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Cathodic Protection System - Richlands Reservoir - OM Manual

28 JULY 1995

BRISBANE CITY COUNCIL


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

OPERATING MANUAL FOR:

RICHLANDS RESERVIOR

CATHODIC PROTECTION SYSTEM..

CLIENT:

DEPARTMENT OF WATER SUPPLY AND SEWERAGE


WATER MAINTENANCE SECTION

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Cathodic Protection System - Richlands Reservoir - OM Manual

MANUAL CONTENTS

(1.0) Introduction
(2.0) Corrosion and Cathodic Protection
(3.0) Reservior Details
(4.0) Cathodic Protection Details
(4.1) Type of System
(4.2) Rectifier
(4.3) Cathode
(4.4) Anodes
(4.5) Test Points
(4.6) Associated Drawings
(4.7) Associated Standards
(4.8) Government Regulations
(5.0) Peformed Testing
(6.0) Conclusion
(7.0) Maintenance

DRAWINGS

JE02/104 Standard Rectifier Wiring Diagram

(No Number) Monthly Maintenance Program.

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Cathodic Protection System - Richlands Reservoir - OM 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 an 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 a reproducible potential at which corrosion does
not occur to be quoted.

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Cathodic Protection System - Richlands Reservoir - OM Manual

(3.0) RESERVIOR DETAILS

Size: 7 Megalitre Steel Reservior with Concrete Base

Coating: Enamel.

Length: N.A

Location: Cnr Rudyard Street and Government Road,Richlands


UBD 51 , G5.

Drawings: Construction: -
6/29.21 Richlands Reservior No2 Capacity 7
Megalitre Details Excavations and
Pipework.
6/29.22 Richlands Reservior No2 Capacity 7
Megalitre Floor Plan and Details.
2/14.185 Cathodic Protection Inala/Richlands
Reservior.

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Cathodic Protection System - Richlands Reservoir - OM Manual

(4.0) CATHODIC PROTECTION DETAILS

(4.1) Type of Cathodic Protection: Impressed Current.

(4.2) Rectifier: Standard 32V Volt, 15 amp direct current output enclosed in a
stainless steel switchboard. Rectifier has a 240V supply from the distribution
switchboard located in the chlorine room,adjacent to the reservior.

(4.3) Cathode: The cathode point is located on the Reservior behind the rectifier
switchboard.The cathode point is where the cabling from the rectifier is
attached to the structure under cathodic protection.

(4.4) Anodes: Four Anode Strings each containing 3 silicon sausage anodes
(240 x 40) were suspended from the ceiling.The sausage anodes were first
potted of with a eppoxy resin and covered with a mastic eleve to extend the
anode's life.

Test Points: Test points are installed on cathodically protected structures to


enable testing to ensure full protection of the reservior. On these reservior
eleven test points have been installed

(4.6) Associated Drawings:


Cathodic Protection Details - 2/14.213
Cathodic Protection Test Point Details - 2/14.199
Standard Rectifier Wiring Diagram - 486/7/7- PE1C0052E
With Data Logging Facilities

(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.

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Cathodic Protection System - Richlands Reservoir - OM Manual

(5.0) PERFORMED TESTING

(1) Natural Potential Survey.

(2) Testing of Insulated Flanges, Joints.

(3) Current Drain Survey.

(4) Pipe Coating Anomaly 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 is registered with the Queensland Electricity
Commission and has approval to operate.

(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.

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Cathodic Protection System - Richlands Reservoir - OM Manual

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.

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Cathodic Protection System - Richlands Reservoir - OM Manual

13th October 1992


Electrical Workshop
Cathodic Protection

CPS 6 Monthly Maintenance Details.

Required:

1/ Notify plant operator and/or sign 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.

Labour:

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.
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/ Comments.
11/ Log entry.

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Cathodic Protection System - Richlands Reservoir - OM Manual

13th October 1992


Electrical Workshop
Cathodic Protection

CPS 60 Monthly Maintenance Details.

Required:

1/ Notify plant operator and/or sign 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.
9/ Rectifier load bank.
10/ PCS2000 Detection Equipment.

Labour:

One 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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Cathodic Protection System - Richlands Reservoir - OM Manual

Brisbane City Council


Dept. W.S.& S.
Metropolitan Division
Eagle Farm Pump Station

Cathodic Protection System Loop Resistance

Date: 29th June 1994


Cathodic Protection System: Richlands 7 Megalitre Reservior
System Operating Volts: 4.5 System Operating amps: 0.3
Test Voltage: Test Current:
(volts) (amps)
0 ;`,....#- - ',°,,,t, 0
4 -pi4-2.,,,:.--,..,,F- ,i-:
0.4
'',.--..,
,<' 3.,
8 1.4 ,- -,- -

l2 -°' - -""
' ,4 2.6
15
.
3.4 - - -/--- * -'

Loop Resistance
(ohms)

3.5

Graph of System voltage vs current.


20

15

o
>
a) 10
ci)
co

o
o 2 3 4
Current (amps)

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Cathodic Protection System - Richlands Reservoir - OM Manual
BRISBANE CITY COUNCIL
MEMORANDUM
To File No.

From Date
Brisbane City
*Z`f / 3 /9;
Subject A Z. L. i ' ,

Pe . 14- v ,30, 30-0 m

C-04,44.4-c,
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BRISBANECathodic Protection System - Richlands Reservoir - OM Manual
CITY COUNCIL

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MEMORANDUM
To File No.

From Date
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:2C./ 4-

Subject ...
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CC132L (G 9/91) Printed by B.C.C. Corporate Printery. Toowong


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Cathodic Protection System - Richlands Reservoir - OM Manual

Base Plate
Appreal 8 as thick of 285/26 Bitrsen
applied to top surface of Pad, and
$ underside of sots plate prised with L.6
Ì ' R.L.82.765 friar before lowering tetton stroke of
DETAIL I
Ressrve!r

úl Air blown bituae.


885/25.
e .'
Top and Bottom I
its Concrete t 1-) isprsgnated asbestos felt PAD to b glared on aggro:: thickness
`t/OFF
Stirrups
0 9 Clos
a 150
OFF 024 Stainless Steel Bolts
' _a 1 metre long
- 0.800 thick approalaately: of85/ 25 Bi tse. app! lad after prisi ng
Som

Concrete sorface of footing ring olIth LSD Prion,.

OFF 0 6 Clona DETAIL 3 -BITUMEN PAD


Scoor Channel Collector Stirrups e 150
t Rise mir 2 per column
75 a 12 : 500 plate
L
1600"
SECTION A A DETAIL 1
Waterproof sealant
(Polyaulphids or
DETAIL OF CENTRE COLUMN FOOTING DETAi L OF COLUMN FOOTING similar).
LO. F.92 Fabric

0 E00 1000 1500 2000


I I t

Seale of Nil llestres


1:10

f 1lolcs iar
\
4 28
4- 24/ Stainless Steal bolts
A t rn. len9 Y nals ..àt.'Coneit, Bond break

DETAIL
Satie eta to be told In posttlor+ b! amans of o rigid cogs
73 1*rvlsea 1
NOTE: iLCI.
R to suit +to *Iotas in column basa phis.
14G Sleds and cost to pin supplied bSOOtractor JOINT
EXPANSION

Waterproof Sealant
DETAIL OF BASE PLATE
7 700 7 700 I 1 520,
Paper Joint
DETAIL
A. LC. F.92 Fabric
/ /(Polysulphide or
alai 1ar):

PLAN OF RESERVOIR FLOOR .415.25 scot

0 1 2 8 0 5 450 íI25
l t t I t 1

Seale of Metren Soo


2.-26 I< Molts
NOTES: 1. All dioensions In sill 'metres. unless otherelse shown: break
Joints In concrete ring to be Dusy Joints 2 RE0b PER COWMN
with NO Interruptlen to reinforcing steel'.
d Bo AO 1(D WD do DETAIL 2
'aper Joint
173 beryl seal.
Contraction Joint ta line up with I 1 I I I I

Scots aj' M415r=etrss


misting Contraction Joints in Floors: I
arty/ R.iGoor nl:ntrax
F 25 200 Internai dii.
IIYO CONTRACTION
0 - MO 200
JOINT
SO
Separator 24-3 W_1, D._oLEOOtLng__ 5h20 hot poured carapha /fa: I
Sealant I
Seal: of millioetr*s.
1

50 0 24 B.O. Bolts 580s long


spaced equally around tank on
8 inn asst*
p/ate W 800 rom
P.C.D. 0 25190 \, Poly solph ids
can tr.z5
_Rwt.e2.76
140 A. L.02.690
200
parato,

Joint Filler'.:
tapi -
l'.LC.,

.Coatof gltsQn
,
F.92 Fabric

±Int
.

of ,1
..
Layer, of
2
RING BEAM SKETCH ( N.T.S.)
`R¢arguard ripa Water dcp
(E5.2nd'hz 230 rnT

RESERVOIR DATA BAR ka


BAR BENDING SCHEDULE

Bd13dth6 p4er . .
_E.wL.a2_g1D

178;Soivi teali
Bocatas 5/xa/Wa// expanda d
the do this ring be gamed
m
rig q03
110

segail tres.
of nAant- using .0, Níb, CAfACI TYt 7

nggregaAcPump 20:x. I0TE0RLL DIA: 25 200 - u. a--1061 5455 I i=56 0:781 02R
TTPE U
4 ÌO 3tlrïuó WTI OF.WATER: it 000 TOTAL COSTS OF 0 16 BAR ' _ .',880.000 metros
eis. .TOTAL' WE 8Rî OF IB BAR -w. 0 t 1.890 Tome*
T.W.L.:. 90.000 intros - TOTAL IOO1V OF 0 12 MAR a 63:000 metres
Ps1at .esrface oe.fou Inds.
coSite concrete
FLOOR LEVEL: 82.690 metre. .TOTAL'REIBI T OF 0 12 BAR _ ,

O.5E9 Tome
; }It11.2 dolts-or bitosftic TOTAL' LO31iOF 0. 10 CAR _ 13.525 metres'
.a)n (See-Detalt:8): 'TOTAL MOIR OF 0,10.10.11 =
TOTAL LE#SlU OF 0 w ' 6,W
0.268
218.095
Tomme
astre.
TOTAL' RE191R.OF 0 :0 a11. = 0.06 Tome
AREA R.LL, F.112 FABRIC = ' 070 se: metres.

0 i00 Agrieblturd Pipe

ALL DIMENSIONS ARE mimic

COUNCIL
.:...BRISBANE_n,CIT;Y;:
AMPIpµENTS.n-,.+Y :
w CAR OEM Cfr, A WATER? SiJPPIY4 . SEWERAGE

507Ee Tbe sub-foundation Is të be founded od a


DETAIL OF WALL' BASE,. AND FOOTING
+ ,
-
, RÌCHLÁÑÓSÌ: 13ESÉRVÖÏRÑÒ.2.
. n.terlat tYtt
In tlie'apiolóCof the eoBlóaor' c 0' KO, -
I
100. . 160 '. 60 %APA'CITYb,;,,7iMEGÄLITRES
FLOÒR :PI ANz& DETAILS

.
ke. ïlelaas biaring ea-posit) óf 190kta 1 --I ' I - 1`
' 161of tl111metn. '
t.
_
- 1 .
w,.i a t.+,.,ZY,

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675 eel Iowan

' L.L.96 690

6500 R.C.P. to drain


loos supplied by Council A installed by
Contractor
o existing drainage In
Government Road (See Dog: r.o 5!79,20)

I,l,6T.020
-Type 316 Stainless Stmal Brackets a 2008
(Supplied A tostailed by Contractor)

0 1833 Standard *inhale


1.1.80.800 -Reservoir Wail
(See Note 2)
PARKING

kW Steel Overflow

Nigh Point
I.L.82.O20 . 210 75 endergreund P.Y.C. Electrical Condulti
1160 0 Overflóí' laid. with 0608, rising main fru
Pooping Station
ELEVATION 1M1í OF G4TRACT
/ ,4io ntabü barbing
loo 0 C.1: Pips---
160 0 alo
Pipe
/ / Sae Dog.,Wd. 6/98.16
DETAIL G ( HEADWALL )
R. L:6L 660
ïm a
C. Il Damp] Ise Scali of s. '

(SEE DETAIL A)

ß,L,82.565
27.100`frm contra of Reservoir. 1.1.81.296

tiLosRttuLl

SECTION OF OVERFLOW PIPE


plo blocks
Road to be ¡loin Cross fall
I .1.01,925. %/ In accordance with Dr9. 00: 6/38.16

1.1.62.020 >.0:V '


' ountabla Kerbing

%
closure for ' Cath Colon
Rypóéblorlte Tank
See Dog; No:2%1LS11
0 300 Sluice Valve
I.L.8i.925
-1

--- '150 Conc. surround


.L.81:265,-.
0 100 Agricultural Pipis Standard - SECTION OF 300mm. C. t. SCOUR LINE
all org. 00.6/88. 16
In Rubble Underdreloi See

.:l'.6L615?O 0':I- 2 $ 6 .5
I.L:61.925

.
.

soa( oF{anè . Scale of antros


z
. . - a
Grade I., lo P30
1.L61.196 I50om Conc: Surround
! .

1.1.813.800 ..
LAYOUT OF UNDERDRAINS AND PIPEWORK D 700 approx. 6 make 8ox A Covar

0 I 2 .8 0 .5 -6' LJ 7 8 . . . . . .' .1.L.BO 800


KOCPips r 7
toral Pipe
I I I
SECTION C>r 300 mm- DIA. C.I. PIPE FROM GULLY TRAP .1.01.070 -
(
IOD ,ipe) ..

Seats of Notres
o 1 2 3' 6 :5 SECTION OF 100rilm.DIA.PIPE FROM UNDERDRAINS
B,
( 1

Scots of Nitres 0 I 2 a 5
I I

- Scale of metros.
1270 pin.

NOTE: Construction of 0 603 Valve Pit is NOT Included In the Contract'.

L.6L 615 5.660_approx"

0 I63O.6tsldard M.8. _0 150 C.I. Downpipe

R.1:8156 LL6L565-, rati LIMIT OF CONTRACT'

NOTES:. I. All disenslons are in iflllmetres unless otberwisesbown.


d 600 S/Yalve 0 600 Caviling otitis 1.6.81.82) - For Details of Slab used for N.N. cover see Droning No.
2113.320 oo Mlles cos spindle hole only to be included ' .

to Solt position of 0 500 :valve. (i.e.: Reinforceoent'uncfiogad),


1.1.110.800 150 C.L

SECTION
DETAIL A
0 1 2 S 6 5

Sule of Makes

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Cathodic Protection System - Richlands Reservoir - OM Manual
BRISBANE CITY COUNCIL
MEMORANDUM
To File No.

From Date
Brisbane City
1// 3 9
Subject

o tlej . . 30-0 m ok

e 1(144-444-c,( -LtoPW
ts1 Ri P
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MEMORANDUM
Cathodic Protection System - Richlands Reservoir - OM Manual

File No.

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Date
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Cathodic
BRISBANE Protection System - Richlands Reservoir - OM Manual
CITY COUNCIL

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Cathodic
BRISBANE Protection System - Richlands Reservoir - OM Manual
CITY COUNCIL
MEMORANDUM
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From Date
Brisbane City .7.41; / eideris
Subject R. CLI6""N 4.4 it-e- S-
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MEMORANDUM

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MEMORANDUM
To File No.

From
Date
Brisbane City
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