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Cathodic ProtectionRequirements forMilitary Projects
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Michael A. Wallace, P.E.Electronics EngineerNACE Cathodic Protection SpecialistEngineering Division
US Army Corpsof EngineersMobile District
Office: 251-694-4068FAX: [email protected]
CESAM-EN-DR109 Saint Joseph St.Mobile, AL 36602-36301-800-543-2021
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Corrosion is a major Economic, Environmental,and Safety Problem which adversely affects our Nation, as well as many of our military facilities.
Impact of Corrosion
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Corrosion is the deteriorationof a material, usually a metal, because of a reaction with itsenvironment.
What is Corrosion?
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Typical Corrosion Cell
TUBERCULAR BUILDUP OF
RUST
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Types of Corrosion Cells
• 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
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Corrosion Control mustbe properly addressed duringthe design, installation, and subsequent operation of systems adversely affectedby the corrosion process.
Corrosion Can Be Controlled
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Corrosion Control Methods
• Protective Coatings• Design• Environmental
Control• Material Selection• Cathodic Protection
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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.
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An electrical method ofmitigating corrosion on metallic structures that areexposed to electrolytes suchas soils and waters.
Cathodic Protection:
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Sacrifical Cathodic Protection
Magnesium or Zinc
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Impressed Current CP
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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
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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)
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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)
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ETL 1110-3-474 requires CP & Coatings regardless of soil or water resistivity for:
• 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
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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.
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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
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Upstream View of Rupture Crater
Carlsbad, NM Explosion
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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
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Removed & Leaking UST
Tank Wall Completely Penetrated Due to Pitting Corrosion
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Corrosion of Steel H Piling Embedded in Concrete
MacDill AFB, Florida
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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.