ACE SERVICES SITE

GROUNDWATER TREATMENT
SYSTEM

OPERATIONS & MAINTENANCE

MANUAL'

IMPRESSED CURRENT

CATHODIC PROTECTION SYSTEM

RECEIVED
DEC 0 5 2003
BUREAU OF

ENVIRONMENTAL REMEDIATION

CAPITAL ELECTRIC COMPANIES

1428 W.9* Street

Kansas City, Missouri 64101-1220
816 472 9501

C6-o<?7-ooooi-2.

Prepared bv

Harold Walters Professional Engineering

828 N.E. Michael Drive

Lee's Summit, Missouri

816 525 1520

March 15,2003

OPERATIONS & MAINTENANCE

MANUAL

IMPRESSED CURRENT

CATHODIC PROTECTION SYSTEM

RECEIVED
DEC 0 5 2003
BUREAU OF

ENVIRONMENTAL REMEDIATION

ACE SERVICES SITE

GROUNDWATER TREATMENT
SYSTEM

TABLE OF CONTENTS

page

Table of Contents

Overall Description & Purpose of the System

Operation

Emergency Operation

Preventive Maintenance

Trouble Shooting

Corrective Maintenance

Notes, Cautions, & Warnings

Parts Lists

Pollution Control

Hazardous Locations & Classifications

Appendix A Rectifier
Appendix B~ Material

Appendix C Data Table

Appendix D~ Drawings

IMPRESSED CURRENT

CATHODIC PROTECTION SYSTEM

Installed by

CAPITAL ELECTRIC COMPAMES

1428 W. 9th Street

Kansas City, Missouri 64101-1220
816 472 9501

Prepared by

Harold Walters Professional Engineering

828 N.E. Michael Drive

Lee's Summit, Missouri

816 525 1520

March 15,2003

TABLE OF CONTENTS

page

Cover Page

Title Page

Table of Contents

Overall Description & Purpose of the System

Operation

Emergency Operation

Preventive Maintenance

Trouble Shooting

Corrective Maintenance

Notes, Cautions, & Warnings

Parts Lists

Pollution Control

Hazardous Locations & Classifications

Appendix A

Appendix B

10

Appendix C

11

Appendix D

12

OVERALL DESCREPTION & PURPOSE OF THE SYSTEM

The cathodic protection system is a simple battery. The above ground storage tank

bottom is the negative cell in the battery. The anode is the positive cell in the battery. The

impressed current cathodicprotection system has four cast iron anodes under each tank
with power supplied by a common rectifier. A rectifier impresses D.C. current from the
anodes onto the tank bottoms, therefore the name "Impressed Current" cathodic

protection system. Properly engineered, installed, a cathodic protection system will

protect the tank bottoms from corroding.

An A.C. Grounding/D.C. Blocking device is installed between the tanks' grounding rings
and the building grounding systems. The device will readily conduct AC between the

tanks and building ground in the event of a lightning strike, but blocks the DC cathodic
protection current from the building grounding system.

OPERATION

The impressed current cathodic protection is put into operation by connecting the above

ground storage tank lead (-) wires to the anode wire(s) via the rectifier. Rectifier output
should be set to provide a rmnimum 100 millivolts of polarization over a 2 - 4 hour time
period after the rectifier is temporarily de-energized .

EMERGENCY OPERATION

The impressed current cathodic protection systems does not pose any problems that
require an emergency operation status.

PREVENTATIVE MAINTENANCE
CLEANING & LUBRICATION

The cathodic protection systems should be retested at one year intervals minimum. Clean
the wire terminals to as new appearance and coat with an anti-corrosion compound.
Tighten electrical connections in the rectifier and lubricate moving parts.

TROUBLESHOOTING

When a cathodic protection system measures below less than a 100 mV polarization a

sequence of tests will indicate the area of trouble. Look in Appendix A for the factory
supplied rectifier operating and installation manual.

1) PD?E TO SOIL TESTING PROBLEMS

Soil Dryness

The soil must be at least moist to accurately test the cathodic protection system. If
possible make sure the soil around the reference cell is moist by adding water. Pour water
in the micro slotted conduits under the tanks for more accurate testing.
Frozen Soil

Frozen soil will affect the test results. Shift the testing to warmer weather.
5

2) MECHANICAL PROBLEMS

Electrical 'shorts' or 'grounds' on the protected underground pipes and fittings are

generally mechanical problems.

Isolation Gaskets

Isolation gaskets become worn or damaged and are erroneously replaced with nonisolation gaskets. Check isolation joints for proper gasket sets.
Conduit or Other Metal Objects Grounding System

Over time the trench soil may settle allowing conduit or other metal object to come into
contact with the protected underground structure. If the current output increases while the
structure polarization decreases the underground structure may be 'shorted' or
'grounded'.
CORRECTIVE MAINTENANCE
Isolation Gaskets

Replace damaged or defective isolation gaskets. Replace with double insulated kits.
Conduit or Other Metal Objects Grounding System

Isolate all sources of possible 'shorts' or 'grounds'. Conduits may need to be moved.

Mounting brackets and clamps may need to be isolated with insulating materials.
NOTES. CAUTIONS. & WARNINGS

An impressed current cathodic protection system can cause damage to systems within its

influence. Neighboring systems or structures should be checked for interference by the

impressed current cathodic protection system.

PARTS LIST

1) Rectifier-See Appendix A

PRICE

$2,871.00

Universal ASI40 - 20 AACFH

Can be purchased from

MESA PRODUCTS

4445 South E. 74th Street

Tulsa, OK 74145-4732
918 627 3188

2) Wire
a) #12RHH
b) #8HMWPE
c) #4HMWPE
d) #2HMWPE
Can be purchased from

$0.21/ft
0.41/ft
0.53/ft
0.65/ft

MESA PRODUCTS

4445 South E. 74th Street

Tulsa, OK 74145-4732
918 627 3188

3)

Impressed current Anotec EHK Tubular Cast

Can be purchased from

109.00 ea

MESA PRODUCTS

4445 South E. 74*80-661

Tulsa, OK 74145-4732
918 627 3188

4) Dairyland Polarization Cell Replacement 3.7

Can be purchased from
MESAPRODUCTS

4445 South E. 74th Street

Tulsa, OK 74145-4732
918 627 3188

5) Terminal Box

a) Above Ground Storage Tanks

Custom made by Harold Walters Professional Engineering
Contact Harold Walters Professional Engineering
828 N.E. Michael Drive

Lee's Summit, MO 64086

816 525 1520

1,600.00 ea

POLLUTION CONTROL

The material used in the cathodic protection systems are not considered hazardous.
HAZARDOUS LOCATIONS & CLASSIFICATIONS
. All locations are non-hazardous.

ABPFJVDLtA
RECTIFIER

CTIF1ERS,

A Hometown American Product

CATHOMC
PROTECTION
RECTIFIERS

Universal Rectifiers, Inc.

1613 Cottonwood Rd.
P.O. Box 1640

Rosenberg, Texas 77471

(281) 342-8471
FAX (281) 342-0292

Operating and
Maintenance

WARNING!. This equipment poses an electrical shock hazard

and the following should only be attempted by
qualified personnel.

I. SITE SELECTION CONSIDERATIONS:

The following should be considered for site selection:

4.

Avoid areas of direct sunlight and lack of proper air

circulation. Do not install the rectifier in a confined

1. The proximity of the cathodic protection system.

area.

2.

The proximity of the available A.C. power source.

5.

Avoid areas that will promote human contact.

3.

Avoid congested areas of electrical or mechanical

heat producing equipment.

6.

Site selection should allow full accessibility to the

rectifier and allow doors to open fully

II. MOUNTING
1.

provide proper door operation.

The rectifier must be mounted securely with minimum

5/16" diameter lag screws, anchor bolts, or machine
bolts to a substantial, permanent, wall, pole or rack

When mounting the rectifier to a hollow wall or

structure, check for concealed wiring, water lines,
etc., before drilling any mounting holes.

assembly.

2.

The rectifier should be mounted level and straight to

WIRING:

1.

All wiring must comply to the National Electrical.

5.

Codes and all existing local codes.

The rectifier cabinet must be grounded by the

grounding terminal provided at the A.C. input power
terminal block marked "G" or "GROUND".

Local electrical codes many require all wiring to be

installed in approved conduit.

6.

A.C. input power must be installed into the appropriate

terminals marked "L" or "UNET and "N" or "NEUTRAL".

3.

A.C. power must be supplied from a disconnect

circuit breaker or branch circuit protection circuit

7.

The NEGATIVE output terminal must be wired to the

STRUCTURE to be protected.

8.

The POSITIVE terminal must be connected to the

breaker.

4.

Wire sizes must comply to the National Electrical

Code.

anodes.

IV. WARNING:

Operating personnel should observe the following before

attempting to operate or adjust the rectifier:
1.

Do not tamper with A.C. power supply terminals of

A.C. circuit within the rectifier unless the A.C. power,

immediately. Do not attempt to operate rectifier until

proper inspection and repairs have been completed.
6.

positive D.C. terminal to the structure to be protected,

as irreparable damage will occur to the structure.

external to the unit, is turned "OFF. Contact with this

high voltage can produce severe or fatal shock.

2.

Rectifiers with D.C. ratings above 50 volts D.C. have

The positive D.C. output terminals should always be

connected to the anodes. NEVER connect this

7.

high voltage on the adjustment taps, A.C. to stack

Oil immersed rectifiers must have the oii level

terminals, and can not be handled unless rectifier

maintained at the specified level for proper cooling of

components and also to meet rigid requirements for

circuit breaker is turned "OFF.

Class 1, Group D hazardous areas.

3.

Do not exceed A.C. or D.C. ratings of the rectifier.

Operating the rectifier at higher than nameplate
ratings will result in eventual failure of the rectifier.

,.

If overload protection trips repeatedly, investigate

and eliminate cause before attempting further
operation of rectifier.

8.

For three phase units, all similar (coarse or fine)

voltage tap settings MUST be on the same "step" in
allphases before A.C. power is turned "ON". Operating
the rectifier with either the coarse or fine taps on

5.

If rectifier components overheat, or there is any

evidence of electrical failure, turn rectifier "OFF

different settings will destroy the transformer.

9.

Return instruction manual and wiring diagrams to

pocket provided on the inside of door. Do not place
in bottom of rectifier and allow ventilation to be
restricted.

RECTIFIERS, inc
V. ROUTINE CHECKS PRIOR TO OPERATION:

Your Universal Rectifier was fully inspected, carefully

tested and was in top operating condition at the time of
shipment. Instances where damage has resulted in
shipping, handling, storage or installation are rare but
possible. As a result, the following routine checks of your

tag attached to panel indicates A.C. voltage wiring of

the unit Wiring diagram indicates changes to be
made for other input A.C. voltages.
3.

circuits are recommended:

1. VISUAL INSPECTION. Inspect unit for possible

damage that may have resulted in shipping, handling,
or installation. If damage exists, do not attempt
operation of rectifier until repairs have been
completed.

2.

A.C. POWER SUPPLY. Check phase and voltage of

A.C. power supply. These should correspond to A.C.
ratings ofthe unit. Where rectifiers have dual voltage
ratings (110/220 or 220/440) care should be taken to
make A.C. connections for voltage employed. Notice

D.C. CIRCUITS. Zero the D.C. meters. External D.C.

load should be in proper operating condition. Connect

ground bed (anodes) to positive (+) D.C. output

Universal Rectifier, as well as the external A.C. and D.C.

terminal. Connectstructureto be protected to negative

(-) D.C. output terminal.
4.

CONNECTIONS. Make sure all connections to and

in your Universal Rectifier are tight Where Universal

voltage tap changer is used, voltage tap adjusting
knobs need only be hand tight.
5.

OIL IMMERSED UNIT. Check cleanliness of tank

interior. Filltankto proper level with electrical insulating

transformer oil.

VI. TO PLACE YOUR UNIVERSAL RECTIFIER IN OPERATION:

'"en in operation, the actual D.C. voltage and current

put of the Universal Rectifier are indicated by the
voltmeter and ammeter on the instrument panel of the
rectifier. Care should be taken that these meter readings
do not exceed either the D.C. voltage or D.C. current

Observe the above and proceed as follows:

1.

Set all voltage tap controls on lowest setting.

ratings of the unit. If. ratings are exceeded, turn A.C.

power "OFF immediately. During the voltage tap
changing operation described below, the A.C. power
should be turned "OFF at the circuit breaker or safety

2.

Turn external A.C. power supply "ON".

3.

Close circuit breaker or safety switch of rectifier

("ON" position).

switch.

4.

Check D.C. ammeter and voltage readings on

instrument panel.

2.

Before Increasing coarse control setting, return fine

control setting to lowest position.

3.

Change coarse control setting to next higher position.

4.

Repeat steps 1, 2, and 3.

5.

Proceed in this manner until current output is obtained.

5.

Severe overloads can permanently damage rectifiers

and special precautions may be requiredforabnormal
or persistent overload exposures.

6.

For oil immersed units, oil should be inspected

periodically. Oil should be replaced when

VII. TO ADJUST D.C. VOLTAGE AND CURRENT:

The following steps should be followed in sequence

observing precautions in steps I, II and III until desired
D.C. current and/or voltage is attained.
1. With coarse control at lowest setting, increase fine
control setting in progressive steps throughout its full

range and observe D.C. output voltmeter and

ammeter.

VIIIL GENERAL MAINTENANCE INSTRUCTIONS:

1. Voltage, current and ambient temperature ratings of
unit should not be exceeded.

Routine cleanliness should be maintained.

3. Adequate ventilation must be provided - screened

openings should be kept free of obstructions.
4. All electrical connections should be tight

contaminated.

IX. MAINTAINING DESIRED CURRENT AND VOLTAGE

The rectifier unit will respond to electrical changes in the

any overloading. Voltage adjustments should be made

system external to the unit, such as pronounced fluctuation

of A.C. line voltage or changes in ground bed resistance.

as required. A permanent record of the current and

Such changes can alter the operating D.C. voltage and/

or current output of the rectifier. Periodic inspections
should be made to assure desired operation and prevent

voltage readings should be maintained. Any pronounced

change that is not attributable to voltage adjustment
should be investigated.

X. TROUBLE SHOOTING HINTS

A wiring diagram for use by experienced personnel is

provided. Only experienced electrical personnel should
attempt location and repair of electrical difficulties,

should they occur. Some symptoms of elementary

trouble and the possible remedy are as follows:
1.

NO D.C. CURRENT OR D.C. VOLTAGE

CHECK: A.C. overload protection for blown

fuses or tripped circuit breaker. Check A.C.

OUTPUT.

power supply.
2.

D.C. VOLTAGE BUT NO D.C. CURRENT

READING.

CHECK: D.C. ammeter. Check D.C, con

nections and external D.C. circuit for

electrical continuity.
3.

D.C. CURRENT READING BUT NO D.C.

CHECK: Check D.C. Voltmeter.

VOLTAGE READING.

4.

MAXIMUM RATED D.C. VOLTAGE

CANNOT BE ATTAINED.

CHECK: Check A.C. line voltage. Check

voltage adjustment settings for maximum.
Check accuracy of D.C. Voltmeter.

MAXIMUM RATED D.C. CURRENT

CANNOT BE OBTAINED AT MAXIMUM

CHECK: Check load resistance of external

D.C. circuit.

D.C. VOLTAGE.

LIMITED WARRANTY

This equipment manufactured and designed by Universal Rectifiers, Inc. is

warranted against defects in design, workmanship or materials, unless other
wise specified, for one year from the date of installation. The obligation of

Universal Rectifiers, Inc. is limited to the adjustment, repair or repfacement

at its factory of the equipment, or part thereof which shall be found defective

upon examination after being returned with transportation charges prepaid.

Universal Rectifiers, Inc. warrants this product and its operation only.
There is no other warranty or liability implied or expressed for the use or
mis-use of this equipment.
UNIVERSAL RECTIFIERS, INC.

FILE: 1500\1502S
NO.

E3-LI0HTRELAY

AIR COOLED STANDARD LINE

THE "STANDARD** LINE

The Universal Standard Line Cathodic Protection

rectifiers are recognized as the leader in quality

and workmanship. Many years of field proven
service has led to the design of our rectifiers.
Conservative-ratings, controlled manufacturing
techniques, plus- many extra features insure lone
and trouble free operation.
Standard features found in the 'Standard Line"
Series

11 gauge hot dipped galvanized case.

Front & side opening doors.
Heavy-dutyidraw-pull latch.
Slide out racks.

Heavy duty transformer with 15% over design

for reserve capacity.

18 step voltage control taps.

Engraved bakelite panel.

Quick change heavy duty knobs for
changing tap link bars.
Minimum 5/16" diameter soldered tap

changing studs.
Accessible shunt, plainly marked.

Heinemann magnetic circuit breaker.

Hoyt Model 17-3 Meters

Tri-amp high density selenium.

Syntron avalanche silicon diodes protected b)
surge suppressors and current limiting fuses.
All electrical connections double nutted or
soldered.

Multi-strand high temperature extra flexible

wire.

Terminal block for AC input wires.

Primary tap-change panel for dual input

voltages.

Dead front-panel supplied on all units over 6C

volts D.C.

RECTIFIER ORDERING CODE

A = Standard line, Air cooled

O = Standard line. Oil immersed

MODEL

G Gas Station
E= ES
P = Proline

S = Swing Out Series

U = Utility Series

jypE

S = Standard Rectifier (Manual taps)

C = Constant Current (Reactor style)
D= Constant Current (Solid state)
E = Constant Voltage (Solid state)

P = Constant Potential (Solid state)

I = Constant Potential IR Free (Solid state)
M= Multiple Modes (Solid state)
V = Variac Control

A = Air Cooled
COOLING

O = Oil Immersed

X = Oil Immersed, Explosion Proof

C = Selenium, Center Tap
S = Silicon, Center Tap

Selenium
Silicon

STACK TYPE

DC VOLTS

List Max. DC Volts Desired

DC AMPS

ListMax. DC Amps Desired

A

AC INPUT

115/230 10
230/460 10
230/460 30

D=208 30
E =115/480 10

F = Specify

SPECIAL FEATURES

A
B

Dual input wired for low voltage

Dual input wired for high voltage

AC and DC arrestors

D
E
F

DC arrester
AC arrester
Filter choke

Communications filter

Meter switches

Base mounting

Pilot light

DC failure light

DC fuse

115 VAC conveaience outlet

Painted cabinet (Galv. std. on most models)

Aluminum cabinet

Anodized aluminum cabinet

Anodized aluminum cabinet with clear coat

P
S
Q
20

20

BCF

Other than standard taps

Multiple circuits (qty.)
Other, specify
EXAMPLE

/\5M ^o-^o AAtFHq

14

nive/iA
RECTIFIERS, inc

This chart is useful for

calculating A.C. line current.

Multiply D.C. volts times the D.C.
amperes to obtain the figures
across the bottom of the chart

and follow a vertical line up until

the A.C. voltage and phase
selected is intersected. Read
across the chart for the A.C. line
current.

Example: A 24 volt 100 amp rec

tifier operating on 230 volts A.C.
three phase will draw 8 A.C.
Amperes.
For units less than 10,000 D.C.
watts, divide all figures by 10.
1000

2000

3000

4000

5000

6000

7000

8000

9000

1000

D.C. Volts X D.C. Amps

MAXIMUM ALLOWABLE CABINET WATTAGE

MAXIMUM ALLOWABLE CABINET

OIL IMMERSED

WATTAGE AIR COOLED

CASE SIZE

OIL CAPACITY
US GALLONS

DC WATTS
SINGLE PHASE

PMO

200

MAO

20

500

AO

55

501 to 1900

DC WATTS
THREE PHASE

CASE SIZE

SINGLE PHASE

1200

2800

2000

6000

6500

10000

0 to 3600

BO

110

1901 to 3400

3601 to 6400

CO

165

3401 to 4250

6401 to 8000

12000

18000

E
213

4251 to 5300

8001 to 10000

EO

300

5301 to 6400

10001 to 12000

FO

465

6401 to 8500

12001 to 16000

GO

600

8501 to 10,600

16001 to 20000

DO

THREE PHASE

AVERAGE SHIPPING WEIGHTS FOR RECTIFIERS BY CABINET SIZE

CASE
SIZE

PMO

MAO

AO

BO

CO

DO

EO

FO

GO

SINGLE
PHASE

60 lbs.

200

450

594

731

935

1020

1200

1400

THREE
PHASE

N/A

N/A

518

660

860

1100

1200

1400

1600

CASE
SIZE

SINGLE
PHASE

135 lbs.

185

300

410

525

THREE
PHASE

N/A

225

385

625

750

15

APPENDIXB
MATERIAL

I::

:-

, - -V

10

ANOTEC INDUSTRIES LTD.

12294 - 104th Avenue, Surrey, B.C. Canada V3V 3H3
Telephone: (604) 583-1794 Fax: (604) 583-1837

ANOTEC

PRODUCT DESCRIPTION

CENTERTEC

Composition

FeSiCr

TUBULAR ANODES

Silicon
Chromium
Carbon

(Weight %)ASTM A518 Grade 3

14.20-14.75%
3.25-5.00%
0.70-1.10%

Manganese
Copper
Molybdenum

1.50% max
0.5.% max
0.20% max

"Chill Cast" in Metal Molds

O.

Assures consistent weight, greater density, less flake graphite

grain boundary, andlower chemical segregation than Sand Cast

Anodes.

The ANOTEC Chill Cast structure is similar to "Spin Cast"

Tubular Anodes.

SPECIAL FEATURES
"Long Life CHILL CAST" proven technology.
CENTER CONNECTION invulnerable to "necking end

Style 1
Compression Wedge
Crimp Connector

effect".

CABLE CONNECTS EXACTLY AT CENTER using one

piece anchor swaged into matching cast seat with anchor groove.
LOW LOW CONNECTION RESISTANCE is less than
.0015 ohms.

RETENTION GROOVES for Epoxy/Sealants.

CONNECTION STRENGTH exceeds strength of copper
cable.

EXPANDED HEAD extra thickness protects connection.

CONSISTENT WEIGHTS AND DIMENSIONS assured by

precision shellcored inside diameter and chill castexterior

surfaces.

Style 2
Compression Wedge
Solder Connector

QUALITY CONTROL in accordance with Specification90-4

for Tubular Anodes.

MANUFACTURED IN NORTH AMERICA.

PERFORMANCE PROVEN

TECHNICALLY ADVANCED DESIGN

Distributed by:

Technical Bulletin No. 90-8

'"' "96.05.14

ANOTEC SOLID CHILL CAST ANODES

SHIPPING INFORMATION
Gross

Weight
Kg.

Anode

Anodes

Type

Per Crate

lbs.

SHA

50

2280

1034

EHA

50

2355

1068

EHM

45

2830

1284

EHK

70

1950

885

EHR

24

2770

1256

Crate dimensions, nominal: 31.5WX63.5L X25H inches 29 cult

(.82 CuM)

(800WX1610LX635Hmm)
Style 1

CONNECTION OPTIONS

(Pin)
Style 2

Pin and Socket Type

(shown with epoxy cap)

(Lead)

Anotec Anodes are supplied with matching tapered steel pins.

When installed as instructed, the pin connection
exceeds the tensile strength of the copper lead wire:
#4AWG/7wire- 13001b (590Kg) force,

#8AWG/7wire- 4001b (181Kg) force. Cable to

anode resistance: less than 0.0030 Ohms.

LEADED CONNECTION

(SHOWN WITH POTTING COMPOUND

AND HEAT SHRINK PE CAP)

Anotec bell-bottomed cavity is shaped for optimum security of

lead, potting compound and strain relief grommet. Like the Pin
and Socket Connection, Anotec's Leaded Connection is suitable

for Epoxy or Heat Shrink Caps to seal out moisture.

Printed in Canada

Technical Bulletin 90-9

94.l2.0T

Rome Cable

SPEC 7882
4-1-87

CORPORATION

Specification
ROME HMW POLYETHYLENE CATHODIC PROTECTION CABLE, 600 VOLTS
1. SCOPE

1.1 This specification describes a special single conductor high molecular weight polyethylene insulated cable designed
for direct earth burial DC service in cathodic protection installations for cables, pipelines, well casings, water storage
tanks and other buried or water-submerged metallic structures.
2. APPLICABLE SPECIFICATIONS

2.1 The following specifications form a part of this specification to the extent specified herein:

2.1.1 American Society for Testing and Materials (ASTM) Specification B-8, latest edition, for Concentric-Lay
Stranded Copper Conductors, Hard, Medium-Hard or Soft.
2.1.2 American Society for Testing and Materials (ASTM) Specification D-1248, latest edition, for Polyethylene
Plastic Molding and Extrusion Materials.
2.1.3 Insulated Cable Engineers Association (ICEA) Pub, No. S-61-402 (NEMAPub. No. WC-5) for Thermoplasticinsulated Wire and Cable for the Transmission and Distribution of Electrical Energy.
3. CONDUCTOR

3.1 The copper conductors shall be Class B Stranded, compressed, annealed, uncoated copper in accordance with
ASTM Specification B-8, latest edition.
4. INSULATION

4.1 The conductor shall be insulated with Rome High Molecular Weight Polyethylene insulation complying with the

physical and electrical requirements of ASTM Specification D-1248, latest edition.

4.2 The average thickness of insulation shall be 0.110 inches for conductor sizes #8 AWG to #2 AWG and 0.125
inches for sizes #1 AWG to #4/0 AWG. The minimum thickness at any point shall be not less than 90% of the
specified average thickness. The insulation shall be applied tightly to the conductor and shall be free-stripping.
5. IDENTIFICATION

5.1 The insulated cable shall be surface ink printed with: "Conductor Size, Manufacturer, HMW/PE CATHODIC
PROTECTION CABLE."
6. TESTS

6.1 The completed cable shall be tested in accordance with the requirements of ICEA Pub. No. S-61-402, Part 6.
7. SHIPPING

7.1 Shipping lengths shall be as specified for the individual order.

7.2 Packaging shall be in accordance with standard commercial practices.

SPEC 7882

Rome Cable

April 1,1987
Supersedes Issue
January 1,1984

CORPORATION

ROME HMW POLYETHYLENE

CATHODIC PROTECTION CABLE
Single Conductor, Copper 600 Volts
APPLICATION: Adirectearth burial, dc feeder cable foruse incathodic
protection systems for pipelines, storage tanks, pilings, well casings,
cables, marine craft and structures and other buried or water-sub

Surface Print

Copper
Conductor

merged metallic structures.

STANDARDS:

1. Stranded copper conductors conform to ASTM Specification B-8,

latest edition.

^M

CATHODIC PROTECTION CABLE

2 High molecular weight Polyethylene Insulation conforms to ASTM

Specification D-1248, Type I, Class C, Category 5, Grades E-5 and

J-1.

CONSTRUCTION: Annealed, uncoated, stranded copper conductor,

Hkah Molecular Weight

Po yethylene Insulation

Rome HMW Polyethylene Black insulation, surface printed.

Nominal d-c
Area

Size
AWG

. 8
6
I

No. of
Stands

cm

16510

Diameter
Inches

Insulation
Thickness
Mils

Nominal
Diameter
Inches

Conductor
mm2

8.367

Approx.
Net Weight
Lb./1000F_t.

Resistance
(ohms/1000 Ft.
@25C)
.652

.142

110

.37

87.

110

.40

' ~"i'22

.411

175

.258

26240

13.30

.179

41740

21.15

.225

110

.45

7
7

66360

33.62

.283

110

.51

260

.162

83690

42.41

.322

125

.58

330

.129

19

1/0

19

105600

53.51

.362

125

.62

401

.102

19

133100

67.44

.406

125

.66

492

.081

2/0

.512

125

.77

750

.051

4/0

19

211600

107.2

Information on this sheet subject to change without notice.

LVA~ii*Jl X

X W*w*w*.w

wa-i

Kl I!

\<\ M

I-

MSk

i < i i-:odi s

Borin - STELTH 2
FrlULT^RflrlCCnON

|#aar.BynncMT;

Stationary Reference Electrodes

for Underground and Concrete Service

Features
Minimum 20-year service life.

28 square inches of sensing surface area gives 9 to 35 times

more surface areas than other electrodes. This makes electrode

positioning less critical to achieve accurate readings.

Will not dry out in desert dry soil, a conditionthat renders
other electrodes ineffective. Cyclical variations in soil
conditions, ranging from hydrated to dehydrated, have no
adverse effect on the Stelth2 electrode.

Will not be destroyed by absolute dry soil conditions. It will

only lie dormant until moisture returns. Electric Mud tm
backfill will keep Stelth2 in a moisture environment which
keeps it continuously active.
Electrode may be taken out of service for extended periods of
time and reintroduced into the system without affecting

http://www.mesaproducts.com/stelth2.html

6/4/02

electrode accuracy or ability to reactivate. Electrode will fire

up in under 5 minutes.

Technologically advanced chloride ion trap prevents chloride

contamination of electrolyte.

Available in three models: Cu-CuS04, Ag-AgCl, Zn-ZnS04.

Color coding matches industry standards. Electrode and wire
are both color coded for quick and easy remote identification
of electrode chemistry.
Fully compatible in a gelatin backfill environment such as
Electric Mud tm.

Complete installation instructions included.

Models

e Size:

Stelth2 Model SRE-007CUY

Copper-Copper Sulfate (CuCuS04)

for Underground & Concrete
Service

1.5" (3.81 mm) diameter x

6" (152 mm) long "space
age" ceramic tube with
yellow protective caps.
Lead Wire:

50' (15.2 m) of #14 RHHRHW yellow wire.

Stability:
10 millivolts with 3.0

microamp load.
Temperature Range:
+32Fto+135F

(0C to+57.2C).

Stelth2 Model SRE-008SUB

Silver-Silver Chloride (AgAgCl)

for High Chloride Underground
& Concrete Service

Size:

1.5" (3.81 mm) diameter x

6" (152 mm) long "space
age" ceramic tube with

blue protective caps.

Lead Wire:

50'(15.2 m) of #14 RHHRHW blue wire.

Stability:
10 millivolts with 3.0

http ://www.mesaproducts.com/stelth2.html

6/4/02

Dairyland
Electrical
Industries
P.O. Box 187

Stoughfon, Wisconsin 53589 U.SJV.

Tel: 608-877-9900
Fox: 608-877-9920

"9

1
MsM
m

M
a?
'&p.-

The Polarization Cell Replacement (PCR)

iBapii;?28-

DC BLOCKING VOLTAGE

mine the DC leakage that occurs for a

given DC voltage across the PCR. see
Figure 3. (Since leakage current
varies with temperature for a given
voltage, this data is given at 20 C and

RATING
Whenever any protective device is
installed on a cathodically protected

system, a certain amount of the DC

cathodic protection current is lost due

at 65 C ambient.)

to DC leakage. The higher the DC

blocking voltage rating of the protec

has considerably higher DC blocking

For example, if the user considers 20

milliamperes as the maximum allow
able DC leakage current. Figure 3
shows that at 20 milliamperes of leak
age current, the PCR could block up to

capabilities than those of a polariza

3.0 volts at 20C or 2.4 volts at 65C.

tive device, the less the DC leakage

current at a given voltage. The PCR

tion cell.

Other design options are possible, so if

a PCR with other voltage blocking
parameters is required, please consult.
Dairyland Electrical Industries or your
local representative.

The actual leakage current of the PCR

is well under 1.0 milliampere under
typical operating conditions where the
DC voltage is in the 0.85 to 1.25 V
range, even when the temperature is
up to 65C. For comparison, polariza
tion cells have a published leakage
current of approximately 10 mil-

The values shown in Figures 1, 2, and

3 apply to the standard PCR. Since
the PCR is intended for use on sys
tems where the DC voltage impressed
across its terminals is of a given polar
ity, the standard PCR was designed
with asymmetrical DC voltage block
ing. That is, the standard PCR blocks
DC voltage at different levels depend-

liamperes at 1.2 volts.

Blocking level

determined by leakage
The amount of acceptable DC leakage
is determined by the user. To deter

ing on polarity. For example. 3.0 volts

negative DC and 1.0 volt positive DC
produce the same leakage current.
Since cathodic protection voltage is

negative, the 3.0 volt blocking level

applies. Cathodic protection voltage
normally falls well within this range.

Customized Blocking Levels

DEI can also provide non-standard

symmetrical PCRs, which can block

up to 4.5 volts in 0.5 volt increments,
and symmetrical PCRs which block up
to 2.5 volts in 0.5 volt increments.
For information about PCRs with

other than standard DC blocking char

acteristics, contact Dairyland Electrical

Industries or your local representative.

SUMMARY
The PCR is a variation of the proven

technology of the Isolator/Surge

Protector but is considerably smaller in
size and lower in cost. The total own

ing cost of the PCR is expected to be

considerably less than the polarization

cells they are intended to replace

because PCRs do not require routine
maintenance. The PCR is suitable for

applications which require blocking

DC while simultaneously conducting
steady-state AC. if present. It also

Figure 3: DC Voltage vs. DC Leakage Current

(Standard Asymmetrical PCR)
10000

Typical applications include protection

of insulated joints, AC voltage mitiga
tion and DC isolation/AC grounding of
cathodically protected equipment such
as motor operated valves, etc. All
components in the PCR have been cus
tom designed for such applications. If
a PCR with other parameters is
required, please contact your local rep
resentative or Dairyland Electrical

ciioo

safely handles lightning or AC fault

currents within the ratings listed.

10

Industries.

rrrri 1111111111111111

o.oi

0.5

1.5

2.5

DC Volts

a>aiiylaradSleetrjMwnauimrra^

3.5

4.5

Th^Polarizaton-Ceir|jfe^

-fW^-'W. -'^[V -u^B ?a9e1 29

'>
PCR FEATURES AND

Field Testing

Hazardous Location

Application

CHARACTERISTICS
The PCR may be field tested with a

UL and CSA Listed

Underwriters Laboratories (UL) has

listed the PCR as meeting the criteria

for an effective grounding path as
defined in Section 250-51 of the U.S.

standard AC/DC multimeter and

clamp-on AC ammeter to verify operability.

as meeting the criteria for effective

grounding paths as defined in CSA
Code Section 10-500.

DEI that this device meets the intent

of ANSI/NFPA 70 (the U.S. National

Electric Code) and CSA (Canadian

Mounting

Standards Association) requirements

for Class I. II and III Division 2 loca

National Electrical Code

(ANSI/NFPA-70), thereby enabling its

use an AC grounding device.
Similarly, the Canadian Standards
Association (CSA) has listed the PCR

ThePCR is a sealed, non-spark-pro

ducing device. It is the opinion of

The PCR is made to mount on a flat

tions. Due to code variations and

surface with two 3/8'" (=10mm) diame

ter bolts furnished by user. An outline

drawing to aid in installation is provid

interpretations, it is recommended that

the user determine the acceptability for
use in potentially hazardous applica

ed with each unit.

tions.

Polarity/Electrical

Enclosure

Connection

Solid-State Design

The enclosure is made of a light gray

fiberglass-reinforced polyester material

Eliminates the use of potentially haz

ardous electrolytes which can be
harmful to equipment, personnel and

suitable for outdoor non-submersible

the environment.

Weight

Also eliminates rou

tine maintenance requirements.

applications. Venting is not required.

Polarity marks (+) and (-) are provided

at the lead connection points to aid in
proper installation. Lead connections
are made to bushings with two-hole
terminal pads. Stainless steel bolts,
nuts and washers are included. Leads

and compression connectors are user

Over-Voltage Protection
Significantly limits voltage to which

personnel and equipment may be

exposed (i.e., less than 10 volts peak
under maximum rated AC fault cur

rent.)

Fail-Safe
An important safety feature of the
PCR is that if it is subjected to AC
fault current or lightning surge cur
rents in excess of rating which could
cause failure, failure will occur in the

shorted mode and in this mode the

PCR will carry current in excess of its

fault current or lightning surge current
rati n 2.

Dairyiartd:H<^^

Approximately 12 to 16 pounds (5.5 to

7.3 kg) depending on model selected.

furnished.

Number of Operations
Size

Virtually unlimited under maximum

ratings, provided the operations are not

PCR-3.7KA andj.PCR-1 OKA.modelss

Length

Width

Height

399mm

J 85mm

154mm

Length

Width

Height

immediately repetitive.

Energy Requirements
None. The device is totally
autonomous.

4'22mm

236mm

165 mm

All models MflHrbprional; 80A.

Steady-State Current Rartngr

Length

Width

16.63"'

"9:3lP'.;'"' '"'^T9^['"

422mm

236mm

Ambient Operating
Temperature

Height_
-40 C to +65 C (-40 F to +150 F)

202mm

^f-ftur.^-^T*'

15.72 [399.4mm]

If

01.12 [28.6mm]

I0.250 [6.4mm]

y Polarity Label

y Nameplate

<b

Negative Terminal (-) j-C

c
-
^

7.057 [179.2mm]

2.750 [69.8mm]

3
to

Positive Terminal (+) '

00.438 [11.1mm]
Thlckness=0.38 [9.65mm]

MB*

kg_

(fl

R0.22 [5.6mm]
00.56 [14.2mm]

12.63 [320.7mm]

oil

r*
Serial Label

ii

4.99NS426.7mm]
Alternate Terminal

D
3

Q.

6.06 [154.0mm]
n
70

1.75 [44.5mm] I j
00.56 [14.2mm]
14.2mm] *
4.00 [101.6mm]
Note:

Applicable To:

PCR-3.7KA & PCR-10KA 60 Hz

PCR-3.5KA &

PCR-9KA & 50 Hz

.PCR-2.6KA & PCR-6.8KA <9 16.67 Hz

;".>

APPENDIX C

FIELD TEST DATA

11

"Wyatt, Kennon W.
(Ken)"

<wyattk@bv.com>

To: "'DGravart@kdhe.state.ks.us'" <DGravatt@kdhe.state.ks.us>

cc: stewart.robert@epa.gov

Subject: RE: Ace Cathodic Protection Manual

12/10/03 08:46 AM

Dan

The field test data was submitted as a shop drawing earlier. It's not in the O&M manual because the test data
indicated no potential shift as there should have been. We found that there were several inappropriate ground paths.
Once we got all the ground paths fixed and verified, we still didn't read the expected potential shift. At that point we
realized that the test reference electrodes were located above the liner under the tanks so there would be no way to
see the potential shift on the tank bottom relative to the underlying soil since the liner was creating a dialectic
barrier. Two additional reference electrodes were placed outside the tanks in proximity to the buried steel pipe
connected to the tanks and test stations were installed to access those new reference electrodes. This was done to

allow future testing of the system. The bottom line to all of this is that Appendix C is going to function as a
repository for the results of any future tests using the new test stations. Inserting what we have now in that location
would be misleading from an O&M perspective since it doesn't represent the final condition of the system. I would
much rather leave that stuff in the shop drawing file.

On the good news side of the ledger, the draft of the groundwater report is done and in review. It should be heading
your way soon.

Regards

Ken

Original Message
From: DGravatt@kdhe.state.ks.us [mailto:DGravatt@kdhe.state.ks.us]
Sent: Tuesday, December 09, 20033:37 PM

To: wyattk@bv.com
Cc: stewart.robert@epa.gov
Subject: Ace Cathodic Protection Manual

Ken,

The copy of the Ace Services cathodic protection system O&M manual I received does not have
any field test data in Appendix C. Was this provided as part of a previous report/submittal or did
Capital Electric just forget to include it?
Sorry to keep pestering you about this stuff but there is so much of it that I have trouble keeping

it all straight in my head...

Thanks,
Daniel R. Gravatt, PG

Environmental Geologist and Project Manager

Bureau of Environmental Remediation, KDHE

Phone (785) 296-6378 Fax (785) 296-4823

APPENDIX D
DRAWINGS

\>'-

12

ANODE JUNCTION SOX

AC GROUNDING DEVICE

IMPRESSED CURRENT ANODE

INSTALLATION

?
V

HARDLD WALTERS PRQT ENG

IMPRESSED CURRENT ANODE

828 HE MICHAEL

TYP

UX'S SUMMIT, HO 64086

816 523 1320

CAPITAL ELECTRIC COMPANIES

1428 W.

ANODE INSTALLATION ELEVATIDN

9tfl STREET

KANSAS CITY. MISSOURI 64101-1220

(816) 472 9300

ACE SERVICES SITE

GROUNDWATER TREATMENT SYSTEM

CATHODIC PROTECTION SYSTEM

ANODE J-HK ENCLOSURE

AWG TYPE CP CABLE

HIGH SILICON
CAST IRON ANODE

TYP._

COPPER SULFATE

RE1

RE2

RE3

Li li

RE4

STRl

Al

AS

A3

AS

A6

A7

AS
.

ANDDE

UNDERGROUND REFERENCE

ELECTRODE

JUNCTION

BOX TERMINATIONS

INFLUENT.&.EFFLUENT WATER STORAGE TANKS

CATHODIC PROTECTION SYSTEM
WIRING DIAGRAM

AC GROUNDING/DC BLOCKING DEVICE.

>

4/0 AVG GROUND CONDUCTOR

WELDED TO TANKS' GROUNDING

4/0 AWG GROUND CONDUCTOR ROUTES TO PLANT GROUND GRID.

RINGS.

K3"

TT

HARDLD WALTERS PRDF ENG

828 HE

L>

RECTIFIER WIRING.
DETAIL-

AC GROUNDING/
DC^ BLOCKING DEVICE

MICHAEL

LEE'S SUHHTT. NO.64086

816 325 1320

CAPITAL ELECTRIC COMPANIES

1488 W. th STREET
KANSAS CITY. MISSOURI 64101-1220
<816) 472 9500

ACE SERVICES SITE

GROUNDWATER TREATMENT SYSTEM

COLBY, KANSAS