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GENERAL CONTRACTORS 835 GIL HARBIN INDUSTRIAL BLVD. VALDOSTA, GA 31601 (229) 244-6709 ● Fax (229) 244-7778
TO: BES Incorporated
2712 Bull Street
Beaufort, SC 29902
P 843.522.2094
SUBMITTAL TRANSMITTAL
DATE June 1, 2010 JOB NO. 09-019
ATTENTION Mr. Robert Beach
RE Enclave Force Protection Access Control Point
Contract W9128F-09-C-0051
Ft. Gillem, Georgia
Submittal Number 26 42 14 SD-02
Description Cathodic Protection
See Form 4025 Attached
COPY TO File
SIGNED
If enclosures are not as noted, kindly notify us at once.
SUBMITTED FOR:Shop Drawings Approval Approved as Submitted
WE ARE SENDING:
Letter Your Use Approved as NotedPrints As Requested Returned After LoanChange Order Review and Comment ResubmitPlans SubmitSamples ReturnedSpecifications Returned for Corrections
Other: Made from Submittal
SENT VIA:Attached
Separate Cover Via: Mail
ü
ü
ü
ü
üDue Date:
TRANSMITTALNo. 00042
ACTION TAKEN:
TO: Slone Associates, Inc.835 Gil Harbin Industrial Blvd.
PROJECT: Ft. Gillem-Enclave Force ProtectionPROJECT NO.: 20918
Ft. Gillem, GA 30297100 Flankers Road Phone:
Fax:404-734-3340770-956-1322
DATE:
REF:
FAX:
5/27/2010
Submittals
(229) 244-7778(229) 244-6709Valdosta, GA 31601
ATTN: Kevin KilpatrickPHONE:
ITEM NO. COPIES DATE ITEM NUMBER REV. NO. DESCRIPTION STATUS
0 NEW5/27/2010 SUT 001 Dwg: Title: Cathodic Protection Desc:Original Submission
26-42-14 SD-02
REMARKS:
Expedition ®
CC: Signed:Andrew Hannon
SUBMITTAL OF CATALOG DATA
FOR
CORROSION PROTECTION MATERIALS
Ft Gillem Enclave Force Protection Gate W9128F-09-C-0085
Cathodic Protection Requirements Forest Park, GA
Submitted to:
Batson-Cook Atlanta, GA
Submitted by:
Company Information
For over 25 years, Corrpro has been a leading provider of cathodic protection systems and engineering services. As a subsidiary of Insituform Technologies, Inc., Corrpro offers corrosion solutions for every industrial market including pipeline, refinery, above and underground storage tanks, water, wastewater, concrete, infrastructure, offshore, and marine.
Corrpro strives to provide high-quality cathodic protection materials and cost-effective services; including engineering, pipeline integrity, construction, and coating inspection.
Dedicated to ensuring preservation of energy resources, protection of the environment, and the integrity of the world's infrastructure, Corrpro has more than 30 operating facilities and warehouses worldwide.
Ft Gillem Enclave Force Protection Gate W9128F-09-C-0085 Cathodic Protection Requirements Forest Park, GA Similar Experience: Site Name Service Date Ft Bragg (Phase I) Engineering & Material 2006-2010 Ft Bragg (Phase II) Engineering & Material 2008-2010 Eglin AFB (AF Hanger) Design & Engineering 2008-2009 Eglin AFB (Dining Facility) Design & Engineering 2008-2009 Eglin AFB (ATC) Design & Engineering 2008-2009 Eglin AFB (Navy Hanger) Design & Engineering 2009 Eglin AFB (Infrastructure) Design & Engineering 2009 MacDill AFB Engineering & Material 2009-2010 Hickam AFB F22 Design & Engineering 2009-2010
Ft Gillem Enclave Force Protection Gate W9128F-09-C-0085 Cathodic Protection Requirements Forest Park, GA Catalog Data of Materials: Item No. Description Quantity 1) #12 RHW-USE Cable 200ft 2) #8 HMWPE Cable (Bonding) 100ft 3) 17-lbs Magnesium Anodes 6pcs 4) 9-lbs Magnesium Anodes 4pcs 5) Thermite Weld Equipment 2set 6) Thermite Weld Elastomeric Filled Caps 58pcs 7) Test Stations 5set 8) Current Measurement Shunt (0.01 Ohm) 5pcs 9) Reference Electrodes 3pcs 10) Test Station Terminal Lugs 25pcs
CATALOG DATA OF MATERIALS
SUBMITTAL
Copper Conductor
90oC
USE-2
RHW-2
RHH
*** 75oC
USE
RHW
ROME VW-1 USE-2 or RHW-2 or RHHRome FR-EPR Insulation, 600 Volts
Size Ampacity
AWG Insulation Nom. Approx.
or No. of Thickness Diam. Net Wt.
kcmil Strands Mils Inches Lb./1000 Ft.
Solid
14 Solid 45 .16 24 25 20
12 Solid 45 .18 32 30 25
10 Solid 45 .20 46 40 35
Stranded
12 7 45 .19 33 30 25
10 7 45 .21 47 40 35
8 7 60 .27 75 55 50
6 7 60 .30 110 75 65
4 7 60 .35 160 95 85
3 7 60 .38 198 110 100
2 7 60 .41 245 130 115
1 19 80 .49 320 150 130
1/0 19 80 .53 390 170 150
2/0 19 80 .57 485 195 175
3/0 19 80 .63 600 225 200
4/0 19 80 .68 745 260 230
250 37 95 .76 890 290 255
300 37 95 .81 1050 320 285
350 37 95 .86 1215 350 310
400 37 95 .91 1375 380 335
500 37 95 .99 1700 430 380
600 61 110 1.10 2065 475 420
750 61 110 1.20 2550 535 475
1000 61 110 1.35 3330 615 545
AMPACITY in accordance with NEC for not more than three conductors. As RHW-2: in raceway, 90oC conductor temperature and 30oC ambient in
wet or dry locations. As RHH: in raceway, 90oC conductor temperature and 30oC ambient in dry locations. As USE-2: direct burial, 90oC conductor
temperature and 30oC ambient in wet locations.
AMPACITY in accordance with NEC for not more than three conductors. As RHW: in raceway, 75oC conductor temperature and 30oC ambient in
wet or dry locations. As USE: direct burial, 75oC conductor temperature and 30oC ambient in wet locations.
The over current protection shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG and 30 amperes for 10 AWG copper.
NOTES: 1. Standard color is black. Other colors available on request.
Information on this sheet subject to change without notice.
**
t
APPLICATION: General purpose wiring for lighting and power-residential,
commercial, industrial buildings in accordance with the National Electrical
Code and for other general purpose wiring applications. Suitable for use in
circuits not exceeding 600 volts at conductor temperatures not exceeding
90oC in wet or dry locations. May be installed in raceway, cable tray, direct
burial and aerial installations.
STANDARDS:
1. Listed by UL as Type USE-2 (90oC wet or dry) per Standard 854 for
Service Entrance Cables.
2. Listed by UL as Types RHW-2 (90oC wet or dry) or RHH (90oC dry) per
Standard 44.
3. All sizes carry the VW-1 flame test designation.
4. Cables are UL listed as Sunlight Resistant (1/0 AWG and larger, black
only).
5. Sizes 1/0 AWG and larger pass UL and IEEE-383 ribbon burner flame test
and are UL listed For CT Use.
6. Conforms to ICEA S-95-658/NEMA WC70, utilizing Column A thicknesses.
CONSTRUCTION: Annealed copper conductor, Rome FR-EPR thermosetting
flame-retardant ethylene-propylene-rubber insulation, surface printed.
*
t
t
t
t
Rome FR-EPR
Insulation
↓↓
↑
Copper
Conductor
SPEC 2255
January 1, 2003
Separator
t
t
t
t
t t
SPEC 2255
1-1-03
Specification
ROME VW-1 USE-2 or RHW-2 or RHH
Rome FR-EPR Insulation, 600 Volts
1. SCOPE
1.1 This specification describes single conductor Rome FR-EPR, Type USE-2 or RHW-2 or RHH, flame-retardant ethylene-
propylene-rubber insulated cables for use in circuits not exceeding 600 volts. Cables are listed by UL as Type USE-2
and are recognized for underground use in wet locations at a maximum continuous conductor temperature of 90oC in
accordance with Article 338 of the National Electrical Code. The cables are also listed by UL as Type RHH or RHW-2
for general purpose wiring applications at maximum continuous conductor temperature of 90oC in dry locations (RHH)
or 90oC in wet or dry locations (RHW-2) and may be installed in air, conduit or other recognized raceways in accor-
dance with Article 310 of the National Electrical Code. All cables comply with UL’s VW-1 (Vertical-Wire) Flame Test.
Sizes 1/0 AWG and larger may be used in cable tray in accordance with Article 392 of the NEC.
2. APPLICABLE STANDARDS
2.1 The following standards form a part of this specification to the extent specified herein:
2.1.1 Underwriters Laboratories Standard 854 for Service Entrance Cables.
2.1.2 Underwriters Laboratories Standard 44 for Rubber-Insulated Wires and Cables.
2.1.3 ICEA Pub. No. S-95-658, NEMA Pub. No. WC70 for Nonshielded Power Cables Rated 2000 Volts or Less.
3. CONDUCTORS
3.1 Conductors shall be solid and Class B stranded, annealed uncoated copper per UL Standard 854 and 44.
4. SEPARATOR
4.1 A suitable separator over the conductor may be used at the option of the manufacturer.
5. INSULATION
5.1 Each conductor shall be insulated with Rome FR-EPR, a flame-retardant ethylene-propylene-rubber complying with
the physical and electrical requirements of UL Standard 854 for Type USE-2 and UL Standard 44 for Types RHW-2 or
RHH and Table 3-7, Class E-2 of ICEA S-95-658. In addition, the Rome FR-EPR insulation shall comply with the For
CT Use (sizes 1/0 AWG and larger) and VW-1 flame test ratings of UL Standard 44.
5.2 The average thickness of insulation, for a given conductor size, shall be as specified in UL Standard 44 for Types
RHH and RHW-2 and Table 3-4, Column A of ICEA. The minimum thickness at any point shall be not less than 90% of
the specified average thickness. The insulation shall be applied tightly to the conductor and shall be free-stripping.
6. IDENTIFICATION
6.1 The wire shall be identified by surface marking indicating manufacturer’s identification, conductor size and metal,
voltage rating, UL symbol, VW-1, type designations and Sunlight Resistant For CT Use (1/0 AWG and larger).
7. TESTS
7.1 Wire shall be tested in accordance with the requirements of UL Standard 854 for Type USE-2, UL Standard 44 for Types
RHW-2 or RHH and ICEA S-95-658.
8. LABELS
8.1 The wire shall bear the Underwriters Laboratories labels for Type USE-2.
CABLE
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
HMWPEHMWPEDirect Burial Cable
Multi-Purpose Cathodic ProtectionCableSelecting the right cable for connecting anodes,power supplies, and structures is an importantpert of any cathodic protection design. Corrpromakes this selection process easy by offering acable manufactured specifically for the cathodicprotection industry. It is composed of copperwire, which is covered by high-molecular-weight polyethylene (HMWPE). The copperwire is stranded and annealed to permit extraflexibility. Because the polyethylene on thecable is approximately twice as thick as onconventional HMWPE wire, it serves as bothelectrical insulator and mechanical cover for theconductor. This provides Corrpro's cathodicprotection cable with outstanding dielectricstrength and moisture resistance. Duringinstallation, the cable can withstand considerablemechanical abuse without risk of damage to thecopper electrical conductor. The polyethylenecover is also chemically resistant, and protectsagainst most organic and inorganic substances.
Corrpro's HMWPE cable is manufacturedaccording to strict quality control standards.The polyethylene coating is made to meetAmerican Society for Testing MaterialsStandard D-1248 for plastic molding andextruded materials. In addition, routine tests areperformed to ensure that the cable possessescertain mechanical and electrical properties.
Typical ApplicationsHMWPE cable is offered in a variety of sizes. Itcan be used as a header cable on cathodicprotection systems, or to make anode-lead ornegative-return connections. The thickpolyethylene cover permits direct burial of thecable in native soils or submersion in freshwater.The cable exhibits superior flexibility, and canbe bent without risk of notch propagation. It isnot recommended for use in environmentscontaining chlorine, hydrochloric acid, orpetroleum hydrocarbons.
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
CABLE
HMWPEHMWPEDirect Burial Cable
Ordering ProcedureCorrpro's HMWPE cable is readily stocked in arange of wire sizes, and in available forimmediate shipping. To order the right cable foryour particular application, indicate that youneed Corrpro HMWPE cable, and specify thelineal feet and wire size desired. An example isprovided to help illustrate this process.
Ordering Procedure ExampleITEM EXAMPLEQuantity(Lineal Feet) 2,000 ft.Wire Size #4 AWG
Wire Type HMWPE
HMWPE Order InformationWIRE SIZE INSULATION
THICKNESSNOMINAL O.D.
AWG (mm2)
NUMBEROF
STRANDS in. (mm) in. (mm)
14 (2.5) 7 0.11 (2.794) 0.299 (7.59)12 (4) 7 0.11 (2.794) 0.31 (7.87)10 (6) 7 0.11 (2.794) 0.34 (8.64)8 (10) 7 0.11 (2.794) 0.36 (9.14)6 (16) 7 0.11 (2.794) 0.41 (10.41)4 (25) 7 0.11 (2.794) 0.46 (11.68)2 (35) 7 0.11 (2.794) 0.52 (13.21)1 (45) 19 0.125 (3.175) 0.59 (14.99)
1/0 (50) 19 0.125 (3.175) 0.63 (16.00)2/0 (70) 19 0.125 (3.175) 0.67 (17.02)4/0 (120) 19 0.125 (3.175) 0.78 (19.81)
SACRIFICIAL ANODES
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
High PotentialHigh PotentialCast Magnesium Anodes
Delivering Superior ProtectionPower in galvanic cathodic protection isgenerated at the anode. With Corrpro'scertified line of high-potential anodes, you getthe most powerful protection available today.Cast from high-purity magnesium, theseanodes produce an open circuit potential of1.75-1.77 volts, with is 20-3- percent greaterthan conventional magnesium anodes. Thishigh driving voltage means greater protectioncan be delivered from fewer anodes.Efficiency of the anode is enhanced evenfurther when installed in a backfill of 75%gypsum, 20% bentonite, and 5% sodiumsulfate. This special mixture lowers anode-to-earth resistance, and allows electrical current toflow more easily to the targeted structure.
Corrpro certified high-potential anodes aremanufactured according to strict quality controlstandards. Each production run of high-potentialanodes is subjected to capacity, potential, andconsumption analysis. This ensures the anodesyou purchase will perform as specified.
Typical ApplicationsHigh potential anodes can be used to protectmost buried metallic structures found in a rangeof soil resistivities. Because they produce ahigher driving voltage than conventionalmagnesum anodes, they are ideally suited forstructures buried in soils with reesistivities inexcess of 2,000 ohm-cm, or containingnumerous corrosion "hot spots".
CHEMICAL COMPOSITIONElement Content %
Al 0.010
Mn 0.50 to 1.30
Cu 0.02 Max
Ni 0.001 Max
Fe 0.03 Max
Other 0.05 each or 0.3 Max Total
Magnesium Remainder
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
SACRIFICIAL ANODES
High PotentialHigh PotentialCast Magnesium Anodes
Ordering ProcedureCertified high-potential anodes aremanufactured in a variety of dimensionsand weights. To order the required anodefor your structure, indicate that you needhigh-potential magnesium anodes, andspecify the quantity desired, the anodetype, and whether they should be packagedor bare. The anodes are shipped standardwith 10 ft.-#12 solid TW lead wire unlessotherwise specified. An example isprovided to help illustrate this process.
Ordering Procedure ExampleITEM EXAMPLE
Quantity 200
Anode Material High-PotentialMagnesium
Anode Type 17S3Packaging(Bare or Pkgd.) Packaged
Wire:Length(10 ft. = Standard)
10 ft.
Size(#12 solid =Standard)
#12
Insulation(TW = Standard) TW
Standard Dimensions and Shipping WeightsNOMINAL DIMENSIONS
in. (mm)NOMINAL WT.
lbs. (kg)ANODETYPE "A" "B" "C" "D" "E" BARE PKGD.
3S3 3 (76) 3 (76) 4.5 (114) 6.5 (165) 6 (152) 3 (1.4) 9 (4.1)
5S3 3 (76) 3 (76) 7.5 (191) 13.5 (343) 6 (152) 5 (2.3) 14 (6.4)
9S2 2 (51) 2 (51) 27 (686) 31 (787) 5 (127) 9 (4.1) 36 (16.3)
9S3 3 (76) 3 (76) 13.5 (343) 17 (432) 6 (152) 9 (4.1) 24 (10.9)
17S2 2 (51) 2 (51) 51 (1295) 55 (1397) 5 (127) 17 (7.7) 61 (27.7)
17S3 3 (76) 3 (76) 25.5 (648) 30 (762) 6 (152) 17 (7.7) 42 (19.1)
20S2 2 (51) 2 (51) 60 (1524) 62.5 (1588) 5 (127) 20 (9.1) 70 (31.8)
32S3 3 (76) 3 (76) 45 (1143) 6 (1549) 6 (152) 32 (14.5) 90 (40.8)
32S5 5 (127) 5 (127) 21 (533) 30 (762) 8 (203) 32 (14.5) 70 (31.8)
40S3 3 (76) 3 (76) 60 (1524) 64(1626) 6 (152) 40 (18.1) 105 (47.6)
48S5 5 (127) 5 (127) 31 (787) 34 (864) 8 (203) 48 (21.8) 96 (43.6)
60S4 4 (102) 4 (102) 60 (1524) 64 (1626) 6.75 (171) 60 (27.2) 130 (59.0)
TEST STATIONS AND JUNCTION BOXES
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
Flush-To-GradeFlush-To-GradeCathodic Protection Test Stations
Suitable For Numerous LandscapesCathodic protection systems are utilized onstructures located in water, on land, in rural,urban, industrial, and residential regions. Tomonitor the performance of these systems inareas where aesthetics are important or trafficflow is present, Corrpro offers flush-to-gradetest stations. The stations are manufactured withtube sections made from various types of plasticmaterials. These special tube sections arelightweight, durable, corrosion resistant, andprovide a watertight area for housing test leadterminals. Terminal boards are connected eitherto the test head cap or recessed into the plastictube for easy access. The test boards canaccommodate from one to nine terminals, whichare made from nickel-plated brass to assuremany years of accurate readings.
The quality of the lid utilized in flush-to-gradetest stations is very important. The lids are theonly means of identifying and locating the teststations, and provide protection against waterpenetration and vandalism. Corrpro flush-to-grade test stations are equipped with speciallocking lids, which are clearly marked for easyidentification. The caps are made from eithercast iron or high-impact-strength plastic, and areavailable with built-in magnets for locating byelectromagnetic detectors.
Typical ApplicationsCorrpro flush-to-grade test stations are designedfor use in areas where maintaining a landscape'saesthetic quality is important. The stations arealso ideal for use in human or vehicle trafficareas, such as roads, parking lots, or sidewalks.Using the test stations, readings can be obtainedto determine structure-to-soil potentials and thelevel of stray currents.
Authorized Distributor for theFollowing ManufacturersCott Manufacturing Company
C. P. Test ServicesHandley Industries
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
TEST STATIONS AND JUNCTION BOXES
Flush-To-GradeFlush-To-GradeCathodic Protection Test Stations
Ordering ProcedureThe flush-to-grade test stations supplied byCorrpro are manufactured by several differentcompanies. To order the required station foryour application, indicate the brand and modeldesired, and specify the quantity and terminalconfiguration needed. An example is providedto help illustrate this process.
Ordering Procedure ExampleITEM EXAMPLE
Quantity 200Test StationManufacturer CottTest Station Model Flush Fink
Number of Terminals 5
Test Station Ordering Information
MANUFACTURER MODEL
STANDARDTERMINAL
LEADS
MAXIMUMTERMINAL
LEADSFlush Fink 5 11CottStreet Fink 5 9
M2 2 2T2 1, 2, 5 5
Handley
T4 1, 2, 5 5NM 4, 5, 7 7Mini 2 5
C. P. TestServices
Glenn 4 5
CottShunt® Cathodic Protection Circuit Components
A calibrated CottShunt® makes it possible to measure cathodic protection currents and potentials with the highest degree of accuracy, reliability, and ease. Designed specifically for the cathodic protection industry and manufactured from the finest materials available by Cott Manufacturing Company in Los Angeles, California, the CottShunt® is available through Cott's worldwide network of authorized distributors.
Features
Circuit Board Makrolon® polycarbonate is one of the world's toughest plastics. Color coded for easy value recognition. Current Strips and Potential Posts Nickel plated brass. Resistance Wire Manganin (ASTM B267, CI.VI) Configuration Standard 1/4" holes on 1" centers fits all Fink® brand cathodic protection test stations. Quality Assurance All CottShunts® are 100% tested and calibrated to within ±1% of advertised resistance value.
Page 1 of 2Cott Shunt
11/16/04http://www.cottmfg.com/shunt.htm
Page 2 of 2Cott Shunt
11/16/04http://www.cottmfg.com/shunt.htm
REFERENCE CELLS
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
PermacellPermacell®® 802 802Permanent Reference Cell
For Reliable Potential MeasurementsOn Buried StructuresPermanent reference electrodes provide accurateand reliable potential measurements on buriedmetallic structures. Their placement in closeproximity to protected structures permitsreadings which are more exact and less affectedby fluctuating soil conditions than thoseobtained by portable cells. Corrpro’s Permacell802 is a permanent copper/copper sulfatereference electrode with a proven track recordfor stability. Long-life performance is achievedthrough a rugged design, which includes impact-resistant PVC tubing. The tubing houses a99.99% pure copper element and asupersaturated solution of copper sulfate. Thecopper sulfate mixture ensures that the copperelement remains electrically stable, so that thecell’s potential value will not fluctuate. Fromthis special composition, the cell achieves aminimum design life of fifteen years, andmaintains an accuracy level of ±5 millivolts.
Corrpro’s Permacell 802 is designed for trouble-free installation. The cell is pre-packaged in acloth bag containing a low-resistance backfillmaterial, and is completely assembled and readyfor immediate installation. Plastic positioningpins on the cell assure that a sufficient amount ofthe backfill will exist around the cell’s electricalcontact point. Because of this, a low-resistancegroundbed can be created simply by wateringthe area surrounding the cell. Lead wireconnections to the cell are made using #14AWG wire containing HMWPE insulation. Thecell is provided with fifteen feet of this wire toaddress numerous types of applications.
Typical ApplicationsThe Permacell 802 permanent reference cell isdesigned to measure electrical potentials onburied metallic structures, such as undergroundpipelines and storage tanks. It is ideal forstructures located under pavement or otherimpediments which prevent the use of a portablecell. The cell can be operated in temperatures ofup to 135°F, but should not be used in areascontaining high chloride concentrations. Thecell should be installed below the frost line inrelatively moist soil.
1090 Enterprise Drive / Medina, OH 44256Tel: 1-330-723-5082 / Fax: 1-330-723-0694http://www.corrpro.com
REFERENCE CELLS
PermacellPermacell®® 802 802Permanent Reference Cell
Ordering ProcedureCorrpro’s Permacell 802 is made according tocustomer specifications. To order this cell foryour particular application, indicate that youneed a Permacell 802 copper/copper sulfatereference electrode, and specify the quantitydesired and the lead wire length, size, andinsulation if different from the standardprovided. An example is included to helpillustrate this process.
Ordering Procedure Example
ITEM EXAMPLE
Quantity 10
ProductPermanent ReferenceCell
Permacell Model 802
Lead Wire:Length(15 ft. = Standard) 15 ft.Size(#14 AWG = Standard) #14 AWGInsulation(HMWPE = Standard) HMWPE
Product SpecificationsNOMINAL
DIMENSIONSin. (mm)
Ø LENGTH
WEIGHTlbs. (kg)
ELECTRICALSTABILITY
DESIGNLIFE
Bare 2(50.8)
8(203.2)
4(1.82)
Pkgd. 8(203.2)
15(406.4)
19(8.62)
±5 millivoltswith 8.0
microamp load20 years
GALVANIC CATHODIC PROTECTION SYSTEM OPERATIONS & MAINTENANCE MANUAL
Ft Gillem Enclave Force Protection Gate W9128F-09-C-0085
Cathodic Protection Requirements Forest Park, GA
PREPARED BY: CORRPRO COMPANIES, INCORPORATED
581 SIGMAN ROAD, SUITE 300 CONYERS, GEORGIA 30013
770-761-5400
2
OPERATION AND MAINTENANCE INSTRUCTIONS GALVANIC CATHODIC PROTECTION SYSTEM
I. THE BASIC CORROSION MECHANISM:
Corrosion has been described as oxidation, a chemical attack, and as an electrical phenomenon, electrolysis. None of these descriptions, by themselves, are correct, yet each one is partially true. It can be stated that the corrosion process is basically electrochemical in nature and that the presence of oxygen in some form is necessary. There are certain conditions which must be met before a galvanic corrosion cell can function. They are: 1. There must be an anode and a cathode. 2. There must be an electrical potential difference between the anode and
cathode. 3. There must be a metallic path electrically connecting the anode and
cathode. 4. The anode and cathode must be immersed in an electrically conductive
electrolyte that is ionized - meaning that some of the water molecules are broken down into positively charged hydrogen ions and negatively charged hydroxyl ions.
Once these conditions are met, an electric current will flow and metals will be consumed at the anode. The major components of a galvanic anode type cathodic protection system are as follows: 1. Metal structure, such as steel pipe, underground storage tanks, or the
external bottoms of on-grade storage tanks. 2. Anode to be placed in the electrolyte. Magnesium is usually employed
as anode material, although zinc and aluminum are sometimes used. The anode may be in the form of a cast ingot or a long rod or ribbon.
3. Metallic connection such as a mechanical ground clamp type or thermite
type connection to the structure. This may be accomplished through a test station or by connecting a wire directly to the structure.
4. Insulators installed at flanges or unions to electrically isolate the structure considered for galvanic cathodic protection from "foreign" structures.
5. Test stations, either flush-to-grade or post mounted. Occasionally,
galvanic type anode systems are installed without test stations.
3
II. BASIC THEORY OF CATHODIC PROTECTION:
As described in the previous section, corrosion is caused by a current flow from an anode to a cathode through an electrolyte. To complete the circuit, the current flows back along the metallic path from the cathode to the anode. This can occur on a single structure with areas of the surface being the anode and cathode (see Figure 1 below).
Figure 1
Thus, corrosion takes place at the anode, where the current leaves the pipe and enters the electrolyte, while none takes place at the cathode - because the cathode is receiving current from the electrolyte. So, it is obvious that if all the exposed surface of the pipe could be made to collect current, it would not corrode because the entire surface would then be cathodic. This is exactly what cathodic protection does. The galvanic anode method of cathodic protection utilizes galvanic anodes that have a high natural potential difference with respect to the structure to be protected. The anodes are made of a material which is anodic to the structure. Generally, magnesium or zinc is used as anode material and the anodes are electrically connected to the structure, either directly or through a test station. With the anodes connected to the structure and a sufficient amount of DC electric current flowing to the structure, the entire structure will become cathodic to its surroundings and the anodic areas will be eliminated.
III. LIMITATIONS OF CATHODIC PROTECTION:
1. Continuous Electrolyte:
The electrolyte with which the structure is in contact must be continuous. Metal above ground will not be protected from atmospheric corrosion by cathodic protection.
2. Continuous Operation:
Cathodic protection is effective only while the system is in operation. Therefore, the cathodic protection system should be allowed to operate continuously.
3. Effect of New Construction:
Addition of new underground metallic structures or alterations made to existing structures can materially affect the operation of a cathodic protection system. If such changes are extensive, a field investigation
4
should be performed to determine the effect of the new construction on the existing structures, which are being cathodically protected.
IV. WHEN TO MEASURE STRUCTURE-TO-ELECTROLYTE POTENTIAL:
1. Tests should be made a short time after the installation of the cathodic
protection system. The methods or testing to use are described in the "Test Procedures" section of these Operation and Maintenance Instructions.
2. After the installation, tests should be performed at least once each year. 3. If operation of the system is interrupted or changed for any of the
following reasons, additional testing should be performed as quickly as is possible:
a. Damage to anodes or test stations where one or more anodes are
connected to the structure through the test station. b. Addition(s) to the piping system as a result of new construction.
V. DESCRIPTION OF THE SYSTEM:
The purpose of the cathodic protection system is to prevent corrosion of the external metallic surfaces. When constructed, the pipelines and/or pipe fittings are provided an external coating. The cathodic protection system supplements the corrosion protection provided by the coating in preventing corrosion at coating holidays. This is accomplished by the passage of DC current from anodes through the soil to the piping. The system is energized by connecting the anodes to the structure(s) to be protected, either directly or through a test station. The cathodic protection system utilizes high purity sacrificial magnesium or zinc anodes, test stations for monitoring the cathodic protection system, and dielectric material to isolate the structure to be protected from all other foreign underground metallic structures.
VI. OPERATION OF THE SYSTEM:
A cathodic protection system that makes use of galvanic type anodes is capable of many years of continuous operation with very little maintenance. In order for the system to function effectively, it is important it be kept in continuous operation and that all dielectric material remain intact. Although a cathodic protection system using galvanic anodes is capable of many years of trouble-free operation, it is recommended that this system be rechecked thoroughly each year by a corrosion engineer or technician. This will insure that the system is operating properly and an adequate level of protection
5
is being maintained. It is possible that changes in conditions such as coating quality, the environment, or in the piping network(s) may have occurred and additional protective current may be required.
VII. MAINTENANCE:
1. Inspection: Inspection of the test stations and dielectric material, flanges or unions should be done at least each month and incorporated into a routine inspection procedure for these facilities. Such appurtenances found damaged or missing should be repaired or replaced immediately. At the time of these inspections, particular attention should be given to the insulating flanges to see if they have been worked on and not repaired properly. Flush-to-grade type test stations should be kept clear of objects or debris placed over them.
2. Cleaning and Clearing:
Dirt and debris should be kept from accumulating within the crevices of all metallic test stations and insulating flanges. Where screws, bolts, or threads are involved, with relation to test stations, such items should be lubricated periodically. Grass, weeds, scrub vegetation, debris, etc., should be cleared from test station areas to enable clear visibility of test stations as well as to facilitate easy access for monitoring purposes.
3. Painting: The test stations installed do not require painting. However, if painting is necessary due to color-coding, company identification, etc., a paint compatible with the test station material should be used, and particular care should be taken to enable easy removal of the covers. When painting the piping in the vicinity of the insulating material, metal-base paints should not be used since the paint itself can provide a path for current to flow and render the insulating material ineffective.
6
VIII. TEST PROCEDURES:
1. Structure-to-Soil Potential Measurements: Structure-to-soil potential measurements should be obtained at least once each year. Equipment should be set-up to obtain potential data as shown in figure 2. The most common criterion is that the potential reading should be more negative than -0.850 volts to satisfy NACE International (formerly the National Association of Corrosion Engineers) criterion for cathodic protection. Where short sections of piping exist, potential measurements should be obtained at representative locations on what exists. Standard equipment required: a. High-impedance digital multimeter. b. Copper-copper sulfate reference electrode. c. Test leads. d. Portable wire reel with 1500 feet of #22 AWG insulated wire. e. Miscellaneous hand tools.
Refer to diagram below for test procedures.
Figure 2
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2. Anode Current Output Measurements:
Anode current output should be made at each of the test stations as shown in Figure 3. If there are no test stations provided with the cathodic protection system, these measurements cannot be obtained. Equipment required: a. DC ammeter or Voltmeter with a minimum of 3-1/2 digit resolution. b. Test leads. c. Miscellaneous hand tools.
Refer to diagram below for test procedures.
Figure 3. Remove brass strap, if applicable, and connect ammeter between the anode and structure leads. Record current measurement. If a shunt is installed between the anode lead and the structure lead, utilize the DC millivolt scale of the multimeter to measure the voltage drop across the shunt and convert to current ("I") using Ohm's Law. To calculate the current flow, the voltage measured (in volts) is divided by the resistance of the calibrated shunt (in ohms).
SECTION I
INTRODUCTION
INTRODUCTION
Corrpro Companies has been retained by Batson-Cook to provide cathodic protection
related services underground utilities for the buildings associated with the Enclave
Force Water Line Ft Gilem, GA. The requirements for cathodic protection are
addressed in Section 26 42 14.00 10 of the Specifications for this project. In
accordance with this document cathodic protection is to be afforded all underground
metallic components of the potable water and fire water pipelines associated with this
project. The type of system is based on the pipeline material selected by the
mechanical contractor.
For this project, the mechanical contractor has opted to utilize a combination of PVC
pipe and ductile iron mechanical fittings for the fire and potable water lines. Therefore,
the buried metallic fittings and sections of ductile iron are to be cathodically protected.
Contained within Section III of this submittal are detail drawings for the cathodic
protection system. In accordance with these drawings each Fire Hydrant fitting is to be
afforded two (2) 17-pound magnesium anodes and each Pipeline fitting is to be afforded
two (2) 9-pound magnesium anodes.
The coating requirements for the fittings are addressed in Chapter 1.2.7 of Section 26 42
14.00 10. In review, the coating is to be a coal tar base mastic. These coatings are well
suited for use on ductile iron pipe with cathodic protection.
Holiday testing of the applied coating should be conducted on the ductile iron fittings
and any damages to the coatings should be repaired prior to back fill.
For a galvanic cathodic protection system to be effective, electrical isolation is a
requirement at building risers and at connections to foreign structures (tie-ins). If
electrical isolation is not used, it is possible that the piping or fitting at that location may
become electrically continuous with other structures (i.e. building ground, existing
metallic pipelines or existing metallic fittings) not being cathodically protected. This
shorted condition would likely prevent the ability to cathodically protect the piping at
these locations. Contractor should review any locations where electrical isolation is a
potential concern during installation.
Calculations illustrating current requirement for each metallic pipe or component are
given in Section II.
SECTION II
CALCULATIONS
COMPUTATIONS:
1 Surface Area to be Protected:
FH assembly = 0.30 sq. ft. (0.02 sq. m)
45-degree bend = 0.04 sq. ft. (0.002 sq. m)
90-degree bend = 0.06 sq. ft. (0.004 sq. m)
tee = 0.07 sq. ft. (0.005 sq. m)
valve = 0.10 sq. ft. (0.008 sq. m)
2 Current Required:
IT = AB (total) x Cd
where:Cd = = 1.0 mA/sq.ft.
Elbows/tees/valves
IT = 0.10 x 1.
IT = 0.10 mA or 0.00010 A
Building Entrance
IT = 0.30 x 1.
IT = 0.30 mA or 0.00030 A
sq. ft. (0.03 sq. m)
For design purposes the elbows, tees, and valves will be assumed to be of the same surface area. Also, the nominal diameter of the fittings ranges from 4-inch to 8-inch; because the 8-inch fittings are the largest and therefore have largest current requirement, the calculations presented here are sufficient for all fittings.
Building entrance, typical length = 10 ft,
= 0.30
The approximate exposed surface area (5% bare) for 8-inch ductile iron fittings with a coal tar epoxy coating is as follows:
The amount of current required to achieve protection is based upon the operating parametersof the structure being protected, the soil conditions and the surface area exposed to the soil.This pipe will operate at ambient temperature and is buired in soils described earlier in thisreport. In this case, a desgin current density of 10.76 mA/sq. m (1 milliamp per square foot) ofexposed area will provide adequate protection for the ductile fittings.
Current density
DESIGN CALCULATIONSDuctile Iron Fittings
Enclave Force Protection Gate-Fort Gillem, GA
Page 1 of 3
Hydrant Assembly
IT = 0.30 x 1.
IT = 0.30 mA or 0.00030 A
3 Cathodic Protection Type Selection
4 Anode Type
High potential alloy magnesium, prepackaged, with #12 Awg/TW lead wire is recommended.Type: P 17s3
Packaged dimensions:diameter: 6 incheslength: 30 inchesAnode bare weight: 17 poundsAnode consumption rate: 17 pounds/amp-yearAnode natural potential: -1.75 volts (relative to Cu/CuSO4 cell)
5 Anode Current Output
30,000 ohm-cm, the current output of a single anode can be calculated using Dwight's equation and Ohm's law as follows:
Dwight's equation for a single anode resistance to earth is:
ρ 0.0627 4 x LR = (ln - 1)
r
where:R = Anode to earth resistanceρ = = 30,000 ohm-cmr = = 3.0 inchesL = = 30.0 inches
ρ 0.0627 4 x 30.R = (ln - 1)
3.0
R = 168.59 ohms
According to Ohm's Law:
I = (EP - Ea) / R
Using a soil resistivity of
L
30.0
Soil resistivityAnode radiusAnode length
Based upon current requirements and fitting arrangement, a galvanic type cathodic protectionsystem would provide the most economical and practical performance. The anodes shall beconnected through monitoring test stations. In addition, the line must be electrically isolated ateach connection to an exisiting line and within casings. This recommendation is based uponthe line being well coated.
)
( )
(
Page 2 of 3
where:R = Anode to earth resistance
Ea = = -1.75 mVEP = = -0.85 mV
I = 0.00534 amps or 5.34 mA per anode
The minimum number of anodes therefore is:
N = IT / I
where N = number of anodes required
Elbows/tees/valve
N = 0.08 / 3.56 = 1 anode
Building Entrance
N = 0.26 / 3.56 = 1 anode
Hydrant Assembly
N = 0.20 / 3.56 = 1 anode
5 Theoretical Anode Life:
0.116 x W x E Y = --------------- -----------------------------------------------
where:Y = anode life in years
W = = 17.0 poundsE = = 50%U = = 70%I = = 0.00010 amps
Y = over 50 years
To ensure adequate current distribution, and to overcome possible unforeseen coating flaws or coating damage, two (2) anodes per fitting shall be used.
Anode current Utilization factor
x U
I
Anode weightEfficiency
Desired Pipe PotentialAnode Potential
Page 3 of 3
SECTION III
INSTALLATION DRAWING
