 foot intervals witnessed by the Contracting Officer. 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.

2.1.5 Achievement of Criteria for Protection

All conductors, unless otherwise shown, shall be routed to or through the test stations. Each system provided shall achieve a minimum pipe-to-soil "instant off" potential of minus 850 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 850 millivolts "instant off" potential between the structure being tested and the reference cell. This potential should be obtained over 95 percent of the metallic area. This must be achieved without the "instant off" potential exceeding 1150 millivolts. Testing will be witnessed by the Contracting Officer. Additional anodes shall be provided by the Contractor if required to achieve the minus 850 millivolts "instant off". Although acceptance criteria of the cathodic protection systems are defined in NACE SP0185, for this project the "instant off" potential of minus 850 millivolts is the only acceptable criteria.

2.1.6 Metallic Components and Typicals

2.1.6.1 Metallic Components

As a minimum, each metallic component shall be protected with two (2) magnesium anodes. This number of anodes is required to achieve minus 850 millivolts "instant off" potential on the metallic area and at the same time not provide overvoltage above 1150 millivolts "instant off." As a minimum, the magnesium anode unpackaged weight shall be 9 pounds . The magnesium anodes shall be located on each side of the metallic component and routed through a test station.

SECTION 26 42 14.00 10 Page 11

2.1.6.2 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 .

2.1.6.3 Pipe Under Concrete Slab

Pipe under concrete slab shall have a minimum of 2 magnesium anodes.

These magnesium anodes shall have an unpackaged weight of 9 pounds . Pipe under concrete slab shall have 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.

2.1.6.4 Valves

Each valve shall be protected with 1 magnesium anodes. The magnesium anode shall have an unpackaged weight of 9 pounds .

2.1.6.5 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 9 pounds .

2.1.6.6 Connectors or Change-of-Direction Devices

Each change-of-direction device shall be protected with 2 magnesium anodes. The magnesium anode shall have an unpackaged weight of 9 pounds .

2.1.7 Metallic Component Coating

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 SP0185 and as specified in these specifications.

2.2 MAGNESIUM ANODES

A minimum of 2 anodes shall be installed on the Pipe system. See Paragraph METALLIC COMPONENTS AND TYPICALS for additional anodes under slab.

2.2.1 Anode Composition

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 B843 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

SECTION 26 42 14.00 10 Page 12

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

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

2.2.2 Dimensions and Weights

Dimensions and weights of anodes shall be approximately as follows:

TYPICAL MAGNESIUM ANODE SIZE

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

Nominal Weight (lbs)

Approx. Size (inch) Nominal Gross Weight (lbs) Packaged in

Backfill

Nominal Package Dimensions (inch)

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

32 5 X 5 X 20-1/2 68 8-1/2 X 28

50 7 X 7 X 16 100 10 X 24

2.2.3 Packaged Anodes

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

SECTION 26 42 14.00 10 Page 13

Material Approximate Percent by Weight

Sodium Sulphate 5

Total 100

2.2.4 Zinc Anodes

Zinc anodes shall conform to ASTM B418, Type II.

2.2.5 Connecting Wire

2.2.5.1 Wire Requirements

Wire shall be No. 12 AWG solid copper wire, not less than 10 feet long, unspliced, complying with NFPA 70 , Type TW 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.

2.2.5.2 Anode Header Cable

Cable for anode header and distribution shall be No. 12 AWG stranded copper wire with type CP high molecular weight polyethylene, 7/64 inch thick insulation, 600-volt rating.

2.3 MISCELLANEOUS MATERIALS

2.3.1 Electrical Wire

Wire shall be No. 12 AWG stranded copper wire with NFPA 70 , Type TW insulation. Polyethylene insulation shall comply with the requirements of ASTM D1248 and shall be of the following types, classes, and grades:

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

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

2.3.1.1 Wire Splicing

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. Sheaths for encapsulating electrical wire splices to be buried underground shall fit the insulated wires entering the spliced joints and epoxy potting compound shall be as specified below.

2.3.1.2 Test Wires

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

2.3.1.3 Resistance Wire

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

SECTION 26 42 14.00 10 Page 14

2.3.2 Conduit

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

2.3.3 Test Boxes and Junctions Boxes

Boxes shall be outdoor type conforming to UL 514A .

2.3.4 Joint, Patch, Seal, and Repair Coating

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

2.3.5 Backfill Shields

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. When joint bonds are required, due to the use of mechanical joints, the entire joint shall be protected by the use of a kraft paper joint cover. The joint cover shall be filled with poured-in, hot coat-tar enamel.

2.3.6 Epoxy Potting Compound

Compound for encapsulating electrical wire splices to be buried underground shall be a two package system made for the purpose.

2.3.7 Test Stations

Stations shall be of the aboveground 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 be provided with a lockable over and shall have an embossed legend, "C.P. Test." A minimum of one (1) test station shall be provided each component of the pipe. 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 from each test station. Other conductors shall be provided for each anode, other foreign pipe, and reference cells as required.

2.3.8 Joint and Continuity Bonds

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

SECTION 26 42 14.00 10 Page 15 exothermic welding. Exothermic weld areas shall be insulated with coating compound and approved, and witnessed by the Contracting Officer.

Continuity bonds shall be installed as necessary to reduce stray current interference. Additional joint bondings shall be accomplished by the Contractor where the necessity is discovered during construction or testing or where the Contracting Officer'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. The Contractor shall t est 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.

2.3.9 Resistance Bonds

Resistance bonds should be adjusted as outlined in this specification.

Alternate methods may be used if they are approved by the Contracting Officer.

2.3.10 Stray Current Measurements

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

SP0185.

2.3.11 Electrical Isolation of Structures

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.

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 force mains and/or gas line; 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.

2.3.11.1 Electrically Isolating Pipe Joints

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

2.3.11.2 Electrically Conductive Couplings

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

SECTION 26 42 14.00 10 Page 16

2.3.11.3 Insulating Joint Testing

A Model 601 insulation checker , as manufactured by "Gas Electronics", shall be used for insulating joint (flange) electrical testing.

2.3.12 Underground Structure Coating

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 SP0185 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 40 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.

2.3.12.1 Field Joints

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 Contracting Officer shall be asked to witness inspection of the coating and testing using a holiday detector.

2.3.12.2 Inspection of Pipe Coatings

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 SP0185 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 Contracting Officer's representative to determine suitability of the detector. All labor, materials, and equipment necessary for conducting the inspection shall be

SECTION 26 42 14.00 10 Page 17 furnished by the Contractor.

2.3.12.2.1 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 .

2.3.13 Resistance Wire

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

2.3.14 Electrical Connections

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.

2.3.15 Electrical Tape

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

2.3.16 Permanent Reference Electrodes

Permanent reference electrodes shall be Cu-CuS04 electrodes suitable for direct burial. Electrodes shall be guaranteed by the supplier for 15 years' service in the environment in which they shall be placed.

Electrodes shall be installed directly beneath pipe, or metallic component.

2.3.17 Casing

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

Acceptance criteria for determining the adequacy of protection on a buried underground pipe shall be in accordance with NACE SP0185 and as specified below.

3.1.1 Iron and Steel

The following method a. shall be used for testing cathodic protection

SECTION 26 42 14.00 10 Page 18 voltages. If more than one method is required, method b. shall be used.

a. A negative voltage of at least minus 850 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. A minimum of minus 850 millivolts "instant off" potential between the underground component being tested and the reference cell shall be achieved over 95 percent of the area of the structure. Adequate number of measurements shall be obtained over the entire structure, pipe, tank, or other metallic component to verify and record achievement of minus 850 millivolts "instant off."

This potential shall be obtained over 95 percent of the total metallic area without the "instant off" potential exceeding 1200 millivolts.

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. 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 four (4) measurements shall be made using subparagraph a., above, and achieving the "instant off" potential of minus 850 millivolts. Two (2) measurements shall be made over the anodes and two (2) measurements shall be made at different locations near the component and farthest away from the anode.

3.1.2 Aluminum

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.

3.1.3 Copper Piping

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.

SECTION 26 42 14.00 10 Page 19

3.2 INSTALLATION

3.2.1 Anode Installation

Unless otherwise authorized, installation shall not proceed without the presence of the Contracting Officer. Anodes of the size specified shall be installed to the depth indicated and at the locations shown on the approved detail drawings . Locations may be changed to clear obstructions with the approval of the Contracting Officer. 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 shall be applied to each filled hole after anode backfilling and tamping has been completed to a point about 6 inch above the anode. After the water has been absorbed by the earth, backfilling shall be completed to the ground surface level.

3.2.1.1 Single Anodes

Single anodes, spaced as shown on the approved detail drawings , shall be connected to the pipeline, allowing adequate slack in the connecting wire to compensate for movement during backfill operation.

3.2.1.2 Groups of Anodes

Groups of anodes, in quantity and location shown on the approved detail drawings , 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 crimp connector or exothermic weld and splice mold kit with appropriate potting compound.

3.2.1.3 Welding Methods

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

3.2.2 Anode Placement - General

Packaged anodes shall be installed completely dry, and shall be lowered into holes by rope sling or by grasping the…