0 to 60: development of a holistic corrosion prevention
TRANSCRIPT
0 to 60: Development of aHolistic Corrosion Prevention & Control Program NICHOLAS D’ANGELO, ASSOCIATE CORROSION ENGINEER
Introduction
• B.S. in Corrosion Engineering, 2018
• Corrosion Prevention & Control Program Engineer• Responsible for revamping CWD’s cathodic
protection approach
Overview
Program History
Asset Overview
AssessmentsCondition AssessmentNACE IMPACT Plus
Program Development
Continuing Work
Program History Cleveland Division of Water’s (CWD) Cathodic Protection program’s implementation has varied from 1970s to present.
Impressed Current Cathodic Protection (ICCP) Assets• Original commissioning of
ICCP systems in 1976• Six rectifiers installed
• Original ICCP success led to expansion
• 23 additional rectifiers installed
• Expanded program to four additional critical water mains in 1992
• 22 additional rectifiers installed
Cathodic Protection Group Staffing• Group existed under the
Hydraulics section
• One Field Technician• General maintenance• Anode installations
• No unified cathodic protection specifications or common design approach
Asset Overview Cleveland Water has an extensive network of impressed current cathodic protection assets, working to mitigate corrosion on nearly 21 miles of transmission mains and over 80 million gallons of potable water
Transmission Mains (5 ICCP Lines)CWD currently has approximately 21 miles of ICCP protected transmission mains.
Within the distribution network, five individual ICCP systems protect five separate mains:
• Brookpark 36” Main
• Lake Ave. 36” Main
• North Park 48” Main
• South Belvoir 48” Main
• Twin 60s 2-60” & 1-48” Mains
Tanks & Towers (24 Sites)CWD currently has 24 tanks with ICCP systems providing automatically controlled cathodic prevention. ICCP systems protect:
• 12 towers
• Three surge tanks
• Four wash tanks
• Five ground tanks
Rectifiers
Currently operate 50 rectifiers across five transmission mains:
• Brookpark: 4• Lake Avenue: 7• North Park: 5 • South Belvoir: 7• Twin 60s: 25• Miscellaneous: 2
Currently operate 24 rectifiers on tanks and towers:
• Towers: 12• Surge tanks: 3• Ground Tanks: 5• Wash Tanks: 4
Tanks/TowerTransmission
CP Test Stations
• CWD has approximately 1600-1800 cathodic protection test stations
• Used to monitor GACP and ICCP performance
• System needs to be verified, inspected, and measured for efficiency
• GACP is installed on transmission and distribution mains
• PCCP1
• DIP• Cast Iron• HDPE2
[1] Continuity Bonding Only[2] Appurtenances Only
ASSESSMENTS
ICCP Baseline Assessment
Conducted across August and September 2018, the purpose was to identify, quantify, and organize CWD’s cathodic protection assets to determine their operational effectiveness
Assessment Goals• Determine system performance
• Data collection
• Design verification
Outcomes• Identified operational issues
• CIP expenditure justification
• Upper-management engagement
NACE IMPACT PLUS Assessment
The Corrosion Management Maturity Assessment was conducted in April 2019 to develop an effective corrosion management (CM) approach
• Develop a holistic corrosion prevention and control approach
• Unify specifications and details across all capital projects
• Develop sound engineering design practices for water main installation and rehabilitation
• Develop consistent standard operating procedures
• Utilize industry best practices
CWD Aspirations • Developed as a result of the
NACE IMPACT Study• Examine the current role of
corrosion management in industry and government to establish best practices
• Allows our organization to:• Develop effective CM
strategies, practices, and systems
• Track program development progress internally
• Benchmark against industry
NACE IMPACT PLUS Assessment cont.
As a result of the IMPACT PLUS assessment, a framework to track program development was developed to guide implementation
• IMPACT PLUS assesses CM maturity across ten domains:
Maturity Model Domains
• Policy• Stakeholder Integration• Organization• Accountability• Resources
• Knowledge Management• Communications• CMP Integration• Continuous Improvement• Performance Measures
Survey Workshop NACE Analysis Aspirations
WorkshopCWD
Implementation
ORGANIZATION RESOURCES
STAKEHOLDER INTEGRATION
COMMUNICATIONS
CONTINUOUS IMPROVEMENT
ACCOUNTABILITY
CULTURE & KNOWLEDGE MANAGEMENT
POLICY & PROCEDURES
PERFORMANCE MEASURES
CMP INTEGRATION5
10
PROGRAM DEVELOPMENT
Guidance
The development of the CPC Program’s architecture incorporates guidance from numerous sources, including:
• Washington Suburban Sanitary Commission Water Main Design Guidelines
• NACE SP21412-2016/SSPC-CPC 1, Corrosion Prevention and Control Planning
• WRF Project #4618: Retrofit and Management of Metallic Pipe with Cathodic Protection
• 2019 NACE IMPACT Plus Corrosion Management Assessment
• 2018 Impressed Current Cathodic Protection Baseline Assessment• Recommendations of 2001 Cleveland Trunk Main Task Force Final
Report
Industry Standards
Internal Assessments
Program Architecture
CPC will integrate industry best practices, updated standards, and modernized technology
CPC
Failure Analysis
Field Work
Project Planning
Design ReviewSpecs
SOPs
Inspection
• Water main design review• New installations• Replacements
• Water treatment plant and secondary facility metallic structures evaluations
• Failure analysis• Anode installations & tracking
• Tank inspections via drone• Inspection of CP construction• Inspection, maintenance, and repair of existing ICCP
and GACP systems• Inter-departmental corrosion education • Coordination with other utilities (oil & gas, electric, rail)• Specification development
Staffing Overview
Corrosion Engineer• Program management
• Specification development
• Common design guidelines
• Standard operating procedures
• Water main design review
• Failure analysis (FA)
• Inter-departmental corrosion education
• Coordination with other utilities
Corrosion Technicians • ICCP and GACP inspection,
maintenance and repair
• CPC construction inspection
• Soil surveying
• Secondary facility inspections
• Record keeping
• Water main design review
• Inter-departmental corrosion education
In order to achieve program objectives, the CPC program will be initially be staffed by a minimum of three (3) technicians and one (1) Corrosion Engineer
Expected Implementation Timelines
• CPC expects a two-year program development cycle:
• Baseline Assessment: 10 months• Program Implementation: 14 months
• The culmination of this work will result in a fully functional Corrosion Prevention and Control program
• Initial staffing of one (1) Corrosion Engineer and three (3) Corrosion Technicians
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Baseline Assessment
Inventory
ICCP Performance
GACP Performance
Post-Assessment
Program Development
Digitization
GIS-Integration
CityWorks Integration
Inventory Database
CPC Database
Management Plan
Technican Hiring
Months
Actual Implementation Schedule
• CPC expected a two-year program development cycle:
• Baseline Assessment: 6 months• Program Implementation: 12 months
• Engineering assessments and program design will be completed within 18 months of the original start
• Field implementation and SOP refinement will follow in 2020
Progress Update1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Baseline Assessment
Inventory
ICCP Performance
GACP Performance
Post-Assessment
Program Development
Digitization
GIS-Integration
CityWorks Integration
Inventory Database
Design Manual
Management Plan
Technican Hiring
Months
CONTINUING WORK
Capital Projects
CPC is undertaking a complete redesign of the ICCP systems, as well as rethinking the current role of cathodic protection
External Corrosion Control Rehabilitation
ICCP Transmission Main Redesign• Phased redesign of existing ICCP systems• Technical assessment, life cycle costing, remaining life predictions
ICCP Tank Rehabilitation • Phased rehabilitation of existing ICCP systems• Instituting an annual inspection and maintenance program
Specification Development• Implementation and refinement of new field practices
• Development of a Cleveland Water Corrosion Design Manual• Unified specifications and details
• Development of a Cathodic Protection Decision Framework• Consistent, unified practices and standard operating
procedures throughout all groups
• Adoption of Industry Best Practices• Adoption of asset management and program implementation
standards
Specification Development
Cleveland Water is improving engineering specifications through rigorous evaluation and research
Technology Improvements
Cleveland Water is integrating new and existing technologies to enhance the CPC Program’s goals
Unmanned Aerial System (UAS) Facility Inspections• Annual visual inspection program to monitor coating performance
and site conditions• Assist with bid specification review to verify consultant reports
Corrosion Field Testing • Procurement of advanced testing equipment
GIS Integrations• Integration of ArcGIS Collector into field staff’s workflows• Real-time editing of assets to promote validity
