Spec 26 42 13.00 25_AMDT 0004.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 Drawings

1.4.2 Regulatory Requirements

1.4.3 "Corrosion Expert" Qualifications

1.4.4 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 Non-metallic Pipe System

2.1.2.4 Coatings

2.1.2.5 Summary of Services Required

2.1.2.6 Tests of Components

2.1.2.7 Electrical Potential Measurements

2.1.2.8 Typical Metallic Components on Non-metallic Systems

2.1.2.8.1 Metallic Components

2.1.2.8.2 Pipe Beneath Concrete Slab

2.1.2.8.3 Valves

2.1.2.8.4 Metallic Pipe Component or Section

2.1.2.8.5 Connectors or Change-of-Direction Devices

2.1.2.9 Metallic Component Coating

2.1.2.10 Location of Test Stations

2.1.2.11 Electrical Isolation of Structures

2.1.2.11.1 Isolation Joint Testing

2.1.2.11.2 Underground Structure Coating

2.1.2.11.3 Field Joints

2.1.2.11.4 Inspection of Pipe Coatings

2.1.2.11.5 Ferrous Surfaces

2.1.3 Performance Requirements

2.1.3.1 Criteria of Cathodic Protection

2.1.3.1.1 Steel

2.2 EQUIPMENT

2.2.1 Corrosion Rate Monitoring

SECTION 26 42 13.00 25 Page 1

AMD 0004

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 Magnesium Anodes

2.4.1.1 Plastisol Coated Slab Anode Composition

2.4.1.2 Dimensions and Weights

2.4.1.3 Packaged Anodes

2.4.2 Test Boxes and Junctions Boxes

2.4.3 Wire and Cable

2.4.3.1 Anode Lead Wire

2.4.3.2 Anode Header Cable

2.4.3.3 Structure (Negative) Cable

2.4.3.4 Test Wires

2.4.3.5 Joint and Continuity Bonds

2.4.3.6 Resistance Bond Wires

2.4.3.7 Cable and Wiring Insulation

2.4.4 Cable and Wire Identification Tags

2.4.5 AC Mitigation Materials

2.4.6 Backfill Material

2.4.7 Permanent Reference Electrodes

2.4.8 Pavement Inserts

2.4.9 Coupons

2.4.10 Isolation Flange Kits

2.4.10.1 Gaskets

2.4.10.2 Isolating Washers and Sleeves

2.4.10.3 Washers

2.4.11 Steel Flanges and Bolting

2.4.11.1 Steel Flanges

2.4.11.2 Bolting

2.4.12 Dielectric Unions

2.4.13 Isolation and End Seals

2.4.13.1 Casing Isolator/Centralizer

2.4.13.2 End Seals

2.5 ACCESSORIES

2.5.1 Conduit

2.5.2 Joint, Patch, Seal, and Repair Coating

2.5.3 Electrical Isolation of Structures

2.5.3.1 Electrically Isolating Pipe Joints

2.5.3.2 Electrically Isolating Couplings

2.5.4 Electrical Connections

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

2.6.1 Non-Destructive Testing of Anodes

PART 3 EXECUTION

3.1 CRITERIA OF PROTECTION

3.1.1 Iron and Steel

3.2 SAFETY PRECAUTIONS AND HAZARDOUS LOCATIONS

3.3 INSTALLATION

3.3.1 Excavation and Trenching

3.3.2 Anode Excavation

3.3.3 Lead Wire Trench

3.4 ANODE INSTALLATION

3.4.1 Anode Installation, General

SECTION 26 42 13.00 25 Page 2

3.4.2 Anode Stud Bolt and Slab Anode Installation Procedure

3.4.3 Installation Details

3.4.4 Underground Pipe Joint Bonds

3.4.5 Anode Junction Boxes

3.4.6 Bonding Boxes

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

ASTM D709 (2017) Standard Specification for Laminated Thermosetting Materials

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

SECTION 26 42 13.00 25 Page 4

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)

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

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

UNDERWRITERS LABORATORIES (UL)

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

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

A PDF or similar file of detail drawings consisting of a complete list of equipment and material including manufacturer's

SECTION 26 42 13.00 25 Page 5 descriptive and technical literature, catalog cuts, results of system design calculations including water-resistivity, installation instructions and certified test data stating the maximum recommended anode current output density and the rate of gaseous production, if any, at that current density. Include in the detail drawings all details required to demonstrate that the system has been coordinated and will function properly, as specified and shown. Include in the detail drawings complete wiring and schematic diagrams to illustrate the test coupon scheme and any other details required to demonstrate that the system has been coordinated and will function properly as a unit.

Isolation flange kits

Anode junction boxes, bonding boxes, and test stations

Joint bonds

Contractor's Modifications; G

A PDF or similar file of detail drawings showing proposed changes in location, scope of performance indicating any variations from, additions to, or clarifications of contract drawings. Show proposed changes in anode arrangement, anode size and number, anode materials and layout details, mounting details, and any other pertinent information to proper installation and performance of the system.

SD-03 Product Data

Equipment; G

An itemized list of equipment and materials (in PDF or similar file)including item number, quantity, and manufacturer of each item. The list must be accompanied by a description of procedures for each type of testing and adjustments. Installation of materials and equipment must not commence until this submittal is approved.

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

SECTION 26 42 13.00 25 Page 6

Spare Parts

Spare parts data for each different item of material and equipment specified, after approval of detail drawings and not later than six months prior to the date of beneficial occupancy. The data must include a complete list of parts, special tools, and supplies, with current unit prices and source of supply. Two spare anodes of each type must be furnished.

SD-06 Test Reports

Tests and Measurements; G

Test reports in a PDF format tabulating all field tests and measurements performed, upon completion and testing of the installed system and including close interval potential survey, interference tests, and final system test verifying protection.

Contractor's Modifications; G

Final report regarding Contractor's modifications. The report, in PDF format must include structure-to-electrolyte measurements throughout the affected area, indicating that the modifications improved the overall conditions. The following special materials and information are required: installation and testing procedures, and equipment; coating material; system design calculations for anode number, life, and parameters to achieve protective potential; bonding and waterproofing details;

exothermic weld equipment and material.

SD-07 Certificates

Cathodic Protection System; G

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

"Corrosion Expert" Qualifications; G

Evidence of qualifications for a "corrosion expert."

a. The Corrosion Expert's name and qualifications must be certified in writing to the Contracting Officer's representative prior to the start of construction.

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

SD-10 Operation and Maintenance Data

Operation and Maintenance Manual; G

Cathodic Protection System; G

Training Course; G

SECTION 26 42 13.00 25 Page 7

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 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 as-built 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 Drawings

Detailed drawings must be provided showing location of anodes, test coupons, coupon test stations, permanent reference cells, and bonding.

Locations must be referenced to two permanent facilities or mark points.

1.4.2 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.

1.4.3 "Corrosion Expert" 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 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

SECTION 26 42 13.00 25 Page 8 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.

1.4.4 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. a. The Contractor must obtain the services of a "corrosion expert" to supervise, coordinate, inspect, and test the installation and performance of the cathodic protection system. "Corrosion expert" refers to a person, who by thorough knowledge of the physical sciences and the principles of engineering and mathematics, acquired by professional education and related practical experience, is qualified to engage in the practice of corrosion control of submerged metallic surfaces. Such a person must be certified by NACE International as a NACE certified Corrosion Specialist or a NACE certified Cathodic Protection (CP) Specialist or be a registered professional corrosion engineer who has certification or licensing that includes education and experience in corrosion control of piping systems with 5 years experience in corrosion control on metallic surfaces of this type under this contract.

b. The "corrosion expert" must closely coordinate their work and the work of their installers with the coating contractors and other contractors doing work. During the fabrication phase, the "corrosion expert" must also ensure that all mounting bolt or stud threads are properly taped and/or otherwise covered prior to painting (in order to insure future good electrical connections). Consequently, the "corrosion expert" must visit the project site where the pipe work is being accomplished in order to assure that the cathodic protection work is properly coordinated and installed. The "corrosion expert" must coordinate with the contractor(s) as often as necessary to ensure all cathodic protection requirements are met. The "corrosion expert" must visit the project site or pipe work site to coordinate, plan, and assure that cathodic protection anode mounting stud or bolt installers and fabrication contractors understand the work necessary to be accomplished during this phase. The "corrosion expert" must assure that the anode stud or bolt installers fully understand where the components are to be welded to the pipe and that they understand the correct procedures to follow. The personnel conducting this work must have at least one anode of each type to be installed at the project fabrication work site in order to assure that the anodes will

SECTION 26 42 13.00 25 Page 9 correctly fit onto the equipment at each required location.

c. The "corrosion expert" must provide inspection, guidance, and direction to the contractor's cathodic protection system installation personnel as required to ensure proper completion of the installation. All components, equipment, and supplies required to complete the installation must be provided by the contractor. The "corrosion expert" must make as many visits to the project site as are necessary to properly accomplish the cathodic protection system installation. The first of these visits must occur prior to the beginning of work on the facility water supply piping. This visit must include obtaining water resistivity data, and gathering any other information necessary from the site in order to properly coordinate with the contractor and plan the installation of the cathodic protection system. This visit must take place prior to the beginning of any fabrication work and, as stated above. During this visit the "corrosion expert" must acknowledge the type of structure coatings to be used and coordinate the coating system with the cathodic protection system installation, and report to the Contractor any problem areas encountered. The cathodic protection system specified in these specifications and shown on the Contract Drawings is based on the use of a well bonded, dielectric coating system; consequently, if any other coating system is planned to be utilized, which is not compatible with this cathodic protection installation, then the "corrosion expert" must notify the government immediately. If a conductive coating system, or other coating system that is not compatible with cathodic protection, is selected or specified for application, then the Government has the option to withdraw these cathodic protection requirements from the contract and the Contractor will credit the Government for the work not yet accomplished. Also, during this visit, or a prior visit, the "corrosion expert" must perform a close interval "native" potential survey on the submerged portions of the piping, as specified in this section; "native" readings must be taken at all locations as that specified herein for ON potential measurements.

d. After the submittals are approved and the materials delivered; and after the "corrosion expert" has already visited the site in order to coordinate, plan, and supervise, as necessary, all anode mounting bolt or stud layout and installation work; and after all pipe coating work is completed; the "corrosion expert" must visit the project site to inspect all cathodic protection anode mounting locations, as well as perform an inspection of the pipe coating integrity to assure that the CP systems are installed properly and that the coatings are applied properly in order to correlate with the CP systems to form a complete and operable corrosion control system. During this visit the "corrosion expert" must ensure the contractor understands best installation practices and laying out the components. The "corrosion expert" must also explain and assure the anode installer understands the amount and locations of plastisol required to be removed from each type of anode. Assuring that the installers understand best installation practices, the laying out of the components must be explained during both the pipe fabrication work visit(s) and at the visits to the project site after the piping has been fabricated in order to properly plan and complete the cathodic protection installation.

e. Another visit (or visits) to the project site must take place prior to piping being buried. During this time, the corrosion expert must

SECTION 26 42 13.00 25 Page 10 verify that all anodes are properly installed and all plastisol has been properly removed. The "corrosion expert" must also ensure that all anodes make good electrical contact with the structure and that all remaining exposed mounting straps, bolts, nuts are coated in accordance with these specifications and the drawings.

f. An additional visit (or visits) must involve the final acceptance testing of the cathodic protection systems. The "corrosion expert" must supervise installation, activation, and testing of all site cathodic protection.

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

a. The Contractor must furnish and install a complete, operating, sacrificial anode cathodic protection system in complete compliance with NFPA 70 , in compliance with the Contract Drawings, in accordance with the recommendations of the manufacturer, in accordance with standard construction practice, and as approved by the Contracting Officer's representative to conform with the minimum requirements of this contract. The services required include planning, installation, adjusting and testing of a cathodic protection system, using sacrificial anodes for cathodic protection of the submerged metallic surfaces of the normally buried portions of the facility water supply piping, or as shown on the drawings. The cathodic protection system must include anodes, studs (or bolts used as studs), nuts, and any other equipment as shown on the drawings and/or as described in these specifications, and as required for a complete operating system providing the NACE criteria of protection as specified. The drawings indicate the extent and arrangement of the anodes. Anodes must be delivered to the location designated by the Contracting Officer's representative and stored at location as specified herein. The Contractor must assure that their Corrosion Expert, as described below, fully coordinates all their work in order to assure that all cathodic protection work required during pipe fabrication work, and before pipe painting, is accomplished.

b. All phases of pipe fabrication, including decisions on when to install the various cathodic protection components, must be fully coordinated with the "corrosion expert" required herein.

SECTION 26 42 13.00 25 Page 11

2.1.1 Corrosion Control System Design

TheA 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 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.

2.1.1.1 Contractor's Modifications

The specified system is based on a complete system with magnesium sacrificial anodes. The Contractor may modify the cathodic protection system after review of the project, site verification, and analysis, if the proposed modifications include the anodes specified and will provide better overall system performance. The modifications must be fully described, be approved by the Contracting Officer's representative, and must meet the following criteria. With cathodic protection applied, the proposed system must achieve a minimum structure-to-electrolyte potential of minus 850 millivolts with reference to a saturated copper-copper sulfate reference cell contacting the electrolyte. Voltage drops other than those across the structure-to-electrolyte boundary must be considered for valid interpretation of these voltage measurements as described in NACE SP0169. Placement of the reference electrode in close proximity to the structure must not be considered in this contract as adequate for elimination of voltage drops other than those across the structure-to-electrolyte boundary since the electrode would have to be close to a coating holiday (the structure is coated). The Contractor must take resistivity measurements of the water in the vicinity of the buried pipe surface. The cathodic protection system must produce sufficient current and voltage in order to produce a minimum of minus 850 millivolts potential (considering IR drop) between the structure being tested and the reference cell. This potential must be obtained over 95 percent of the submerged metallic area. The anode system must be designed for a life of twenty-five (25) years of continuous operation.

SECTION 26 42 13.00 25 Page 12

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.

2.1.2.2 Anode and Bond Wires

The total number of anodes, of each type specified and indicated, must be provided and installed on the described piping as described in these specifications. Anodes of the type indicated must be located where shown on the drawings. For each cathodic protection system, the metallic components and structure surfaces to be protected must be made electrically continuous. This will be accomplished by installing bond wires between the various structure surfaces as, and if necessary.

Bonding of existing submerged structures may be required to preclude detrimental stray current effects and safety hazards. Provisions must be included to return stray current to its source without damaging structures intercepting the stray current. The electrical isolation of submerged facilities in accordance with acceptable industry practice must be included under this section. All tests must be witnessed by the Contracting Officer's representative.

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.

2.1.2.3 Non-metallic Pipe System

In the event pipe other than metallic pipe is approved and used in lieu of

SECTION 26 42 13.00 25 Page 13 metallic pipe, protect all metallic components of this pipe system per expert recommendations and standard practice 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.

2.1.2.4 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.

2.1.2.5 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.

2.1.2.6 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.

2.1.2.7 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 13.00 25 Page 14

h. Isolation testing and bonding testing.

2.1.2.5 Summary of Services Required

The scope of services must include, but is not limited to, the following:

a. Close-interval potential surveys (grid as described)

b. Cathodic Protection Systems' planning,installation, drawings, etc.

c. System testing

d. Interference testing

e. Preparation and provision of all reports/documentation

2.1.2.6 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 b. Shutoff valves.

dc. Metallic pipes extended from aboveground locations.

ed. Connectors or change-of-direction devices.

f e. Metallic pipe components or sections.

gf. Backflow preventers.

i h. Casings.

2.1.2.7 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.

2.1.2.7 Electrical Potential Measurements

For all surfaces that are submerged or buried during testing, all potential tests must be made at a minimum grid of 5 foot horizontal

SECTION 26 42 13.00 25 Page 15 intervals across and 3 foot vertical intervals. These measurements must be witnessed by the Contracting Officer's representative. Submittals must identify test locations on separate drawing, showing all metal to be protected and all cathodic protection equipment. Test points, equipment, and protected metal must be easily distinguished and identified.

2.1.2.8 Typical Metallic Components on Non-metallic Systems

2.1.2.8.1 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.

2.1.2.8.2 Fire Hydrants

Provide fire hydrant pipe components with a minimum of two anodes. These galvanic anodes must have an unpackaged weight of20 pounds.

2.1.2.8.2 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.

2.1.2.8.3 Valves

Protect each valve with a minimum of 2 galvanic anodes. The galvanic anode must have an unpackaged weight of 20 pounds.

2.1.2.8.4 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.

2.1.2.8.5 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.

2.1.2.9 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.

2.1.2.10 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

SECTION 26 42 13.00 25 Page 16 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.

2.1.2.11 Electrical Isolation of Structures

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

(1) Connection of new metallic piping or components to existing piping.

(2) Pressure piping beneath floor slab to a building.

b. Provide isolation at metallic connection of all lines to existing system 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.

2.1.2.11.1 Isolation Joint Testing

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

2.1.2.11.2 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.

2.1.2.11.3 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

SECTION 26 42 13.00 25 Page 17 coating and testing using a holiday detector.

2.1.2.11.4 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.

2.1.2.11.5 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:

2.1.2.11.5 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.

SECTION 26 42 13.00 25 Page 18

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.

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

SECTION 26 42 13.00 25 Page 19 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.

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 Magnesium Anodes

At a minimum, the total number of bolted on magnesium slab anodes, as described herein and as shown on the drawings, must be provided. The anodes must be installed at the locations as shown on the drawings and/or as described in these specifications. Magnesium anodes must comply with all standards within ASTM B843.

2.4.1.1 Plastisol Coated Slab Anode Composition

Magnesium slab anodes must meet the H-1, Grade B, alloying standard. All slab anodes must have the manufacturer's supplied plastisol coating, which must be only removed in areas as described herein and/or as shown on the drawing details. All Magnesium slab type anodes as indicated on the

SECTION 26 42 13.00 25 Page 20 drawings must conform to ASTM B 843 and to the following analysis (in percents) unless otherwise indicated:

Aluminum 5.3-6.7%

Manganese 0.15-0.7%

Zinc 2.5-3.5%

Silicon, max. 0.30%

Copper, max. 0.05%

Nickel, max. 0.003%

Iron, max. 0.003%

Other impurities

- total, max. 0.30%

Magnesium Remainder

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

2.4.1.2 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

SECTION 26 42 13.00 25 Page 21

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

Nominal Weight

Bare Approximate Size

Packaged Weight

Nominal Packaged Dimensions

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

2.4.1.3 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:

Material Approximate Percent by Weight

Gypsum 75

Bentonite 20

Sodium Sulfate 5

Total 100

2.4.2 Galvanic Anodes

2.4.2.1 Magnesium Anodes

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

2.4.2.1.1 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

SECTION 26 42 13.00 25 Page 22

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

Magnesium Remainder

2.4.2.1.2 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

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