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PART 2
<br />— CP SYSTEM MATERIALS
<br />2.1 MAGNESIUM BAG ANODES
<br />A.
<br />THE ANODES SHALL BE PREPACKAGED, HIGH POTENTIAL
<br />MAGNESIUM WITH A PACKAGED WEIGHT
<br />OF
<br />60—POUNDS AND AN INGOT WEIGHT OF 20---POUNDS NOMINAL.
<br />THE MAGNESIUM ALLOY SHALT_ MEET THE
<br />FOLLOWING CHEMICAL ANALYSIS:
<br />ELEMENT CONTENT
<br />MANGANESE 0.50-1.3%
<br />SILICON 0.05% MAX
<br />IRON 0.03% MAX
<br />COPPER 0.02% MAX
<br />ALUMINUM 0.01 % MAX
<br />NICKEL 0.001 % MAX
<br />OTHERS EACH 0.05% MAX
<br />MAGNESIUM REMAINDER
<br />B.
<br />EACH ANODE SHALL BE CONNECTED WITH #10 AWG
<br />STRANDED COPPER LEAD WIRE WITH FED
<br />RHW-2/USE-2 INSULATION. LEAD CABLES SHALL BE MINIMUM 20—FT IN LENGTH EACH.
<br />C.
<br />EACH ANODE SHALL BE PACKAGED IN A COTTON BAG AND FILLED WITH A MIXTURE OF 75% HYDRATED
<br />GYPSUM, 20% BENTONITE, AND 5% SODIUM SULFATE.
<br />2.2 AT
<br />—GRADE TEST STATION
<br />A.
<br />THE AT —GRADE TEST STATION SHALL BE HIGH DENSITY REINFORCED CONCRETE TRAFFIC VALVE BOXES,
<br />WITH A BOLT DOWN CAST IRON COVER, WITH STAINLESS STEEL HARDWARE AS MANUFACTURED
<br />BY
<br />CHRISTY OR ENGINEER APPROVED EQUAL. THE TRAFFIC VALVE BOXES SHALL HAVE AN AASHTO H
<br />20
<br />TRAFFIC RATING. THE COVER SHALL BE MARKED "CP TEST'.
<br />B.
<br />TERMINAL BOARD SHALL BE "BIG FINK," BLUE IN COLOR,
<br />WITH STAINLESS STEEL HARDWARE
<br />AS
<br />MANUFACTURED BY COTT.
<br />C.
<br />SHUNT SHALL BE 0.1 OHM, RATED FOR 2 AMPS, AND RED
<br />IN COLOR AS MANUFACTURED BY COTT.
<br />D.
<br />WIRE TERMINAL CONNECTORS FOR TEST LEAD CABLES SHALL
<br />BE THOMAS & BETTS NYLON INSULATED
<br />RING CONNECTORS (10RC-12) OR APPROVED EQUAL.
<br />2.3 GROUNDING CLAMP
<br />i
<br />I
<br />A.
<br />GROUNDING CLAMP SHALL BE BRONZE OR COPPER ALLOY,
<br />FOR USE IN CONNECTING CONDUCTOR
<br />TO
<br />COPPER WATER PIPE. SHALL BE SIZED FOR USE WITH
<br />WATER PIPE AND #10 AWG WIRE CA
<br />LE
<br />SIZE.
<br />II-3"
<br />2.4 PIPELINE
<br />TEST CABLES
<br />A.
<br />PIPELINE_ TEST CABLES SHALL BE 25—FEET LONG, #10 AWG STRANDED COPPER WITH BLACK HM
<br />PE
<br />INSULATION AND SHALL BE SPLICE FREE FROM THE
<br />GROUNDING CLAMPS TO THE TEST STATION
<br />TERMINAL BOARD,
<br />A.
<br />EACH INSULATING FLANGE KIT SHALL CONSIST OF A FULL
<br />—FACE INSULATING GASKET, A FULL—LENGTH
<br />INSULATING SLEEVE FOR EACH FLANGE BOLT, AND TWO'', INSULATING WASHERS WITH TWO
<br />STAINLESS
<br />STEEL WASHERS FOR EACH BOLT. THE INSULATING FLANGE GASKET SHALL BE A LINEBACKER
<br />MODEL
<br />AS
<br />MANUFACTURED BY CPT, ISOGUARD MODEL AS MANUFACTURED BY LAMONS, OR TROJAN
<br />MODEL
<br />AS
<br />MANUFACTURED BY ADVANCED PRODUCTS & SYSTEMS.
<br />B.
<br />THE GASKET SHALL BE FULL —FACE TYPE 'E' 1/8—INCH
<br />THICK CONSTRUCTED OF G-10
<br />GLASS
<br />REINFORCED EPDXY, WITH A EPDM SEAL ELEMENT.
<br />C.
<br />THE INSULATING BOLT SLEEVES AND INSULATING WASHERS SHALL BE CONSTRUCTED OF G-10
<br />GLASS
<br />REINFORCED EPDXY.
<br />D.
<br />THE COMPLETE ASSEMBLY SHALL HAVE AN ANSI PRESSURE RATING EQUAL TO THAT OF THE
<br />FLAN
<br />ES
<br />BETWEEN WHICH IT IS INSTALLED.
<br />A. COATINGS FOR
<br />BURIED INSULATING FLANGES SHALL CONSIST OF A TWO—PART
<br />VISCOUS ELASTIC
<br />(VISCOELASTIC)
<br />PASTE AND TAPE WRAP COATING SYSTEM.
<br />THE VISCOELASTIC PASTE
<br />SHALL BE MOLDED
<br />AROUND THE BOLTS
<br />AND UNEVEN SURFACES OF THE FLANGES
<br />TO PROVIDE A CONTINUOUS BARRIER
<br />AGAINST MOISTURE INFILTRATION. THE TAPE WRAP SHALL
<br />BE USED AROUND
<br />THE FLANGE
<br />FOR
<br />PROTECTION OF
<br />THE SUBSTRATE AND ADDITIONAL CORROS
<br />ON PREVENTION. THE COATING SYSTEM SH
<br />LL
<br />BE VISCOPASTE
<br />AND VISCOWRAP—ST AS MANUFACTURED BY
<br />VISCOTAQ, OR APPROVED
<br />EQUAL.
<br />PART 1 — GENERAL
<br />1.1 SCOPE OF WORK
<br />A. THE WORK COVERED BY THIS SECTION CONSISTS OF PROVIDING ALL LABOR, EQUIPMENT, SUPPLIES,
<br />MATERIALS, TRANSPORTATION, HANDLING AND STORAGE, AND PERFORMING ALL SERVICES NECESSARY TO
<br />COMPLETE THE CONSTRUCTION AND INSTALLATION OF A CATHODIC PROTECTION SYSTEM TO PROVIDE
<br />CORROSION CONTROL FOR THE COPPER WATER PIPELINES AS DESCRIBED IN THESE CONSTRUCTION
<br />DOCUMENTS.
<br />1.2 PERMITS
<br />A. THE CONTRACTOR IS RESPONSIBLE FOR OBTAINING ALL NECESSARY PERMITS AS REQUIRED BY BOEING
<br />AND THE CITY OF EVERETT, WA.
<br />1.3 ONE CALL LOCATES
<br />A. THE CONTRACTOR SHALL NOTIFY THE ONE CALL UTILITY LOCATE CENTER A MINIMUM OF 48 HOURS
<br />PRIOR TO CONDUCTING ANY EXCAVATION ACTIVITIES. THE CONTRACTOR SHALL ALSO BE RESPONSIBLE TO
<br />MAINTAIN THE MARKINGS FROM THE VARIOUS UTILITY COMPANIES AS REQUIRED THROUGHOUT
<br />CONSTRUCTION. THE ONE CALL PHONE NUMBER IS 811.
<br />1.4 APPLICABLE STANDARDS
<br />A. COMPLY WITH ALL STATE, CITY, AND LOCAL CODES, OSHA REQUIREMENTS, SAFETY CODES, AND
<br />REGULATIONS.
<br />1.5 EQUIPMENT, MATERIALS, AND WORKMANSHIP
<br />A. IT IS THE INTENT OF THESE DOCUMENTS TO ESTABLISH QUALITY STANDARDS FOR ALL EQUIPMENT AND
<br />MATERIALS, AND TO ENSURE FIRST CLASS WORKMANSHIP. ALL EQUIPMENT AND MATERIALS SHALL BE
<br />NEW AND OF THE HIGHEST QUALITY AVAILABLE. QUALIFIED, EXPERIENCED PERSONNEL WORKING UNDER
<br />CONTINUOUS AND COMPETENT SUPERVISION SHALL ACCOMPLISH ALL WORK. THE WORKMANSHIP SHALT_
<br />BE OF THE HIGHEST GRADE AND SHALL BE IN STRICT ACCORDANCE WITH INSTALLATION INSTRUCTIONS
<br />AND RECOMMENDATIONS MADE BY THE MANUFACTURERS OF THE EQUIPMENT AND MATERIALS USED. ALL
<br />EQUIPMENT AND MATERIALS SHALL BE HANDLED WITH EXTREME CARE WHEN BEING MOVED OR
<br />TRANSPORTED FROM ONE LOCATION TO ANOTHER, IN ORDER TO PREVENT DAMAGE. ALL EQUIPMENT AND
<br />MATERIALS SHALL BE PROPERLY STORED. IN THE EVENT THAT IT IS NECESSARY TO STORE EQUIPMENT
<br />AND/OR MATERIALS OUTSIDE, THEY SHALL BE STORED AT A SUITABLE DISTANCE OFF OF THE GROUND
<br />AND SHALL BE ADEQUATELY COVERED TO PREVENT DAMAGE FROM ADVERSE WEATHER CONDITIONS, I.E.
<br />WATER, ETC.; AND POTENTIAL DAMAGE THAT COULD BE CAUSED BY PHYSICAL OR ACCIDENTAL MEANS.
<br />1.6 TESTING
<br />A. THE COMPLETED CATHODIC PROTECTION SYSTEM, INCLUDING THE PIPE CONNECTIONS, ANODE
<br />INSTALLATIONS, AND ALL OTHER ASSOCIATED ITEMS SHALL BE INSPECTED, CHECKED, AND TESTED BY A
<br />BOEING REPRESENTATIVE. ANY SYSTEM DISCREPANCIES OR MALFUNCTIONS FOUND DURING TESTING THAT
<br />ARE DETERMINED TO BE THE DIRECT RESULT OF UNAUTHORIZED CONSTRUCTION OR INSTALLATION
<br />PROCEDURES, DEPARTURES FROM THE DESIGN, WILLFUL OR UNWILLFUL NEGLIGENCE, ERRORS IN
<br />JUDGMENT BY THE CONTRACTOR'S PERSONNEL, OR ANY OTHER SUCH REASON, THE DISCREPANCIES
<br />AND/OR MALFUNCTIONS SHALL BE COMPLETELY CORRECTED AT THE CONTRACTOR'S SOLE EXPENSE.
<br />B. SACRIFICIAL ANODES SHALL BE TESTED PRIOR TO CONNECTION TO THE STRUCTURE TO BE PROTECTED
<br />(E.G. PIPELINE, TANK, ETC.). OPEN CIRCUIT CIRCUIT POTENTIAL OF HIGH POTENTIAL MAGNESIUM ANODE
<br />MUST EXCEED —1700 MV, RELATIVE TO A COPPER/COPPER—SULFATE REFERENCE ELECTRODE.
<br />C. COPPER PIPING SHALL ACHIEVE BY A MINIMUM OF 100 MV OF CATHODIC POLARIZATION. EITHER THE
<br />FORMATION OR DECAY OF THIS POLARIZATION MUST BE MEASURED TO SATISFY THIS CRITERION.
<br />D. DIELECTRIC UNIONS SHALL BE TESTED TO CONFIRM PROPER ELECTRICAL ISOLATION. UNIONS MAY BE
<br />TESTED WITH A RADIO FREQUENCY INSULATOR TESTER (RF-IT) OR FIXED CELL POTENTIAL TESTING.
<br />E. MAXIMUM DEFLECTION OF THE RF—IT METER (ALL THE WAY TO THE RIGHT) INDICATES HIGH RESISTANCE
<br />AND PROPER ELECTRICAL ISOLATION.
<br />F. THE FIXED CELL POTENTIAL TEST INDICATES PROPER ELECTRICAL ISOLATION IF THE POLARIZED
<br />POTENTIAL MEASURED ON BOTH SIDES OF THE UNION IS SIGNIFICANTLY DIFFERENT (OVER 10 MV).
<br />1.7 COORDINATION
<br />A. COORDINATE ALL WORK WITH THE APPROPRIATE BOEING REPRESENTATIVES.
<br />B. COORDINATE ALL WORK WITH OTHER TRADES.
<br />1.8 SUBMITTALS
<br />A. THE CONTRACTOR SHALL SUBMIT SHOP DRAWINGS OR CATALOG CUTS OF THE FOLLOWING MATERIALS TO
<br />THE ENGINEER FOR APPROVAL PRIOR TO PURCHASING MATERIALS.
<br />o ANODES AND ANODE CABLE
<br />® AT —GRADE TEST STATION
<br />® TEST STATION TERMINAL BOARD
<br />® RING TERMINALS FOR #10 AWG CONDUCTORS
<br />® GROUNDING CLAMP
<br />PIPELINE TEST CABLE
<br />® INSULATING FLANGE GASKET
<br />0 BURIED INSULATING FLANGE COATING
<br />mwkIF 11*67111f ■11[6 Ri1[i117
<br />A. HIGH POTENTIAL PREPACKAGED MAGNESIUM ANODES S�ALL BE INSTALLED AS INDICATED ON THE
<br />PROJECT DRAWINGS.
<br />l'IIIETAllml
<br />C. ANODE LEAD CABLES SHALL BE BUNDLED AND BURIED A MINIMUM OF 24" BELOW GRADE AS INDICATED
<br />ON THE PROJECT DRAWINGS.
<br />3.2 AT —GRADE TEST STATION
<br />A. PIPELINE TEST LEAD CABLES SHALL BE LANDED ON TIE TERMINAL BOARD AS INDICATED ON THE
<br />DRAWINGS.
<br />C. THE FINAL LOCATION OF THE TEST STATION MAY BE DETERMINED BY THE ON —SITE ENGINEER OR
<br />BOEING CATHODIC PROTECTION REPRESENTATIVE.
<br />3.3 GROUNDING CLAMP
<br />D. INSTALL CLAMPS SECURELY ON COPPER PIPELINE RISERS ABOVE GRADE. CLAMP MUST CONTACT THE
<br />BARE METALLIC SURFACE OF THE RISER. CLAMPS SHALL BE INSTALLED ON RISERS AS INDICATED ON
<br />THE DRAWINGS.
<br />E. CONNECT ANODE AND PIPELINE TEST CABLES TO THE GROUNDING CLAMPS WITH A BOLTED MECHANICAL
<br />CONNECTION.
<br />3.4 INSULATING FLANGE:
<br />A. CLEAN ALL INSULATING COMPONENTS OF THE INSULATING FLANGED GASKET SET OF ALL DIRT, GREASE
<br />OIL AND OTHER FOREIGN MATERIALS IMMEDIATELY PRIOR TO ASSEMBLY. PROPERLY ALIGN BOLT HOLES
<br />IN MATING FLANGES AT THE TIME BOLTS AND INSULATING SLEEVES ARE INSERTED TO PREVENT DAMAGE
<br />TO THE INSULATION. AFTER FLANGED BOLTS HAVE BEEN TIGHTENED, INSPECT EACH INSULATING WASHER
<br />FOR CRACKS OR OTHER DAMAGE. REPLACE ALL DAMAGED WASHERS.
<br />B. TEST ISOLATION FITTINGS USING A RADIO FREQUENCY INSULATOR TESTER (RF—IT) METER. IF INSULATING
<br />FLANGE WILL BE BURIED, TEST PRIOR TO COATING AND BACKFILLING. MAXIMUM DEFLECTION OF THE
<br />RF—IT METER INDICATES HIGH RESISTANCE AND PROPER ELECTRICAL ISOLATION. REPAIR OR REPLACE
<br />DEFECTIVE ISOLATION FITTINGS.
<br />C. REPAIR OR REPLACE DEFECTIVE DIELECTRIC ISOLATION FITTINGS.
<br />D. AFTER TESTING, COAT ALL BELOW GRADE INSULATING JOINTS AS SPECIFIED BELOW.
<br />2. BURIED INSULATING FLANGE COATING:
<br />A. CLEAN SURFACES OF ALL
<br />DIRT,
<br />GREASE, OIL AND OTHE
<br />FOREIGN MATERIALS IMMEDIATELY PRIOR TO
<br />COATING. REMOVE LOOSE
<br />RUST,
<br />PAINT AND OTHER FOREIGN
<br />MATTER. MOLD THE PASTE
<br />COATING AROUND THE FLANGE BOLTS AND IRREGULAR SURFACES
<br />TO CREATE A SMOOTH PROFILE PRIOR
<br />TO WRAPPING. PASTE SHALL BE
<br />CUT INTO SMALL PIECES
<br />FOR EASIER APPLICATION. PACK THE PASTE
<br />AT A 45—DEGREE ANGLE
<br />FROM
<br />THE FLANGE RIM TOWARD
<br />THE PIPELINE, INSTALL IN A MANNER TO
<br />AVOID INCLUSION OF AIR
<br />AND
<br />MOISTURE. SPIRALLY WRAP
<br />THE TAPE COATING FROM PIPE TO PIPE,
<br />OVER THE FLANGE, TO PROTECT
<br />THE OUTER EDGE OF THE
<br />FLANGE AND SUBSTRATE. USE A MINIMUM
<br />OF 1/—INCH OVERLAP. AT
<br />THE COMPLETION OF EACH ROLL
<br />THE OVERLAPS SMOOTH BY HAND IN THE
<br />DIRECTION OF THE SPIRAL
<br />TO ENSURE SEALING OF THE OVERLAP.
<br />FACILITY DESIGN BY CEI
<br />DATE 03.26.19
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