s water maintenance section

26TH NOVEMBER, 1993

BRISBANE CITY COUNCIL DEPARTMENT OF WATER SUPPLY AND SEWERAGE MECHANICAL AND ELECTRICAL BRANCH ELECTROLYSIS SECTION EAGLE FARM PUMPING STATION

OPERATING MANUAL FOR:

KARAWATHA HIGH LEVEL RESERVOIR CATHODIC PROTECTION SYSTEM.

CLIENT:

DEPARTMENT OF WATER SUPPLY AND SEWERAGE WATER MAINTENANCE SECTION

s

Cathodic Protection System - Karawatha High Level Reservoir - OM Manual

Q-Pulse Id TMS1269 Active 21/07/2015 of 19

(1.0) .

(2.0) (3.0) . ` .

(4.0) . .

(4.1) .

: (4.2) -

(43) . .

(4:4) .

(4.5) -

(4.6). .

(4.7) (4.8) :

(5.0) (6.0) (7:0)

MANUAL CONTENTS

Introduction Corrosion and Cathodic .Protection Mains Details Cathodic Protection

. Type of System Rectifier Cathode :

Anodes Test Points Associated Drawings. Associated Standards Government Regulations Peformed Testing Conclusion Maintenance

DRAWINGS

486/6/8-TB1C0030E *

486/6/8-TB1C0029E. *

(No Number) 486/6/8-TB1C0005E 486/4/8-TB010P ' 486/4/8-TB08P .

External Pipework rectifier /termination board wiring diagram.. Cathodic protection general. layout. .

Monthly Maintenance Program. Underground conduits and pit layout. .

Scour overflow :pipe details. Pipework layout plan and details. .

* denotes drawings included in manual:



(1..0) 'INTRODUCTION

Steel when immersed or . covered in water has a tendency to corrode (or rust) as the oxidized form is more stable than the metal.

Because of this, -precaution must be taken to stop, or minimize the corrosion reaction to an ,acceptable level consistent with the design life of the structure. This is normally achieved by the use of protective coatings which control the corrosion 'reaction by isolating the steel from its surrounding environment.

However, it is not practical to achieve .a perfect coating and coating damage will always occur with time Because of this, corrosion may occur at imperfections in the paint coating, causing further -deterioration in the coating as well as loss of metal.

As a result of this, the coating defects must be rectified by periodic maintenance or an additional method of protection used to prevent this deterioration and corrosion occurring.' This additional protection is achieved by the cathodic protection system.

(2.0) CORROSION AND CATHODIC PROTECTION

Corrosion is ari electrochemical process in that it is accompanied by a flow of ' electrical current.

Corrosion occurs on the surface of metals . at active - areas known as anodes, which are electrically continuous with less active or passive areas known as cathodes. The electric current flows from the anode through the electrolyte to the cathode, with the circuit being completed by the electrical continuity between the cathode and anode. In practice anodes and cathodes are generally part of the same metallic surface and individual anodic areas may be small.

In applying cathodic protection and external current is , applied to the surface so that the entire surface to be 'protected' acts as a cathode. This involves the use of an auxiliary anode and when the current flow from this anode is sufficient, . no part of the structure acts as an anode.

An external .source of direct current such as a transformer 'rectifier is used in conjunction with an anode consisting of material with a very slow corrosion rate:

While it is the flow 'of. current which achieves the cathodic protection, of the surface it is:

impractical to :measure these currents over individual anodic areas . to. determine ̀ when cathodic protection has been achieved... However, with the flow of cathodic 'protection current, the structure becomes more negative with respect to the surrounding electrolyte. Because . of this, it is possible to state values of metal /electrolyte 'potential at which corrosion .does not occur. This.. metal/electrolyte potential is generally, measured against : a standard reference electrode which allows á reproducible potential at which corrosion. does not 'occur to be quoted. "



(3.0) MAINS DETAILS

Size: Dìa 750 - Pia 600 mild steel cement lined:

Coating: Low density fusion banded polyethylene outer coating.

Length: 0.1 km

Location: Karáwatha High :Level Reservoir Kárawatha 4117 UBD 54 H6.

Construction Drawings: 486/4/8-TB08P to 486/418-TB010P



(4.0) CATHODIC PROTECTION DETAILS

(4.1) Type of Cathodic Protection: Impressed Current.

Rectifier: Standard, 32V. Volt, 15 amp direct current output enclosed in a stainless steel: switchboard.' Rectifier has à 240V supply from the :distribution _ switchboard.Rectifer is located on the first- flóór against the handrails.

(4.3) Cathode: The cathode points are lòcated on top of the pipe, resevoir side of the inlet and outlet valves,- scour valve and overflow. The cathode point is

° where the cabling from the rectifier is attached to the structure under cathodic protection.

(4.4) Anodes: One 1500 x 75mm silicone iron anode was installed approximately 29:0 metres from the inlet valve pit in a vertical bed. The anodes were first backfilled . with cokebreeze thereby improving anode - ground resistance. The anodes are identified by a marker pit and label. Refer attached drawing.

(4.5) Test Points: Test points are installed on cathodically protected structures to enable testing to ensure full protection of the mains. On these pipes, eight . test points have been installed and bought back to the distribution switchboard. Refer to attached drawing.

(4.6) . Associated. Drawings: Cathodic Protection Details - 2/14.213

, Cathodic Protection Test Point Details - 2/14.199 Standard Rectifier Wiring Diagram - JE02/104 .

(4.7) Associated Standards: AS 3000 1986 Australia Wiring Rules AS 2832.1 1985 Pipes, ,Cables,' Ducts, Guide to Cathodic Protection;

Part One:

(4..8) . Government Regulations: Queensland Electricity Acts and Regulations.



(5.0) . PERFORMED TESTING

(1) Natural Potential Survey.

(2) Testing of Insulated Flanges, Joints. .

(3) . Soil Resistance Testing. .

(4) Current Drain Survey.

(5). Rectifier Loop Resistance.

(6) Foreign Structure Interference Survey and Mitigation.

(7) 'Final Potential Survey and Commissioning.

NOTE: Details of above testing have not been included in this manual but are available upon request.

(6.0) CONCLUSION

Full Cathodic protection has been achieved on this section of trunk mains. The cathodic protection system will be registered : with the Queensland. Electricity Commission.

7.0) MAINTENANCE

The cathodic protection system is maintained on a monthly basis after commissioning. These checks involve testing rectifier operation and .

recording of pipe to soil potentials..



12th October 1992 Electrical - Workshop Cathodic Protection

CPS Monthly Maintenance Details. . .

Required:

1/ Notify plant operator and/or sign entry logs where necessary. 2/ Have appropriate keying.

Labour:

One tradesperson, one vehicle. . 20 minutes per site.

Procedure:

1/ Identify installation. 2/ Check system for operation. 3/ Record voltmeter.. .

4/ Record. ammeter. 5/ . Comments. 6/ Log entry.



13th October 1992 Electrical Workshop Cathodic Protection

CPS 6 Monthly Maintenance Details.

Required:

1/ Notify plant operator and/or sigh entry logs where necessary. 2/ Have appropriate keying. 3/ Set of tools. (Electricians) 4/ Multimeter. 5/ DC clampmeter. .

6/ Copper sulphate reference cell and leads. 7/ Cleaning equipment: '

. 8/ Gatic cover lifters.

Laboúr:

One tradesperson electrical; one laborer, one vehicle. Two hours per site.

Procedure:

1/ Identify system.. : 2/ Check system for operation.

3/ . Record voltmeter. '

4/. Record ammeter. 5/ Record "on" potentials for all test points. 61 Record "instant off" potentials for. all test points. 7/ Récord "off" potentials for all test points: 8/ Perform loop resistance and record. 9/ Check and record anode string currents. 10 /. Comments. 11/ 'Log entry.



13th October 1992 Electrical Workshop Cathodic Protection

CPS 60 Monthly Maintenance Details.

Required:

1/ Notify plant :operator and/or sign en_ try logs where necessary.' 2/ Have appropriate keying. 3/ . Set of tools. (Electricians) 4/ Multimeter. 51 DC clampmeter. .

6/ Copper sulphate reference cell and leads. 7/ Cleaning equipment. 8/ Gatic cover lifters. 9/ Rectifier load bank. 10/ PCS2000 Detection Equipment,

Labour:

tradesperson electrical, one laborer, one vehicle; Eight hours per Site.

Procedure:

1/ Identify system. 2/ Check system for operation. 3/ Record voltmeter. 4/' Record . ammeter. 5/ Record "on" potentials for all test points. 6/ Record "instant off" potentials for all test points. .

7/ Record "Off" potentials for all test points. 8/ Perform loop resistance: and record. 9/ Check and record anode string currents. 10/ Load test rectifier for 10 minutes. 11/ Check' all switchboard and testpoint terminals for tightness. 12/ .Check all switchboard and testpoints are labelled and I.D:..tags attached. 13/ Check plans are correctly drawn and modify if ,necessary: 14/ Remove and inspect anodes. 15/ Recheck all interference (CPS) bleeds. .

16/ Pipecamp structure if applicable. 17/ Apply for "continue to operate" permit if . applicable.

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DEPARTMENT OF WATER SUPPLY AND SEWERAGE

MECHANICAL AND ELECTRICAL BRANCH

METROPOLITAN DIVISION

EAGLEFARM PUMPING STATION..

ELECTRICIAL WORKSHOP

INSULATED JOINT TESTING DETAILS:

DATE ;21-470% -97.1 '

DESCRIPTION

MAINS DETAILS:- LOCATIONS:- KY>RAwRttAQ Rc`ScfZvOR. itvc"T SIZE:- .C1CA0,nM .

MATERIAL:- SaTEL= COATING:= pvc NUMBER:-.

IN GROUND TESTING

BOLT TO FLANGE RESISTANCE: - `>à.c.An NUMBER OF BOLT:- 1611(.14..7,:a.) pER rLANC; b

FLANGE TO FLANGE RESISTANCE:- 30n, WS INSULATION CHECKER MODEL 702: - 0.K.

POTENTIAL DIFFERENCE TO REFERENCE. CELL

PROTECTED SIDE: - RCSc42Vcn1R UNPROTECTED SID:E:

- -mLu40t wipm4

ABOVE TESTING

BOLT TO FLANGE RESISTANCE:-

NUMBER OF BOLTS:=. FLANGE TO FLANGE RESISTANCE:--

COP1MEIdTS.

IC) SZ.. ACRáSS. 1-1-11.4 GE

EU R PL.PGEt1 ß`i wIzITc.R ' S:.1PPL4

TESTED BY

M iJ GOÇtAtC.K -



DEPARTMENT. OF WATER SUPPLY AND SEWERAGE

MECHANICAL AND ELECTRICAL BRANCH

METROPOLITAN DIVISION

.EAGLE FARM PUMPING STATION

ELECTRICIAL WORKSHOP

INSULATED JOINT TESTING DETAILS:. .

DATE Z.L1, -05 - DESCRIPTION

MAINS DETAILS:= LOCATIONS:- KARAwATHta'R._ScR.lotQ SIZE:- 492:C rn Nn MATERIAL:.- SSeEt` COATING: - F`,G NUMBER: - .

IN GROUND TESTING

BOLT TO FLANGE RESISTANCE: - NUMBER OF BOLT:- pEF FLAtVGa FLANGE TO FLANGE RESISTANCE:-. gs,z2,.T,

INSULATION CHECKER MODEL 702:- POT.ENTIAL DIFFERENCE TO REFERENCE .CELL

PROTECTED SIDE;- REScR.JotR. _--t UNPROTECTED SIDE:--TRvr.,K MAIN . -1;33 mV.

ABOVE TESTING

BOLT TO FLANGE. RESISTANCE: NUMBER OF BOLTS: - .

FLANGE TO FLANGE RESISTANCE:

COMMENTS

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