11_ITEM 01.2-12_ADD 02_Section 26 42 13.pdf

ANG/WI - F-35: 3-Bay Specialized Hangar 20202700F353BAY Addendum No. 02 8 June 2022

SECTION 26 42 13

GALVANIC (SACRIFICIAL) ANODE CATHODIC PROTECTION (GACP) SYSTEM

05/21

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.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.1 (2003; R 2018) Unified Inch Screw Threads (UN and UNR Thread Form)

ASME B1.20.1 (2013; R 2018) Pipe Threads, General Purpose (Inch)

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.21 (2021) Nonmetallic Flat Gaskets for Pipe Flanges

ASME B16.39 (2020) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)

ASME B18.2.2 (2022) Nuts for General Applications:

Machine Screw Nuts, and Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASTM INTERNATIONAL (ASTM)

ASTM A194/A194M (2020a) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A307 (2021) Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength

ASTM B3 (2013) Standard Specification for Soft or Annealed Copper Wire

ASTM B8 (2011; R 2017) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

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ASTM B418 (2016a; R2021) Standard Specification for Cast and Wrought Galvanic Zinc Anodes

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

ASTM C94/C94M (2021b) Standard Specification for Ready-Mixed Concrete

ASTM D709 (2017) Standard Specification for Laminated Thermosetting Materials

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

ASTM D2028/D2028M (2015) Cutback Asphalt (Rapid-Curing Type)

ASTM D3381/D3381M (2018) Standard Specification for Viscosity-Graded Asphalt Binder for Use in Pavement Construction

ASTM F1182 (2007; R 2019) Anodes, Sacrificial Zinc Alloy

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 15589-2 (2012) Petroleum, Petrochemical and Natural Gas Industries - Cathodic Protection of Pipeline Transportation Systems - Part 2: Offshore Pipelines

NACE INTERNATIONAL (NACE)

NACE SP0106 (2018) Control of Internal Corrosion in Steel Pipelines and Piping Systems

NACE SP0176 (2007) Corrosion Control of Submerged Areas of Permanently Installed Steel Offshore Structures Associated with Petroleum Production

NACE SP0177 (2019) Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems

NACE SP0186 (1986; R 2007) Application of Cathodic Protection for External Surfaces of Steel Well Casings

NACE SP0188 (1999; R 2006) Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

NACE SP0193 (2016) Application of Cathodic Protection to Control External Corrosion of Carbon Steel On-Grade Storage Tank Bottoms

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NACE SP0196 (2020) Galvanic Anode Cathodic Protection of Internal Submerged Surfaces of Steel Water Storage Tanks

NACE SP0200 (2014) Standard Practice Steel-Cased Pipeline Practices

NACE SP0285 (2021) External Corrosion Control of Underground Storage Tank Systems by Cathodic Protection

NACE SP0286 (1997; R 2007) Standard Practice Electrical Isolation of Cathodically Protected Pipelines

NACE SP0388 (2018) Impressed Current Cathodic Protection of Internal Submerged Surfaces of Carbon Steel Water Storage Tanks - Item No. 21040

NACE SP0607 (2007) Petroleum and Natural Gas Industries — Cathodic Protection of Pipeline Transportation Systems — Part 2:

Offshore Pipelines

NACE SP21424 (2018) Alternating Current Corrosion on Cathodically Protected Pipelines: Risk Assessment, Mitigation and Monitoring

NACE TPC 11 (2008) A Guide to the Organization of Underground Corrosion-Control Coordinating Committees

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

ANSI C119.1 (2016) Electric Connectors - Sealed Insulated Underground Connector Systems Rated 600 Volts

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA RN 1 (2005; R 2013) Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit

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. DEPARTMENT OF DEFENSE (DOD)

MIL-A-18001 (1993) Anodes, Sacrificial Zinc Alloy

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MIL-I-1361 (1985; Rev C; Notice 1 1991; Notice 2 2021) Instrument Auxiliaries, Electrical Measuring: Shunts, Resistors and Transformers

UNDERWRITERS LABORATORIES (UL)

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

UL 44 (2018; Reprint May 2021) UL Standard for Safety Thermoset-Insulated Wires and Cables

UL 83 (2017; Reprint Mar 2020) UL Standard for Safety Thermoplastic-Insulated Wires and Cables

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

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

UL 514B (2012; Reprint May 2020) Conduit, Tubing and Cable Fittings

1.2 DEFINITIONS

It is convenient to classify corrosion by the forms in which it manifests itself, the basis for this classification being the appearance of the corroded metal. Each form can be identified by visual observation, although, in some cases, magnification is required. Valuable information for the solution of a corrosion problem can often be obtained through careful observation of the corroded test specimens or failed equipment.

Examination before cleaning is particularly desirable. Cathodic Protection is a method used to control corrosion.

1.2.1 Cathodic Protection

Cathodic Protection (CP) is an electrochemical (half electrical and half chemical) method used to control corrosion of buried or submerged metallic structures. It prevents corrosion by making the protected structure a cathode by installing a more anodic metal (sacrificial or galvanic) anode or a metallic (impressed current) anode connected to a Direct Current (DC) power source. When the proper amount of current is applied to the structure, it becomes a cathode. Since all corrosion occurs at the anode, the structure no longer corrodes. The electrons move in the metallic path (electrical). Reduction (chemical) reactions occur at the surface of the cathode resulting in a hydrogen coating and more alkaline environment.

Oxidation (chemical) reactions occur at the surface of the anode resulting in corrosion and a more acidic environment. After a CP system is installed and adjusted to provide adequate protection, the hydrogen coats the defects in the coating and polarizes in the negative direction (to a copper/copper sulfate reference electrode) over time the current and potentials remain relatively stable; changes in currents or potentials indicate a problem. An error-free measurement of negative 850 millivolts DC or more negative to the copper/copper-sulfate reference electrode

SECTION 26 42 13 Page 4 proves the structure is a cathode and corrosion has been mitigated.

1.2.2 Corrosion

It is convenient to classify corrosion by the forms in which it manifests itself, the basis for this classification being the appearance of the corroded metal. Each form can be identified by visual observation, although, in some cases, magnification is required. Valuable information for the solution of a corrosion problem can often be obtained through careful observation of the corroded test specimens or failed equipment.

Examination before cleaning is particularly desirable. Some of the eight forms of corrosion are unique, but all of them are more or less interrelated.

The eight forms of corrosion are: (1) Uniform Attack, (2) Galvanic or Two-Metal Corrosion, (3) Crevice Corrosion, (4) Pitting Corrosion, (5) Intergranular Corrosion, (6) Selective Leaching, (7) Erosion Corrosion, and (8) Stress Corrosion Cracking. This listing is arbitrary but covers practically all corrosion failures and problems. The forms are not listed in any particular order of importance. Below, the eight forms of corrosion are discussed in terms of their characteristics, mechanisms, and preventive measures. Hydrogen damage, although not a form of corrosion, often occurs indirectly as a result of corrosive attack and is, therefore, included in this discussion.

1.2.3 Alternating Current (AC) Corrosion

AC corrosion occurs when there is a source of AC current, typically from a high voltage overhead AC (OHAC) power-line, when there is a low soil resistivity - typically less than 5,000 ohm-cm and there is a very small coating holidays. The AC corrosion pits typically have a tubercle of corrosion product at the pit. AC interference study modeling software can determine the mitigation solution to solve this problem. Typically, AC Corrosion mitigation is done in conjunction with high AC potentials and fault current mitigation.

1.2.4 AC Interference

AC interference occurs when a pipeline parallels a high-voltage overhead AC (OHAC) power-line. An interference study is required when this situation occurs as AC interference can cause high AC potentials along the pipeline (safety), can cause a fault condition between the pipeline and power-line and could cause AC corrosion to occur. The pipeline coating when exposed can have blisters/bubbles caused by the excessive AC. The interference study will use modeling software to determine what combination of interference may be occurring (if any) and provide the mitigation solution to solve the problem.

1.2.5 Uniform Attack

Uniform attack is the most common form of corrosion. It is normally characterized by a chemical or electrochemical reaction that proceeds uniformly over the entire exposed surface or over a large area. The metal becomes thinner and eventually fails. For example, a piece of steel or zinc immersed in dilute sulfuric acid normally dissolves at a uniform rate over its entire surface. A sheet iron roof shows essentially the same degree of rusting over its entire outside surface.

Uniform attack, or general overall corrosion, represents the greatest

SECTION 26 42 13 Page 5 destruction of metal on a tonnage basis. This form of corrosion, however, is not of great concern from a technical standpoint, because the life of equipment can be accurately estimated on the basis of comparatively simple tests. Merely immersing specimens in the fluid involved is often sufficient. Uniform attack can be prevented or reduced by (1) materials, such as coatings, that reduce contact between metal and electrolytes, (2) inhibitors, or (3) CP.

1.2.6 Galvanic or Two-Metal Corrosion

A potential difference usually exists between two dissimilar-metals when they are immersed in a corrosive or conductive solution. If these metals are placed in contact (or otherwise electrically connected), this potential difference produces electron flow between them. Corrosion of the less corrosion-resistant metal is usually increased, and attack of the more resistant material is decreased, compared to the behavior of these metals when they are not in contact. The less resistant metal becomes anodic and the more resistant metal becomes cathodic. Usually the cathode or cathodic metal corrodes very little or not at all in this type of couple. Because of the electric currents and dissimilar-metals involved, this form of corrosion is called galvanic, bi-metallic or two-metal, corrosion. Galvanic corrosion is restricted to electrochemical corrosion caused by dissimilar-metal effects. It is electrochemical corrosion, but this document must restrict the term galvanic to dissimilar-metal effects for purposes of clarity.

1.2.7 Crevice Corrosion

Intense localized corrosion frequently occurs within crevices and other shielded areas on metal surfaces exposed to corrosives. This type of attack is usually associated with small volumes of stagnant solution caused by holes, gasket surfaces, lap joints, surface deposits, and crevices under bolt and rivet heads. As a result, this form of corrosion is called crevice corrosion or, sometimes, deposit or gasket corrosion.

1.2.8 Pitting Corrosion

Pitting is a form of extremely localized attack that results in holes in the metal. These holes may be small or large in diameter, but in most cases they are relatively small. Pits are sometimes isolated or so close together that they look like a rough surface. Generally a pit may be described as a cavity or hole with the surface diameter about the same as or less than the depth. Pitting is one of the most destructive and insidious forms of corrosion. It causes equipment to fail because of perforation with only a small percent weight loss of the entire structure. It is often difficult to detect pits because of their small size and because the pits are often covered with corrosion products. In addition, it is difficult to measure quantitatively and compare the extent of pitting because of the varying depths and numbers of pits that may occur under identical conditions. Pitting is also difficult to predict by laboratory tests. Sometimes the pits require a long time (several months or a year) to show up in actual service. Pitting is particularly vicious because it is a localized and intense form of corrosion, and failures often occur with extreme suddenness.

1.2.9 Intergranular Corrosion

Grain boundary effects are of little or no consequence in most applications or uses of metals. If a metal corrodes, uniform attack

SECTION 26 42 13 Page 6 results since grain boundaries are usually only slightly more reactive than the matrix. However, under certain conditions, grain interfaces are very reactive and intergranular corrosion results. Localized attack at and adjacent to grain boundaries, with relatively little corrosion of the grains, is intergranular corrosion. The alloy disintegrates (grains fall out) or loses its strength. Intergranular corrosion can be caused by impurities at the grain boundaries, enrichment of one of the alloying elements, or depletion of one of these elements in the grain-boundary areas. Small amounts of iron in aluminum, wherein the solubility of iron is low, have been shown to segregate in the grain boundaries and cause intergranular corrosion. It has been shown that, based on surface tension considerations, the zinc content of a brass is higher at the grain boundaries. Depletion of chromium in the grain-boundary regions results in intergranular corrosion of stainless steels.

1.2.10 Selective Leaching

Selective leaching is the removal of one element from a solid alloy by corrosion processes. The most common example is the selective removal of zinc in brass alloys (dezincification). Similar processes occur in other alloy systems in which aluminum, iron, cobalt, chromium, and other elements are removed. Selective leaching is the general term to describe these processes, and its use precludes the creation of terms such as de-aluminumification, de-cobaltification. Parting is a metallurgical term that is sometimes applied, but selective leaching is preferred.

1.2.11 Erosion Corrosion

Erosion corrosion is the acceleration or increase in rate of deterioration or attack on a metal because of relative movement between a corrosive fluid and the metal surface. Generally, this movement is quite rapid, and mechanical wear effects or abrasion are involved. Metal is removed from the surface as dissolved ions, or it forms solid corrosion products, which are mechanically swept from the metal surface. Sometimes, movement of the environment decreases corrosion, particularly when localized attack occurs under stagnant conditions; this is not erosion corrosion because deterioration is not increased. Erosion corrosion is characterized in appearance by grooves, gullies, waves, rounded holes, and valleys and usually exhibits a directional pattern. In many cases, failures because of erosion corrosion occur in a relatively short time, and they are unexpected largely because evaluation corrosion tests were run under static conditions or because the erosion effects were not considered.

1.2.12 Stress-Corrosion Cracking

Stress-corrosion cracking refers to cracking caused by the simultaneous presence of tensile stress and a specific corrosive medium. Many investigators have classified all cracking failures occurring in corrosive media as stress-corrosion cracking, including failures due to hydrogen embrittlement. However, these two types of cracking failures respond differently to environmental variables. To illustrate, CP is an effective method for preventing stress-corrosion cracking; however, hydrogen-embrittlement may be caused when excessive current is applied, especially on stainless steel. Hence, the importance of considering stress-corrosion cracking and hydrogen embrittlement as separate phenomena is obvious. During stress-corrosion cracking, the metal or alloy is virtually unattacked over most of its surface, while fine cracks progress through it. This cracking phenomenon has serious consequences, since it can occur at stresses within the range of typical design stress.

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1.2.13 Exothermic Welding

Exothermic welding is used in CP to connect a copper wire to a metallic structure, usually steel or cast-iron. It is a pyrotechnic composition of copper oxide, aluminum powder and magnesium powder. The magnesium powder is ignited with a spark gun or electronic ignition equipment. The aluminum powder serves as fuel, and melts the copper oxide, which bonds the wire to the structure. Although not explosive, it can create brief bursts of heat and high temperature in a small area.

1.2.14 Error-Free

Potential measurement error due to a voltage drop caused by current flowing through a resistor (the electolyte) between the reference electrode and the protected structure.

1.3 ADMINISTRATIVE REQUIREMENTS

After award of the contract, but prior to commencement of any work at the site, meet with the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. Develop a mutual understanding relative to the administration of the value engineering, the safety program, preparation of the schedule of prices or the earned value report. Review shop drawings, and other submittals, scheduling programming, execution of the work, and clear expectations of the "Interim Department of Defense (DD) Form 1354" submittal. Major subcontractors who will engage in the work must also attend.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are [for Contractor Quality Control approval.][for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Preconstruction Survey

SD-02 Shop Drawings

Drawings ; G[, [_____]]

Isolation flange kits

Anode junction boxes, bonding boxes, and test stations

Joint bonds

Contractor's Modifications ; G[, [_____]]

SD-03 Product Data

Qualifications

Equipment ; G[, [_____]]

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Anodes ; G[, [_____]]

Anode junction boxes, bonding boxes, and test stations

Dielectric unions

Wires

Cable and wire

Casings, isolation, and seals

Shunts

Permanent reference electrodes ; G[, [_____]]

Spare Parts

SD-06 Test Reports

Tests and Measurements ; G[, [_____]]

Contractor's Modifications ; G[, [_____]]

SD-10 Operation and Maintenance Data

Cathodic Protection System ; G[, [_____]]

Training Course ; G[, [_____]]

Cathodic Protection System , Data Package 5; G[, [_____]]

SD-11, Closeout Submittals

Initial Cathodic Protection System Field Testing ; G[, [_____]]

One Year Warranty Period Cathodic Protection System Field Test Report ; G[, [_____]]

Final Cathodic Protection System Field Test Report ; G[, [_____]]

1.4.1 Material and Equipment Manufacturer Data

DATE I SSUE NO. REQUEST DATE REQUESTED BY REQUEST REF. NO.

MANUFACTURER NAME

DESCRI PTI ON OF EQUI PMENT

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DATE I SSUE NO. REQUEST DATE REQUESTED BY REQUEST REF. NO.

1.5 MAINTENANCE MATERIAL SUBMITTALS

1.5.1 Spare Parts

After approval of shop drawings, furnish spare parts data for each different item of material and equipment specified. The data must include a complete list of parts, special tools, and supplies, with current unit prices and source of supply.

After approval of shop drawings, furnish revised spare parts for any changes made from original submittal. One spare anode of each type must be furnished. In addition, supply information for material and equipment replacement for all other components of the complete system, including anodes , cables, splice kits and connectors, corrosion test stations, and any other components not listed above. Furnish [one reference electrode on a hand reel with 350 feet of conductor], [one digital voltmeter that can be used in the maintenance of this CP system]. Demonstrate use of furnished equipment in actual tests during the training course . Provide a description of equipment of the pipe-to-soil protected structure and foreign structures at electrical isolation between the utility supplier and the facility piping.

1.5.2 Extra Materials

Furnish [one reference electrode on a hand reel with 350 feet of conductor], [one high-input-impedance digital multimeter that can be used in the maintenance of this CP system]. Demonstrate use of furnished equipment in actual tests during the training course. Provide a description of equipment of the pipe-to-soil protected structure and foreign structures at electrical isolation between the utility supplier and the facility piping. Include a description of the equipment and measurement of the pipe-to-soil potentials, anode voltage, anode current and soil condition.

1.6 QUALITY CONTROL

1.6.1 Regulatory Requirements

Obtain the services of a corrosion expert to supervise, inspect, and test the installation and performance of the cathodic protection system. The term "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

SECTION 26 42 13 Page 10 submerged metallic structures.

1.6.2 Qualifications

The corrosion expert must be accredited or certified by NACE International, as a CP-4 CP Specialist or be a NACE International certified Corrosion Specialist or a registered professional engineer who has certification or licensing that includes education and experience in CP of the type of CP system being installed. The corrosion expert must have not less than [three] [five] [_____] years of experience in the type of CP for buried or submerged metallic structures under this contract.

Submit evidence of qualifications of the corrosion expert including their name and qualifications certified in writing to the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager prior to the start of construction. Certification must be submitted giving the name of the firm, the number of years of experience, and a list of not less than five of the firm's installations, three or more years old, that have been tested and found satisfactory.

1.6.3 Services of Corrosion Expert

The "corrosion expert" must make a minimum of three visits to the project site. The first of these visits will include obtaining soil resistivity data, acknowledging the type of pipeline coatings to be used and reporting to the contractor the type of CP required (GACP or ICCP). Once the submittals are approved and the materials delivered, the "corrosion expert" will revisit the site to verify the materials meet submittal requirements, ensure the contractor understands installation practices and that the contractor is capable and qualified to complete the installation.

The "corrosion expert" will be available (but not necessarily be onsite the entire time) during the installation of the CP system to answer questions, approve any changes or additions required during construction, or to provide recommendations as required. The third visit is to complete the training and demonstrations to applicable personnel on proper testing and maintenance techniques and to complete testing the installed CP systems to ensure it has been installed properly and meets adequate CP criteria. An additional visit is required if the One-Year-Warranty-Period-Testing is required.

1.7 DELIVERY, STORAGE AND HANDLING

Storage area for corrosion materials will be designated by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. If materials are not stored in a building, tarps or similar protection must be used to protect material from inclement weather. Resack and add backfill to packaged anodes that are damaged as a result of improper handling or exposure to rain.

1.8 PROJECT/SITE CONDITIONS

1.8.1 Environmental Requirements

1.8.2 Existing Conditions

Prior to start of any onsite construction activities, perform a Preconstruction Survey of the project site with the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager, and take photographs showing existing environmental conditions in

SECTION 26 42 13 Page 11 and adjacent to the site. Submit a report for the record. Include in the report a plan describing the features requiring protection under the provisions of the Contract Clauses, which are not specifically identified on the drawings as environmental features requiring protection along with the condition of trees, shrubs and grassed areas immediately adjacent to the site of work and adjacent to the contractor's assigned storage area and access route(s), as applicable. The Contractor and the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager will sign this survey report upon mutual agreement regarding its accuracy and completeness. Protect those environmental features included in the survey report and any indicated on the drawings, regardless of interference that their preservation may cause to the work under the Contract.

1.9 WARRANTY

Provide equipment items that are supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Corrosion Control System Description

A corrosion control system consists of several systems which work together to mitigate corrosion on buried or submerged metallic structures. Failure to comply with the requirements of any one of these systems may result in inadequate corrosion control and premature failure of the structure being protected. Each system's guide specifications must be included in the design and installation of a complete corrosion control system and must be adhered to in the design and execution of the corrosion control of a structure being protected. Determination of Need for CP must be made by government requirements and policy directives.

a. Construction Design Requirements (CDR) for protected structures are found in the UFGS for the structure being protected. For water storage tanks refer to Section 33 16 15 WATER STORAGE STEEL TANKS, NACE SP0388, and NACE SP0196, underground storage tanks NACE SP0285, aboveground storage NACE SP0193, fuel storage piping Section 33 52 40 FUEL SYSTEMS PIPING (NON-HYDRANT), aviation fuel piping Section 33 52 43.13 AVIATION FUEL PIPING, leak detection systems Section 33 01 50.31 LEAK DETECTION FOR FUELING SYSTEMS, offshore pipelines NACE SP0607 and ISO 15589-2 , offshore structures and NACE SP0176, pipeline casings structures (railroad, highway and water crossing) NACE SP0200 and for well casings NACE SP0186.

b. Coating Systems (CS) are a critical factor in performance of a GACP system. All coatings, including coatings in structure guide specifications and Green Seal (GS) coatings, must be compatible with the structure and the CP system, and have high disbondment capabilities. A high resistance to cathodic disbondment is critical for long term service life of coatings on buried or submerged metallic structures under CP. For paints and coatings refer to Section 09 90 00 PAINTS AND COATINGS, and for discontinuity (Holiday) testing of new protective coatings on conductive substrates refer to NACE SP0188.

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c. Mechanical Damage Systems (MDS) such as bedding and rock control barriers normally included in Structure GS may be required by design for some locations. Electrical Isolation is required for all galvanic anode CP systems. For an Electrical Isolation System (EIS) refer to

NACE SP0286.

d. An Electrical Continuity System (ECS) of the protected structure is critical to the operation of the CP system. The types of joints such as bonding and couplings are normally included in Structure GS, this is particularly important to nonwelded pipelines to allow sufficient CP current to conduct to the entire structure.

e. Stray Current (Interference) Systems must be considered in design, monitored during construction, and interference testing must be completed during the final testing. Design must consider all other cathodic protection systems which may affect other systems or systems which may affect the project, including foreign systems. All foreign systems must be contacted for information and notification and any joint testing which may be required. Corrosion Coordinating Committees may exist. Reference NACE TPC 11 .

f. Pipelines that parallel overhead high voltage AC transmission power systems are subject to induced AC. Induced AC has several potential adverse impacts on the safety of personnel and pipeline integrity.

Assuming that these conditions exist, there are several measures that can be taken to mitigate the induced AC present on a pipeline. These induced AC mitigation strategies are detailed in various international standards including NACE SP0177.

g. Galvanic Anode CP Monitoring System is a solution for remote monitoring (and optionally controlling) different kinds of galvanic anode CP applications, mainly to protect underground pipelines used in oil and gas distribution systems, but the same system can be used to monitor other galvanic anode CP applications like tank farms and oil platforms. These Monitoring Systems are detailed in various international standards including NACE TPC 11 .

h. When a project is connecting to an existing infrastructure with CP the design must be compatible with the existing structure(s) CP system.

Existing structures may have Impressed Current CP (ICCP) Anode Systems using Remote Anode Systems, Deep Anode Systems, Linear Anode Systems, or Distributed Anode Systems. Existing structures may also have Galvanic CP (GACP) Systems which may be distributed or remote.

Existing structures might not have CP. They may use alternative methods of corrosion mitigation instead of CP such as Inhibitor System/Internal Corrosion Control. For control of internal corrosion in steel pipelines and piping systems refer to NACE SP0106. Due to the limited voltage and current of galvanic anodes the protected structure must be coated and isolated from other structures.

i. A highly dielectric bonded coating is required to attain adequate CP.

Unbonded coatings block the protective current from the pipeline or structure and must not be used with CP. Failure to isolate other metallic structures will result in loss of protection. Isolation from other metallic structures must be maintained.

j. Continuity of the structure with low resistance is crucial to proper operation of a galvanic anode system. All joints must be continuous or be bonded to both sides of the joint.

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k. A conductive electrolyte is required to allow current flow from the galvanic anodes. Use of galvanic anode systems are normally restricted to electrolytes with resistivities below 30,000 ohm-cm.

Small well coated structures such as coated valves, tees and elbows have very high resistance to earth in high resistance soils. Galvanic anodes in electrolytes over 30,000 ohms also have very high resistance to earth. High circuit resistance with the low voltage of galvanic anodes will not allow sufficient current to meet instant off or depolarization criteria. Additional anodes under these conditions will not noticeably increase the current applied to the structure.

Reference SP0169 for criteria in high resistance electrolytes.

2.1.2 Design Requirements

2.1.2.1 Electrical Isolators

Isolators are required to isolate the [protected structure] [pipes] [_____] from any other structure. Provide isolators at all locations where the indicated [protected structure] [pipes] [_____] contact any other metallic structure. Provide locations and detailed drawings of required installations. Include any requirements for lightning protection, test stations, surge protection, or other requirements and include locations and details in design drawings.

2.1.2.2 Anode and Bond Wires

Provide a minimum of [5] [8] [25] [_____] magnesium anodes with an unpackaged weight of [_____] pounds at uniform distances along the metallic pipelines. Use a minimum of [3] [5] [10] [_____] test stations for these anodes. Provide these anodes in addition to anodes for the pipe under concrete slab and casing requirements. For each cathodic system, provide metallic components and structures that are electrically continuous by installing bond wires between the various structures.

Bonding of existing buried structures may also be required to preclude detrimental stray current effects and safety hazards. Return stray current to its source without damaging structures intercepting the stray current. Provide electrical isolation of underground facilities in accordance with acceptable industry practice. All tests must be witnessed by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager.

2.1.2.3 Surge Protection

Install approved zinc grounding cells or sealed weatherproof lightning and surge arrestor devices across isolation flanges or fittings installed in underground piping as indicated on the drawings. Provide gapless, self-healing, solid state type arrestor. Provide zinc anode composition conforming to ASTM B418, Type II. Provide number 4 AWG copper lead wires with High Molecular Weight Polyethylene (HMWPE) insulation. Zinc grounding cells must be prepackaged in backfill install as detailed on the drawings. Lightning arrestors or zinc grounding cells are not required for isolation flanges on metallic components used on non-metallic piping systems.

2.1.2.4 Non-metallic Pipe System

In the event pipe other than metallic pipe is approved and used in lieu of metallic pipe, protect all metallic components of this pipe system with

SECTION 26 42 13 Page 14

CP. Submit detailed drawings of CP for each component to the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager for approval within 45 days after date of receipt of notice to proceed, and before commencement of any work.

2.1.2.5 Coatings

Provide coatings for metallic components as required for metallic fittings. Complete and test protective coating on each metallic component (such as valves, hydrants and fittings). Provide coating as required for underground metallic pipe. Each test must be witnessed by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. Select, apply, and inspect coatings as specified in these specifications. The use of non-metallic pipe does not change other requirements of the specifications. Submit any deviations due to the use of non-metallic pipe for approval.

2.1.2.6 Tracer Wire

When a non-metallic pipeline is used to extend or add to an existing metallic line, exothermic-weld No. 8 AWG copper wire with THHN insulation to the existing metallic line and run the length of the new non-metallic line. Use this wire as a locator tracer wire and to maintain continuity to any future extensions of the pipeline.

2.1.2.7 Drawings

Submit [six] [_____] copies of detail drawings consisting of a complete list of equipment and material including manufacturer's descriptive and technical literature, catalog cuts, contractor's modifications , results of system design calculations including soil-resistivity, installation instructions and certified test data showing location of anodes and stating the maximum recommended anode current output density. Include in the detail drawings complete wiring and schematic diagrams, isolation fittings, test stations, permanent reference electrodes and bonding and any other details required to demonstrate that the system has been coordinated and will function properly as a unit. Reference locations to two permanent facilities or mark points. Provide [one] [_____]electronic [digital] [PDF] [_____] copy and digital photos of the completed installation.

2.1.2.8 Summary of Services Required

Include the following scope of services:

a. Close-interval potential surveys,

b. CP Installation System,

c. System testing,

d. Casing corrosion control,

e. Interference testing,

f. Training,

g. Operating and maintenance manual, SECTION 26 42 13 Page 15

h. Isolation testing and bonding testing,

i. Coating and holiday testing.

2.1.2.9 Tests of Components

Perform a minimum of four tests at each metallic component in the piping system. Two measurements must be made directly over the anodes and the other two tests must be over the outer edge of the component, but at the farthest point from the anodes. Provide a field drawing showing the component, the structure, all components of the CP system and their relationship to each other. Also provide a narrative describing how the CP system will work and the testing at each component. Components requiring CP must include but not be limited to the following:

a. Pipes beneath the floor slab or foundations.

b. Post Indicator Valve (PIV).

c. Shutoff valves.

d. Metallic pipes extended from aboveground locations.

e. Connectors or change-of-direction devices.

f. Metallic pipe components or sections.

g. Backflow preventers.

h. Culverts.

i. Casings.

2.1.2.10 Electrical Potential Measurements

Make all potential tests at a minimum of 10 foot intervals witnessed by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. Provide submittals identifying test locations on separate drawings, showing all metal to be protected and all CP equipment. Distinguish and identify test points, equipment, and protected metal.

2.1.2.11 Typical Metallic Components on Non-metallic Systems

2.1.2.11.1 Metallic Components

As a minimum, protect each metallic component with two galvanic 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 1200 millivolts "instant off." As a minimum, the galvanic anode unpackaged weight must be [9] [17] [_____] pounds . Locate the galvanic anodes on each side of the metallic component and route through a test station.

2.1.2.11.2 Fire Hydrants

Provide fire hydrant pipe components with a minimum of two anodes. These galvanic anodes must have an unpackaged weight of [_____] pounds .

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2.1.2.11.3 Pipe Beneath Concrete Slab

Pipe beneath concrete slab must have a minimum of [2] [3] [_____] galvanic anodes. These galvanic anodes must have an unpackaged weight of [9] [17] [_____] pounds . Pipe beneath concrete slab must have [1] [2] [_____] permanent reference electrodes located beneath the slab. Locate one permanent reference electrode where the pipe enters the concrete slab.

Route all conductors to a test station.

2.1.2.11.4 Valves

Protect each valve with [1] [2] [_____] galvanic anodes. The galvanic anode must have an unpackaged weight of [9] [17] [_____] pounds .

2.1.2.11.5 Metallic Pipe Component or Section

Protect each section of metallic pipe with [2] [3] [_____] galvanic anodes. The galvanic anodes must have an unpackaged weight of [9] [17] [_____] pounds .

2.1.2.11.6 Connectors or Change-of-Direction Devices

Protect each change-of-direction device with [2] [3] [_____] galvanic anodes. The galvanic anode must have an unpackaged weight of [9] [17] [_____] pounds .

2.1.2.12 Metallic Component Coating

Coatings for metallic components will be required for metallic fittings as indicated. These metallic fittings will include fire hydrants, tees, elbows, and valves. Coatings must be selected, applied, and inspected as specified in the coating specifications referenced and be compatible with the structure being protected. All coatings must be in accordance with all applicable Federal, State, and local regulations. Unbonded coatings must not be used with CP.

2.1.2.13 Location of Test Stations

Provide test stations of the type and location shown and [curb box] [post] [wall] mount. Provide buried isolation joints with test wire connections brought to a test station. Reference all test stations with GPS coordinates. Unless otherwise shown, locate other test stations as follows:

a. At 1,000-foot intervals or less.

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

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

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

2.1.2.14 Electrical Isolation of Structures

As a minimum, provide isolating flanges or unions at the following locations:

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

SECTION 26 42 13 Page 17

b. Pressure piping beneath floor slab to a building.

Provide isolation at metallic connection of all lines to existing system and where connecting to a building. Additionally, provide isolation between [water] [_____] or [gas] [_____] [forced main] line; and foreign pipes that cross the new lines within 10 feet . Install isolation fittings, including isolating flanges and couplings, aboveground or in a concrete pit.

2.1.2.14.1 Gas Distribution Piping

Provide electrical isolation at each building riser pipe to the pressure regulator, at all points where a short to another structure or to a foreign structure may occur, and at other locations as indicated on the drawings.

2.1.2.14.2 Isolation Joint Testing

An isolator checker or insulation tester will be used for isolation or insulating joint (flange or dielectric) electrical testing.

2.1.2.14.3 Underground Structure Coating

This coating specification takes precedence over any other project specification and drawing notes, whether stated or implied, and also applies to the pipeline or tank supplier. Variance in coating quality is not 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 must have a high quality factory-applied coating. This includes all carbon steel, cast-iron and ductile-iron pipelines or vessels. Select, apply, and inspect coatings as specified. If non-metallic pipelines are installed, coat all metallic fittings on pipe sections in accordance with this specification section.

a. The nominal coating thickness for the metallic pipe joint or other component coating must be [8][16][24][40][60][_____] mils , plus or minus 5 percent.

b. Apply pipe and joint coating for factory applied or field repair material as recommended by the manufacturer. Coating must 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.

2.1.2.14.4 Field Joints

Coat all field joints with materials compatible with the pipeline coating compound. Apply the joint coating material to an equal thickness as the pipeline coating. Do not use unbonded coatings for 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, conduct an inspection of the coating. This inspection must include electrical holiday detection. Repair any damaged areas of the coating. The Contracting Officer or the Contracting Officer's Representative, Technical

SECTION 26 42 13 Page 18

Expert or Project Manager must be asked to witness inspection of the coating and testing using a holiday detector.

2.1.2.14.5 Inspection of Pipe Coatings

Any damage to the protective coating during transit and handling must be repaired before installation. After field coating has been applied, inspect the entire pipe using an electric holiday detector in accordance with NACE SP0188 using a full-ring, spring-type coil electrode. The holiday detector must be equipped with a bell, buzzer, or other type of audible signal which sounds when a holiday is detected. Upon detection, immediately repair all holidays in the protective coating. Occasional checks of holiday detector, operation will be made by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager to determine suitability of the detector. Provide all labor, materials, and equipment necessary for conducting the inspection.

2.1.2.14.6 Protective Coating for Aboveground Piping System

Provide finish painting conforming to the applicable paragraph of Section 09 90 00 PAINTS AND COATINGS and as follows:

2.1.2.14.7 Ferrous Surfaces

Touch-up shop-primed surfaces with ferrous metal primer. Solvent-clean surfaces that have not been shop-primed. Surfaces that contain loose rust, loose mill scale, and other foreign substances must be mechanically-cleaned by power wire-brushing and primed with ferrous metal primer. Finish primed surface with two coats of exterior oil paint and vinyl paint.

2.1.3 Performance Requirements

The design must allow for synchronized interruption of all applied current.

2.1.3.1 Criteria of Cathodic Protection

The design must allow for synchronized interruption of all applied current. All galvanic anode leads, or header cables, must be connected to the protected structure through test stations or junction boxes and must never be connected directly to the protected structure.

a. Determination of the on and polarized (instant off) potentials must be made with the protective current applied to the [structure] [tank] [pipeline] [coupon] for a minimum of [1] [2] [4] [_____] [days].

Polarized potentials may be determined using a coupon test station (Error-Free (IR Free) test station). Polarized potentials must be determined by interrupting all the current being applied to the structure or coupon.

b. The potential measurements for the native measurement and the polarized potential must be made with the reference electrode at the same exact location. The polarization decay measurements must also be made with the reference electrode at the same exact location as the polarization potential.

c. The polarization decay measurements will be the difference between the polarized potential and a voltage measurement made [24] [48] [_____] hours after the interruption of protective current.

SECTION 26 42 13 Page 19

2.1.3.1.1 Steel

A negative polarized potential of 0.85 volts (850 millivolts) or more negative. The voltage must not be more negative than a negative polarized potential of 1.200 volts (1200 millivolts).

2.1.3.1.2 Aluminum

Aluminum underground component must not be protected to a potential more negative than minus 1200 millivolts, measured between the underground component and a saturated copper/copper sulfate reference electrode contacting the earth, directly over the metallic component. Resistance, if required, must 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 must be a minimum negative polarization shift of 100 millivolts measured between the metallic component and a saturated copper/copper sulfate reference electrode contacting the earth, directly over the metallic component. The polarization voltage shift must be determined as outlined for iron and steel.

2.1.3.1.3 Copper Piping

For copper piping, the following criteria must 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 must be determined as outlined for iron and steel.

2.2 EQUIPMENT

2.2.1 Remote Monitoring

Remote monitoring equipment must be designed, manufactured and procured specifically for cathodic protection use and must be provided as per design and drawings to monitor [potential (requires permanent reference electrode)] [bond(s)] [interference bond] [test station(s) shunts] [_____] and must match or be compatible with previously installed remote monitoring equipment in use at the installation.

2.2.2 Corrosion Rate Monitoring

Corrosion probes must be designed, manufactured and procured specifically for the application and matched to the structure being protected.

Manufacturer must match or be compatible with previously installed rate monitoring equipment in use at the installation.

2.2.3 Polarization Cell Replacement (PCR) and (PCRH) for Hazardous Locations

PCRs and PCRHs must be designed, manufactured, and procured specifically for the application and must exceed the modeled AC steady-state current and fault conditions. For Hazardous locations, the PCRH model must be used.

SECTION 26 42 13 Page 20

Characteristic PCR PCRH

AC steady-state…