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Cathodic Protection Requirements for Military Projects

Cathodic Protection Requirements for Military Projects. Michael A. Wallace, P.E. Electronics Engineer NACE Cathodic Protection Specialist Engineering Division. US Army Corps of Engineers Mobile District. CESAM-EN-DR 109 Saint Joseph St. Mobile, AL 36602-3630 1-800-543-2021.

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Cathodic Protection Requirements for Military Projects

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  1. Cathodic ProtectionRequirements forMilitary Projects

  2. Michael A. Wallace, P.E.Electronics EngineerNACE Cathodic Protection SpecialistEngineering Division US Army Corps of Engineers Mobile District CESAM-EN-DR 109 Saint Joseph St. Mobile, AL 36602-3630 1-800-543-2021 Office: 251-694-4068 FAX: 251-694-4057 michael.a.wallace@sam.usace.army.mil

  3. Impact of Corrosion Corrosionis a major Economic, Environmental, and Safety Problem which adversely affects our Nation, as well as many of our military facilities.

  4. What is Corrosion? Corrosion is the deterioration of a material, usually a metal, because of a reaction with its environment.

  5. Typical Corrosion Cell TUBERCULAR BUILDUP OF RUST

  6. Dissimilar Metal Cell Concentration Cell Differential Aeration Cell Stray Current Cell Stress Cell New Pipe and Old Pipe Cell Motion Cell Combination Cell Temperature Cell Types of Corrosion Cells

  7. Corrosion Can Be Controlled Corrosion Controlmust be properly addressed during the design, installation, and subsequent operation of systems adversely affected by the corrosion process.

  8. Corrosion Control Methods • Protective Coatings • Design • Environmental Control • Material Selection • Cathodic Protection

  9. Protective Coatings • Normally first line of defense against corrosion: provides barrier between a corrosive environment and the structure. • No coating is perfect and consists of holidays (voids) often resulting from improper application and/or damage. • Cathodic Protection often used in conjunction with coatings to protect the holidays or voids in the coating system.

  10. Cathodic Protection: An electrical method of mitigating corrosion on metallic structures that are exposed to electrolytes such as soils and waters.

  11. Sacrifical Cathodic Protection Magnesium or Zinc

  12. Impressed Current CP

  13. Standards and Laws • NACE International Standards (National Association of Corrosion Engineers) • 40 CFR Part 280 - Underground Storage Tanks (UST) • 49 CFR Part 192 - Transportation of Natural Gas and other Gas by Pipeline • 49 CFR Part 195 - Transportation of Hazardous Liquids by Pipeline • Individual State Environmental and Safety Laws

  14. Military Criteria • ETL 1110-3-474, Cathodic Protection • TM 5-811-7, Cathodic Protection • MIL-HDBK-1004/10, Electrical Engineering, Cathodic Protection • MIL-HDBK-1136, Maintenance and Operation of Cathodic Protection Systems (Draft)

  15. Military Criteria (Cont.) • Guide Specifications (Army) • UFGS 13110A Cathodic Protection System (Sacrificial Anode) • UFGS 13111A Cathodic Protection System (Steel Water Tanks) • UFGS 13112A Cathodic Protection System (Impressed Current)

  16. Natural Gas and propane piping Liquid fuel piping Oxygen piping Underground storage tanks (UST) systems Fire protection piping Steel water tank interiors Ductile or cast iron pressurized piping under floor slab Underground heat distribution & chilled water piping in metallic conduit Other structures with hazardous products ETL 1110-3-474 requires CP & Coatings regardless of soil or water resistivity for:

  17. Designer Qualifications • Design must be accomplished by qualified personnel. ETL 1110-3-474 requires the following: • All pre-design surveys, designs, and acceptance surveys must be by a “Corrosion Expert.” • “Corrosion Expert” is a NACE Certified Corrosion Specialist, CP Specialist, or registered Professional Corrosion Engineer. • “Corrosion Expert” must have a minimum of 5 years experience in CP design and experience must be type specific.

  18. Advantages of Adequate Corrosion Control • Extended Coating and Structure Life yielding Cost Savings • Protection of Environment • Improved Public and Employee Safety • Avoidance of costly Litigation resulting from non-adherence to Laws and Regulations

  19. Carlsbad, NM Explosion Upstream View of Rupture Crater

  20. Lively, TX Explosion • Gas Explosion - killed 2 Teenagers • Oil Company did not maintain CP system and falsified records to OPS • Jury awarded over 300 million dollars to Plaintiff

  21. Removed & Leaking UST Tank Wall Completely Penetrated Due to Pitting Corrosion

  22. Corrosion of Steel H Piling Embedded in Concrete MacDill AFB, Florida

  23. Summary • Corrosion is costly and its effects can cause harm to our environment, as well as to human life. • Cathodic Protection can effectively control corrosion. • Cathodic protection is required by many laws and regulations and must be designed by qualified personnel.

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