Dexter Amendment 0002 Spec Changes Package.pdf

Dexter Dam Adult Fish Facility Upgrades

SECTION TABLE OF CONTENTS

DIVISION 26 - ELECTRICAL

SECTION 26 42 13.00 25

GALVANIC (SACRIFICIAL) ANODE CATHODIC PROTECTION (GACP) SYSTEM

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 MAINTENANCE MATERIAL SUBMITTALS

1.3.1 Spare Parts

1.4 QUALITY CONTROL

1.4.1 Regulatory Requirements

1.4.2 Qualifications

1.4.3 Services of Corrosion Expert

1.5 DELIVERY, STORAGE AND HANDLING

1.6 WARRANTY

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Corrosion Control System Design

2.1.1.1 Contractor's Modifications

2.1.2 Design Requirements

2.1.2.1 Electrical Isolators

2.1.2.2 Anode and Bond Wires

2.1.2.3 Surge Protection

2.1.2.4 Non-metallic Pipe System

2.1.2.5 Coatings

2.1.2.6 Tracer Wire

2.1.2.7 Drawings

2.1.2.8 Summary of Services Required

2.1.2.9 Tests of Components

2.1.2.10 Electrical Potential Measurements

2.1.2.11 Typical Metallic Components on Non-metallic Systems

2.1.2.11.1 Metallic Components

2.1.2.11.2 Fire Hydrants

2.1.2.11.3 Pipe Beneath Concrete Slab

2.1.2.11.4 Valves

2.1.2.11.5 Metallic Pipe Component or Section

2.1.2.11.6 Connectors or Change-of-Direction Devices

2.1.2.12 Metallic Component Coating

2.1.2.13 Location of Test Stations

2.1.2.14 Electrical Isolation of Structures

2.1.2.14.1 Isolation Joint Testing

2.1.2.14.2 Underground Structure Coating

2.1.2.14.3 Field Joints

2.1.2.14.4 Inspection of Pipe Coatings

2.1.2.14.5 Protective Coating for Aboveground Piping System

2.1.2.14.6 Ferrous Surfaces

2.1.3 Performance Requirements

SECTION 26 42 13.00 25 Page 1

AMD 0002

2.1.3.1 Criteria of Cathodic Protection

2.1.3.1.1 Steel

2.2 EQUIPMENT

2.2.1 Corrosion Rate Monitoring

2.2.2 Solid State Decoupler (SSD)

2.3 COMPONENTS

2.3.1 Test Stations

2.3.1.1 Post Top Mounted

2.3.2 Shunts for Test Stations and Junction Boxes

2.3.3 Junction Box Enclosures

2.3.3.1 Nameplates

2.3.4 Terminal Boards

2.4 MATERIALS

2.4.1 Galvanic Anodes

2.4.1.1 Magnesium Anodes

2.4.1.1.1 Anode Composition

2.4.1.1.2 Dimensions and Weights

2.4.1.1.3 Packaged Anodes

2.4.2 Wire and Cable

2.4.2.1 Anode Lead Wire

2.4.2.2 Anode Header Cable

2.4.2.3 Structure (Negative) Cable

2.4.2.4 Test Wires

2.4.2.5 Joint and Continuity Bond Cables

2.4.2.6 Resistance Bond Wires

2.4.2.7 Polyethylene Insulation

2.4.3 Cable and wire Identification Tags

2.4.4 AC Mitigation Materials

2.4.5 Backfill Material

2.4.6 Permanent Reference Electrodes

2.4.7 Pavement Inserts

2.4.8 Coupons

2.4.9 Isolation Flange Kits

2.4.9.1 Gaskets

2.4.9.2 Isolating Washers and Sleeves

2.4.9.3 Washers

2.4.10 Steel Flanges and Bolting

2.4.10.1 Steel Flanges

2.4.10.2 Bolting

2.4.11 Dielectric Unions

2.4.12 Isolation and End Seals

2.4.12.1 Casing Isolator/Centralizer

2.4.12.2 End Seals

2.5 ACCESSORIES

2.5.1 Conduit

2.5.2 Joint, Patch, Seal, and Repair Coating

2.5.3 Underground Splices

2.5.3.1 Cast-Type Splice

2.5.3.2 Gravity-Poured Splice

2.5.3.3 Heat Shrinkable Splice

2.5.4 Electrical Isolation of Structures

2.5.4.1 Electrically Isolating Pipe Joints

2.5.4.2 Electrically Isolating Couplings

2.5.5 Electrical Insulating Coating

2.5.6 Buried Cable Warning and Identification Tape

2.5.7 Electrical Connection to Structures

2.5.7.1 Exothermic Welds

2.5.7.2 Electrical-Shielded Arc Welds

2.5.7.3 Brazing

SECTION 26 42 13.00 25 Page 2

2.5.8 Electrical Tape

2.5.9 Exothermic Weld Kits

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

2.6.1 Non-Destructive Testing of Anodes

PART 3 EXECUTION

3.1 SAFETY PRECAUTIONS AND HAZARDOUS LOCATIONS

3.2 INSTALLATION

3.2.1 Excavation and Trenching

3.2.2 Anode Excavation

3.2.3 Lead Wire Trench

3.3 ANODES AND LEAD WIRE

3.3.1 Anode Installation

3.3.1.1 Single Anodes

3.3.1.2 Group of Anodes

3.4 INSTALLATION DETAILS

3.4.1 Anode Installation

3.4.2 Lead Wire Installation

3.4.2.1 Lead Wire Connections

3.4.2.2 Metallic Underground Pipeline Connection

3.4.3 Underground Pipe Joint Bonds

3.4.4 Anode Junction Boxes

3.4.5 Bonding Boxes

3.4.6 Test Stations and Permanent Reference Electrodes

3.4.7 Permanent Reference Electrode Verification

3.4.7.1 Field Drawings

3.5 ELECTRICAL ISOLATION OF STRUCTURES

3.5.1 Isolation Fittings

3.5.2 Dielectric Unions

3.5.3 Joint Bonds

3.5.4 Casings, Isolation, and Seals

3.6 FIELD QUALITY CONTROL

3.6.1 Tests and Measurements

3.6.1.1 Native Potentials

3.6.1.2 Protected Potentials

3.6.1.3 Isolation Testing

3.6.1.4 Isolation Tester

3.6.1.5 Anode Output

3.6.1.6 Reference Electrode Potential Measurements

3.6.1.7 Casing Tests

3.6.1.8 Holiday Test

3.6.1.9 Stray Current Measurements

3.6.1.10 Induced AC Testing

3.6.1.11 Interference Tests

3.6.1.12 Initial Cathodic Protection System Field Testing

3.7 CLOSEOUT ACTIVITIES

3.7.1 Reconditioning of Surfaces

3.7.1.1 Concrete

3.7.1.2 Restoration of Sod

3.7.1.3 Restoration of Pavement

3.7.2 Training

3.7.2.1 Instruction to Government Personnel

-- End of Section Table of Contents --

SECTION 26 42 13.00 25 Page 3

SECTION 26 42 13.00 25

GALVANIC (SACRIFICIAL) ANODE CATHODIC PROTECTION (GACP) SYSTEM

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 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 (2022) 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

ASTM B843 (2018) Standard Specification for

SECTION 26 42 13.00 25 Page 4

Magnesium Alloy Anodes for Cathodic Protection

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

NACE INTERNATIONAL (NACE)

NACE SP0169 (2013) Control of External Corrosion on Underground or Submerged Metallic Piping Systems

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

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

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

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

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; TIA 22-1; ERTA 1 2022) National Electrical Code

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 1110-2-2704 (2004) Engineering and Design -- Cathodic Protection Systems for Civil Works Structures

SECTION 26 42 13.00 25 Page 5

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

UL 514A (2013; Reprint Jun 2022) UL Standard for Safety Metallic Outlet Boxes

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

1.2 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are 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-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

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

SECTION 26 42 13.00 25 Page 6

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

1.3 MAINTENANCE MATERIAL SUBMITTALS

1.3.1 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 and 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.

1.4 QUALITY CONTROL

1.4.1 Regulatory Requirements

Obtain the services of a corrosion expert to design, 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 submerged metallic structures.

1.4.2 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

SECTION 26 42 13.00 25 Page 7

CP of the type of CP system being installed. The corrosion expert must have not less than 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. 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.

1.4.3 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.

1.5 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.

1.6 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 Design

The corrosion expert must design a complete and operational sacrificial anode cathodic protection system for underground metallic pipes and pipeline components, in accordance with EM 1110-2-2704 , NACE SP0169, and NFPA 70 , and as specified herein. The design must include the number, location, and arrangement of the anodes, permanent reference electrodes, test stations, and junction boxes, wiring diagram, details of electrical

SECTION 26 42 13.00 25 Page 8 bonding and isolation, and any other pertinent information to ensure proper installation and performance of the system. Include system commissioning and testing plans. The design must be approved by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager.

2.1.1.1 Contractor's Modifications

The specified system is based on a corrosion protection system with magnesium sacrificial anodes. The Contractor may modify the cathodic protection system after review of the project, site verification, and analysis, if the proposed modifications include the anodes specified and will provide better overall system performance. The modifications must be designed and approved by the corrosion expert. Submit a detailed description and drawings of the proposed changes in scope of performance indicating any variations from, additions to, or clarifications of the design. The modifications must be approved by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager.

2.1.2 Design Requirements

2.1.2.1 Electrical Isolators

Isolators are required to isolate the pipes from any other structure.

Provide isolators at all locations where the 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 magnesium anodes with an unpackaged weight of 20 pounds at uniform distances along the metallic pipelines. Provide the number of anodes required to achieve minus 850 millivolts "instant off" potential on the metallic pipeline surface and at the same time not provide ovrevoltage above 1200 millivolts "instant off." Route the anodes through test stations. 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 sealed weatherproof lightning and surge arrestor devices across isolation flanges or fittings installed in underground piping.

Provide gapless, self-healing, solid state type arrestor. Provide number 4 AWG copper lead wires with High Molecular Weight Polyethylene (HMWPE) insulation. Lightning arrestors are not required for isolation flanges on metallic components used on non-metallic piping systems.

SECTION 26 42 13.00 25 Page 9

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 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 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 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, SECTION 26 42 13.00 25 Page 10

g. Operating and maintenance manual,

h. Isolation testing and bonding 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.

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.

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

Provide the number of anodes 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 20 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 of20 pounds.

SECTION 26 42 13.00 25 Page 11

2.1.2.11.3 Pipe Beneath Concrete Slab

Pipe beneath concrete slab must have a minimum of 2 galvanic anodes.

These galvanic anodes must have an unpackaged weight of 20 pounds. Pipe beneath concrete slab must have 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 a minimum of 2 galvanic anodes. The galvanic anode must have an unpackaged weight of 20 pounds.

2.1.2.11.5 Metallic Pipe Component or Section

Protect each section of metallic pipe with a minimum of 2 galvanic anodes. The galvanic anodes must have an unpackaged weight of 20 pounds.

2.1.2.11.6 Connectors or Change-of-Direction Devices

Protect each change-of-direction device with a minimum of 2 galvanic anodes. The galvanic anode must have an unpackaged weight of 20 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 post 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.

b. Pressure piping beneath floor slab to a building.

Provide isolation at metallic connection of all lines to existing system

SECTION 26 42 13.00 25 Page 12 and where connecting to a building. Additionally, provide isolation between 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 Isolation Joint Testing

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

2.1.2.14.2 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 pipe 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 pipes to be cathodically protected must have a high quality factory-applied coating.

This includes all carbon steel, cast-iron and ductile-iron pipes. Select, apply, and inspect coatings as specified. If non-metallic pipes are installed, coat all metallic fittings on pipe sections in accordance with this specification section.

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

2.1.2.14.4 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.

2.1.2.14.5 Protective Coating for Aboveground Piping System

Provide finish painting conforming to the applicable paragraph of Section 09 90 00.00 28 PAINTS AND COATINGS and as follows:

SECTION 26 42 13.00 25 Page 13

2.1.2.14.6 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 pipeline for a minimum of 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 48 hours after the interruption of protective current.

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).

2.2 EQUIPMENT

2.2.1 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.

2.2.2 Solid State Decoupler (SSD)

SSDs must be designed, manufactured, and procured specifically for the application and must exceed the modeled AC steady-state current and fault conditions. SSDs must be installed with a protective ground-based enclosure to secure the cable connections and prevent electrical hazards.

SECTION 26 42 13.00 25 Page 14

Characteristic SSD

AC steady-state current, rms 45A

AC fault current, rms. at 0.5s 1.2 to 5 kA

Lightning current, 8x20micros, peak 75-100 kA

Hazardous location certification Division 2, Zone 2

Rain Proof, IP66 Yes

Submersible, IP68 or NEMA 6P Yes

2.3 COMPONENTS

2.3.1 Test Stations

2.3.1.1 Post Top Mounted

NEMA ICS 6 . Metallic or non-metallic with terminal board, a minimum of 6 terminal posts and lockable lid. A non-metallic enclosure must be high impact strength molded plastic. The unit must be of standard design, manufactured for use as a CP test station, complete with cover, terminal board, shunts, and brass or Type 304 or 316 stainless steel hardware. The terminal board must be removable for easy access to wires. The test station must be mounted atop 6 foot long polyethylene conduit with anchor. Terminal connections will be permanently tagged to identify each termination of conductors (e.g. identify the conductors connected to the protected structure, anodes, and reference electrodes).

2.3.2 Shunts for Test Stations and Junction Boxes

Provide 0.1 or 0.01 ohm, 2 or 8 ampere repectively as appropriate at each location, accuracy plus or minus one percent, polycarbonate circuit board type, color coded for value recognition, red for 0.1 ohm shunt and yellow for 0.01 ohm shunt, with nickel-plated brass posts and standard 0.25 inch inch holes on 1 inch centers to fit test stations and terminal boards manganin wire type.

2.3.3 Junction Box Enclosures

NEMA ICS 6 , Type 4X enclosure with Type 304 or 316 stainless steel hinges and latched cover and padlocked hasp. Enclosure must be of painted steel construction with terminal board. Knockout for conduit must be the size and location as per submitted drawings.

SECTION 26 42 13.00 25 Page 15

2.3.3.1 Nameplates

Provide nameplate in accordance with ASTM D709. Provide laminated plastic nameplates for each enclosure as specified or as indicated on the drawings. Each nameplate inscription must identify the function.

Nameplates will be melamine plastic, 0.125 inch thick, white with black center core. Surface will be matte finish. Corners will be square.

Accurately align lettering and engrave into the core. Minimum size of nameplates must be 25 inch by 2.5 inches. Lettering must be a minimum of

0.25 inch high normal block style.

2.3.4 Terminal Boards

Provide terminal boards for anode junction boxes, bonding boxes, and test stations made of phenolic plastic 1/4 inch thick with dimensions as indicated. Insulated terminal boards must have the required number of terminals (one terminal required for each conductor). Install solderless copper lugs and copper buss bars, shunts, and variable resistors on the terminal board as indicated. Test station terminal connections will be permanently tagged to identify each termination of conductors (e.g.

identify the conductors connected to the protected structure, anodes, reference electrodes and coupons).

2.4 MATERIALS

2.4.1 Galvanic Anodes

2.4.1.1 Magnesium Anodes

Install magnesium anodes on the pipe system. See Paragraph METALLIC COMPONENTS ON NON-METALLIC SYSTEMS AND TYPICALS for additional anodes under slab.

2.4.1.1.1 Anode Composition

Anodes must be of high-potential magnesium alloy, made of primary magnesium obtained from sea water or brine, and not made from scrap metal. Magnesium anodes must conform to ASTM B843 and to the following analysis (in percent) otherwise indicated:

Aluminum 0.010 percent

Manganese 0.50 to 1.30 percent max

Zinc 0.05 percent max

Silicon 0.05 percent max

Copper 0.02 percent max

Nickel 0.001 percent max

Iron 0.03 percent max

Other impurities 0.05 each or 0.3 percent max total

SECTION 26 42 13.00 25 Page 16

Magnesium Remainder

2.4.1.1.2 Dimensions and Weights

The following dimensions and weights of anodes are not all inclusive and are presented as examples, various manufacturers may have additional sizes not included in the following table:

a. Bare anode weight: 20 pounds.

Typical Magnesium Anode Size (may be round, square, or D shaped)

Nominal Weight

Bare Approximate Size

Packaged Weight

Nominal Packaged Dimensions kg lbs Width Height Length kg lbs Diameter Length mm inch mm inch mm inch mm inch mm inch

1 1.75 1.75 8 5 3.25 9

3 3.5 3.75 5 8 6 10

5 3.5 3.75 8.5 17 6 12

9 2.75 3 27 15.9 35 5.5 32

9 3.5 3.75 14 27 6 17

17 2.75 2.75 50.25 60 6 55

17 3.5 4 25.75 45 6.5 29

20 2.75 3.75 59.75 70 5 66

32 3.5 3,75 45.25 91 6.5 53

32 5.5 5 20.5 70 8 28

40 3.5 3.75 59.75 96 6.5 66

48 5.5 5.75 31 100 8 38

60 4 4 60 125 7 64

2.4.1.1.3 Packaged Anodes

Provide anodes in packaged form with the anode surrounded by specially-prepared quick-wetting backfill and contained in a water permeable cloth or paper sack. Anodes must be centered by means of spacers in the backfill material.

The backfill material will have the following composition, unless otherwise indicated:

SECTION 26 42 13.00 25 Page 17

Material Approximate Percent by Weight

Gypsum 75

Bentonite 20

Sodium Sulfate 5

Total 100

2.4.2 Wire and Cable

2.4.2.1 Anode Lead Wire

Wire must be No. 12 AWG solid copper wire, not less than 10 feet long, without any splices, complying with NFPA 70 , Type Thermoplastic Heat and Water-resistant Nylon-coated (THHN) Rubber Heat (resistant) Wire (RHW) RHW-USE insulation. Connecting wires for magnesium anodes will be factory installed with the place or emergence from the anode in a cavity-sealed flush with a dielectric sealing compound.

2.4.2.2 Anode Header Cable

Cable for anode header and distribution will be No. 4 AWG stranded copper wire with type CP HMWP, 7/64 inch thick insulation, 600-volt rating.

2.4.2.3 Structure (Negative) Cable

Structure connecting wire must be No. 2 AWG stranded copper wire with type CP high molecular weight insulation, 7/64 inch thick insulation, 600 volt rating. Copper conductors conforming to ASTM B3 and ASTM B8.

2.4.2.4 Test Wires

Test wires must be No. 12 AWG stranded copper wire with NFPA 70 Type Thermoplastic Wire (TW) or RHW or polyethylene insulation. Copper conductors conforming to ASTM B3 and ASTM B8.

2.4.2.5 Joint and Continuity Bond Cables

Provide bonds across joints or any electrically discontinuous connections in the piping, and other pipes and structures with other than welded or threaded joints included in this CP system. Unless otherwise specified, bonds between structures and across joints in pipe with other than welded or threaded joints must be with No. 4 AWG stranded copper cable with polyethylene insulation. Bonds between structures must contain sufficient slack for any anticipated movement between structures. Bonds across pipe joints must contain a minimum of 4 inch of slack to allow for pipe movement and soil stress. Bonds must be attached by exothermic welding.

Exothermic weld areas must be insulated with coating compound and approved by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. Continuity bonds must be installed as necessary to reduce stray current interference. Additional joint bonding must be done where determined during construction or testing or as directed. Joint bonding must include excavation and backfilling. There must be a minimum of 2 continuity bonds between each structure and other than welded or threaded joints. Electrical continuity must be tested across joints with other than welded or threaded joints and across metallic portions of sewage lift stations and water booster stations.

SECTION 26 42 13.00 25 Page 18

Copper conductors conforming to ASTM B3 and ASTM B8.

2.4.2.6 Resistance Bond Wires

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

2.4.2.7 Polyethylene Insulation

Polyethylene insulation must comply with the requirements of ASTM D1248 and of the following types, classes, and grades:

2.4.3 Cable and wire Identification Tags

Stainless steel material with engraved letters. Print letters and numbers a minimum of 3/16 inch in height. Provide identifier legend .

2.4.4 AC Mitigation Materials

If required, AC mitigation materials typically consist of a mitigation material either zinc ribbon or copper cable, interconnecting coated copper cables, solid state decouplers to control the AC current flow and test stations.

2.4.5 Backfill Material

The backfill material must have the following composition, unless otherwise indicated:

Material Approximate Percent by Weight

Gypsum 75

Bentonite 20

Sodium Sulfate 5

Total 100

2.4.6 Permanent Reference Electrodes

Permanent reference electrodes must be copper/copper-sulfate specifically manufactured for underground use. Must never need recharging, maintenance, or recalibration. Must have impregnated membrane which keeps electrode electrolytes from drying out or getting the reference electrode electrolyte contaminated. Must have ion trap to prevent reference electrode damage from hydrogen sulfide or excess chloride ions. The electrode will be prepackaged by the manufacturer with a backfill material as recommended by the manufacturer. Provide electrodes with No. 12 AWG, RHW-USE cable of sufficient length to extend to the test station or junction box without splicing. Reference electrodes will have a minimum 20-year life, stability of plus or minus 5 millivolts under 3 microamp load. The manufacturer must calibrate the PRE to 316 mV plus or minus 10mV referenced to a standard hydrogen electrode (SHE) and provide a calibration certificate detailing the results of the calibration.

Procedures for evaluating the accuracy annually must be included in the Operation and Maintenance Manual.

SECTION 26 42 13.00 25 Page 19

2.4.7 Pavement Inserts

Pavement insert must be a non-metallic flush type test station without terminal board, and must allow a copper/copper sulfate reference electrode to contact the electrolyte beneath the pavement surface. Provide traffic valve box capable of withstanding H-20 traffic loads.

2.4.8 Coupons

Coupons must match the material of the structure, with 2 integrated connection(s) with electrical wire(s) and be designed, manufactured and procured for use as a corrosion coupon, IR-Free reference electrode, or AC reading electrode.

2.4.9 Isolation Flange Kits

Provide full-faced gaskets, isolating sleeves and washers, and steel washers. Provide isolation flange kits rated for operation at the rated pressure and temperature.

2.4.9.1 Gaskets

ASME B16.21 . Neoprene faced phenolic or laminated phenolic material .

2.4.9.2 Isolating Washers and Sleeves

Two sets 1/8 inch laminated phenolic. Isolating washers must fit within the bolt facing on the flange over the outside of the fabric reinforced phenolic sleeve.

2.4.9.3 Washers

Steel, cadmium plated, to fit within the bolt facing on the flange.

2.4.10 Steel Flanges and Bolting

2.4.10.1 Steel Flanges

ASME B16.5 , 150 lb..

2.4.10.2 Bolting

ASTM A307, Grade B for bolts; ASTM A194/A194M , Grade 2 for nuts.

Dimensions: ASME B18.2.1 for bolts, ASME B18.2.2 for nuts. Threads:

ASME B1.1 , Class 2A fit for bolts, Class 2B fit for nuts. Bolts must extend completely through the nuts and may have reduced shanks of a diameter not less than the diameter at the roof of threads.

2.4.11 Dielectric Unions

ASME B16.39 , Class 150 for dimensional, strength, and pressure requirements. Insulation barrier must limit galvanic current to one percent of the short-circuit current in a corresponding metallic joint.

Provide insulating material impervious to water.

SECTION 26 42 13.00 25 Page 20

2.4.12 Isolation and End Seals

2.4.12.1 Casing Isolator/Centralizer

High density (linear), injection molded virgin Polyethylene positive electrical isolation, high abrasion resistance and low coefficient of friction.

2.4.12.2 End Seals

Ethylene Propylene Diene Monomer (EPDM) Neoprene rubber end seals, thickness of 1/8 inch or more, with 2 Stainless Steel Pipe Clamps per end seal, 1/8 inch thick and 1/2 inch wide or more.

2.5 ACCESSORIES

2.5.1 Conduit

UL 6 , rigid galvanized steel, Outlet boxes: UL 514A and fittings UL 514B , threaded hubs. Non-metallic conduit must conform to NEMA TC 2.

2.5.2 Joint, Patch, Seal, and Repair Coating

Sealing and dielectric compound must be a black, rubber based compound that is soft, permanently pliable, tacky, moldable, and unbacked.

Compound will be applied as recommended by the manufacturer, but not less than 1/2-inch thick. Pressure-sensitive vinyl plastic electrical tape and rubber insulated tape must conform to UL 510 .

2.5.3 Underground Splices

Provide splices with a compression connector on the conductors, and insulation and waterproofing using one of the following methods which are suitable for continuous submersion in water and comply with ANSI C119.1 .

2.5.3.1 Cast-Type Splice

Provide cast-type splice insulation by means of molded casting process employing a thermosetting epoxy resin insulating material applied by a gravity poured method or pressure injected method. Provide component materials of the resin insulation in a packaged form ready for convenient mixing without removing from the package.

2.5.3.2 Gravity-Poured Splice

Gravity-poured method must employ materials and equipment contained in and approved commercial splicing kit which includes a mold suitable for the cables to be spliced. When the mold is in place around the joined conductors, prepare the resin mix and pour into the mold.

2.5.3.3 Heat Shrinkable Splice

Provide heavy wall heat shrinkable splice insulation by means of a thermoplastic adhesive sealant material which must be applied by a clean burning propane gas torch.

SECTION 26 42 13.00 25 Page 21

2.5.4 Electrical Isolation of Structures

2.5.4.1 Electrically Isolating Pipe Joints

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

2.5.4.2 Electrically Isolating Couplings

Electrically isolating couplings will be of a type that has a published maximum electrical resistance rating given in the manufacturer's literature. Cradles and seals will be of a type that is in regular factory production made for the purpose of electrically isolating the carrier pipe from the casing and preventing the incursion of water into the annular space.

2.5.5 Electrical Insulating Coating

Heat-shrinkable tape or conformable watertight sealant having dielectric strength not less than 15 kV for a 1/8 inch thick layer.

2.5.6 Buried Cable Warning and Identification Tape

Polyethylene tape, manufactured for warning and identification of buried cable and conduit. Tape must be 3 inches wide, Yellow in color and read "Caution Buried Cable Below" or similar. Color and lettering must be permanent and unaffected by moisture or other substances in backfill materials.

2.5.7 Electrical Connection to Structures

2.5.7.1 Exothermic Welds

Electrical connections to metallic structures must be made using exothermic welds in strict accordance with the manufacturer's recommendations.

2.5.7.2 Electrical-Shielded Arc Welds

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

2.5.7.3 Brazing

Brazing will be as specified by manufacturer using specialized equipment designed for that purpose.

2.5.8 Electrical Tape

Pressure-sensitive vinyl plastic electrical tape and rubber insulated tape must conform to UL 510 .

2.5.9 Exothermic Weld Kits

Exothermic weld kits specifically designed by the manufacturer for exothermic welding wires to metallic surfaces. Molds must be for specific type of metallic structure (steel, cast iron), specific diameter of pipe or metallic surface and specific size (AWG)and type of wire (solid, stranded).

SECTION 26 42 13.00 25 Page 22

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

2.6.1 Non-Destructive Testing of Anodes

Contractor must perform the tests in the presence of the Contracting Officer or the Contracting Officer's Representative. One anode of each type will be chosen at random for non-destructive testing and will be submerged in a container of fresh water for about 30 minutes. Contractor must then measure the anode-to-water potential difference between a calibrated copper/copper sulfate reference electrode. Potential differences must generally be within the following ranges:

Anode Type DC Volts to Calibrated Cu/CuSO4 Reference Electrode

High Potential Magnesium More Negative than Negative 1.65 Volts DC

Standard Magnesium More Negative than Negative 1.4 Volts DC

Failure of the test anode to conform to this specification can be cause for rejecting all anodes from the same lot as the test anode. The contractor must mark all rejected anodes on the ends with a 6 inch high "X" using yellow spray paint. The contractor must replace any rejected anodes at the contractor's expense. The destructive testing provision must also apply to replacement anodes as well.

PART 3 EXECUTION

3.1 SAFETY PRECAUTIONS AND HAZARDOUS LOCATIONS

Any personnel performing operations that will generate heat, sparks, or flame in hazardous locations must first perform adequate safety precautions. A trained responsible person must ensure the area is safe to perform the operation. Required actions include ensuring adequate ventilation before work starts, air monitoring, and a fire watch must be provided and remain for 30 minutes after the operation is completed. A minimum of 20 pound ABC type fire extinguisher must be available and must be inspected before each use. Equipment being used must be inspected and used in accordance with manufacturer recommendations. Combustibles that are in the work area(s) must be moved or if they cannot be moved, be covered with fire retardant welding blankets. When performing exothermic welding, properly sized charges and inspection of the structure condition must be accomplished to ensure a safe operation.

3.2 INSTALLATION

3.2.1 Excavation and Trenching

Perform trenching and backfilling in accordance with Section 31 00 00.00 25 EARTHWORK. In the areas of the anode beds, all trees and underbrush will be cleared and grubbed to the limits shown or indicated. In the event rock is encountered in providing the required depth for anodes, determine an alternate approved location and, if the depth is still not provided, submit an alternate plan to the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. Alternate techniques and depths must be approved prior to implementation.

SECTION 26 42 13.00 25 Page 23

3.2.2 Anode Excavation

a. Excavate hole to a minimum 3 inches larger than the packaged anode diameter.

3.2.3 Lead Wire Trench

b. Excavate lead wire trench to 24 inches deep.

3.3 ANODES AND LEAD WIRE

3.3.1 Anode Installation

Unless otherwise authorized, installation must not proceed without the presence of the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. Locations may be changed to clear obstructions with the approval of the corrosion expert and approval of the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager. Anodes will be installed in sufficient number and of the required type, size, spacing, and depth to obtain a uniform current distribution over the surface of the structure. The anode system will be designed for a life of 25 years of continuous operation. Anodes must be installed as indicated and 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 must not be used for lowering the anode into the hole. The annular space around the anode must be backfilled with fine earth in 6 inch layers and each layer must be hand tamped.

3.3.1.1 Single Anodes

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

3.3.1.2 Group of Anodes

Groups of anodes, in quantity and location shown, must be connected to an anode header cable. The anode header cable must make contact with the structure to be protected only through a test station. Anode lead connection to the anode header cable must be made by an approved crimp connector or exothermic weld and splice mold kit with appropriate potting compound.

3.4 INSTALLATION DETAILS

3.4.1 Anode Installation

Do not lift or support anode by the lead wire. Where applicable, remove manufacturer's plastic wrap/bag from the anode. Exercise care to preclude damaging the cloth bag and the lead wire insulation. Center the packaged anode in the hole with native soil in layers not exceeding 6 inches. Hand tamp each layer to remove voids taking care not to strike the anode lead wire. When the backfill is 6 inches above the top of the anode, pour at least ten gallons of water into the hole to saturate the anode backfill and surrounding soil. Anodes must not be backfilled prior to inspection and approval by the Contracting Officer or the Contracting Officer's Representative, Technical Expert and Project Manager.

SECTION 26 42 13.00 25 Page 24

3.4.2 Lead Wire…