Facilities Instructions, Standards, and Techniques Volume ...

1 Department of the Interior Bureau of Reclamation Denver, Colorado September 2013 Facilities instructions , standards , and Techniques Volume 4-5 corrosion and cathodic protection REPORT DOCUMENTATION PAGE Form Approved OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions , searching existing data sources, gathering and maintaining the data needed, and completing and reviewing this collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302.

2 Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS. T1. REPORT DATE (DD-MM-YYYY)T 09-16-2013 T2. REPORT TYPET Draft T3. DATES COVERED (From - To)T Implementation Date: 01-01-2014 T4. TITLE AND SUBTITLE FIST 4-5, corrosion and cathodic protection 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) Bureau of Reclamation Materials Engineering Research Laboratory Mail Code 86-68180 Denver, Colorado 5d. PROJECT NUMBER 5e. TASK NUMBER 5f.

3 WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Materials Engineering Research Laboratory, Bureau of Reclamation Denver Federal Center Box 25007 Denver CO 80225-0007 8. PERFORMING ORGANIZATION REPORT NUMBER FIST 4-5 9. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES) Power Resources Office Bureau of Reclamation Mail Code 86-61600 PO Box 25007 Denver CO 80225-0007 10. SPONSOR/MONITOR S ACRONYM(S) 11. SPONSOR/MONITOR S REPORT NUMBER(S) 12. DISTRIBUTION / AVAILABILITY STATEMENT Available from the National Technical Information Service, Operations Division, 5285 Port Royal Road, Springfield, Virginia 22161 13. SUPPLEMENTARY NOTEST 14. ABSTRACT This document provides field personnel the principles they need for a clearer understanding of basic corrosion processes and methods to deal with them.

4 It further describes some simple situations in which they might design and install a cathodic protection system using site forces. The document also describes general cathodic protection monitoring procedures. In most circumstances, however, field personnel should seek some level of participation and assistance from corrosion professionals. 15. SUBJECT TERMS corrosion , corrosion mitigation, corrosion principles and concepts, oxidizer, oxidation, reduction, polarization, depolarization, passive, corrosion cell, galvanic series, concentration cell, pH cell, stray current corrosion , attenuation, cathodic protection , coatings, galvanic anode cathodic protection , impressed current cathodic protection , anodes, rectifier, test station, junction box, bond box, service life.

5 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT UL 18. NUMBER OF PAGES 88 19a. NAME OF RESPONSIBLE PERSONT Power Resources Office a. REPORT UL b. ABSTRACT UL c. THIS PAGE UL 19b. TELEPHONE NUMBER (include area code) 303-445-2922 SSStandard Form 298 (Rev. 8/98) P Prescribed by ANSI Std. 239-18 Department of the Interior Bureau of Reclamation Denver, Colorado September 2013 Facilities instructions , standards , and Techniques Volume 4-5 corrosion and cathodic protection Materials Engineering and Research Laboratory Disclaimer This written material consists of general information for internal use only by Bureau of Reclamation operations and maintenance staff.

6 Information contained in this document regarding commercial products or firms may not be used for advertising or promotional purposes and is not to be construed as an endorsement or depreciation of any product or firm by the Bureau of Reclamation. iii Acronyms and Abbreviations AC Alternating current CP cathodic protection CSE Copper sulfate electrode DC Direct current D&S Directive and Standard ERI Electrical resisting imaging FIST Facilities Instruction, standards , and Techniques HMWPE High molecular weight polyethylene HSCI High-silicon cast iron ICCP Impressed current cathodic protection IR Infrared PPM Parts per million SOP Standard Operating Procedures TSC Technical Service Center UV Ultraviolet iv corrosion and cathodic protection v Table of Contents Page Acronyms and Abbreviations.

7 Iii Introduction .. 1 Purpose .. 1 Scope .. 1 Reclamation Standard Practices .. 1 Effect of Section Headings .. 2 General .. 2 corrosion Terms .. 2 Forms of corrosion .. 2 Taking Action and Getting Help .. 3 corrosion Principles and Concepts .. 4 Soil and Water Corrosivity 4 Water .. 4 Oxidizers .. 5 Ionizable Chemicals .. 5 Temperature .. 6 Chemical Changes Due to corrosion .. 6 Metal/Alloy Susceptibility Factors .. 7 The Metal or 7 Passive Films .. 7 Ferrous corrosion Products .. 8 corrosion Cell 8 Microcells and Macrocells .. 9 Common corrosion Cells .. 10 Specific corrosion Issues .. 11 Galvanic Series and Coupling Metals/Alloys.

8 11 Acceptable and Unacceptable Couples .. 11 Specificity of Galvanic Series .. 12 Why Some Alloys Are Listed Twice .. 13 Reference Electrodes .. 13 Minimizing Galvanic corrosion .. 14 Electrical Isolation .. 15 Concentration Cell corrosion .. 16 corrosion in Cementitious Materials and the pH Cell .. 17 Minimizing pH Cell corrosion .. 18 Stray Current corrosion .. 18 Detection of Stray Currents .. 19 corrosion and cathodic protection vi Indicators of Corrosive 20 Soil Corrosivity .. 20 Water 21 Protective Coatings .. 22 Coating 22 Selection and Application of Coatings .. 23 Coatings in Conjunction with cathodic protection .. 23 cathodic protection Design Considerations.

9 24 cathodic protection Equipment .. 24 cathodic protection Criteria .. 25 Structure Current Requirements .. 26 Current Requirements per Exposed Area .. 26 Exposed Metal .. 27 cathodic protection System Capacity .. 28 cathodic protection Circuit Resistance .. 30 Anode Grounding Resistance .. 30 Protected Structure Grounding Resistance .. 33 Wiring and Structure Linear Resistance .. 34 Installation and Placement of 36 Test Stations, Junction Boxes, and Bond Boxes .. 38 Attenuation .. 40 Anode Service Life Efficiency and Utilization .. 41 Sacrificial/Galvanic Anode Systems .. 43 Principles of Operation .. 43 Galvanic Anodes .. 44 Impressed Current (Rectifier) Systems.

10 45 General Description .. 45 Rectifiers .. 47 Impressed Current System Installation .. 48 CP System Maintenance and Testing .. 49 General .. 49 Buried vs. Immersed Structures .. 49 General Safety .. 50 Personnel .. 51 Equipment Used for Testing .. 51 Voltmeter .. 51 Reference Electrode or Cell .. 51 Reference Cell Calibration .. 52 Galvanic Anode Systems .. 53 Monthly Checks .. 53 corrosion and cathodic protection vii Yearly Inspections .. 54 Impressed Current 56 Safety .. 57 Monthly Checks .. 57 Yearly Inspections .. 58 Appendix A Simple GACP Designs .. 63 Appendix B Failed Pipe Reporting Form .. 71 Appendix C References .. 77 Appendix D Definitions.