Alaska Railroad Corporation. Seward Marine Terminal Passenger Dock Cathodic Protection System Repair Project. Design Package

Transcription

1 Alaska Railroad Corporation Seward Marine Terminal Passenger Dock 2018 Cathodic Protection System Repair Project Design Package May 2018 SUBMITTED BY Taku Engineering, LLC P.O. Box Anchorage, Alaska

2 FINAL DESIGN PACKAGE Client: Alaska Rail Road Corporation Project: Seward Marine Terminal Passenger Dock 2018 CP System Repairs Table of Contents 1 Executive Summary Problem Statement Preliminary Design Existing Conditions Site Conditions Scope Scope Overview Implementation Instructions Codes and Standards Technical Specifications Materials Construction Documentation Requirements As-Built Drawings... 5 Appendix A: Seward CP System Repair Specification... Appendix B: Seward CP System Repair Design Drawings... 2

3 1 Executive Summary 1.1 Problem Statement FINAL DESIGN PACKAGE Client: Alaska Rail Road Corporation Project: Seward Marine Terminal Passenger Dock 2018 CP System Repairs Bents 10 through 63 of the Alaska Rail Road s (ARRC) Seward Passenger Dock are protected by an impressed current system. Fifty-eight of the dock cathodic protection (CP) system impressed current anodes have reached the end of life and need to be replaced. In 2015 sixty-three out of the one hundred and twenty-one system anodes were replaced. At that time the remaining fifty-eight were still functioning. They have since reached the end of their useful life and need to be replaced. The ARRC has decided to replace the remaining anodes and has tasked Taku Engineering, LLC (Taku) with developing the engineering design package for the Seward Passenger Dock 2018 CP System Repair Project, detailing the replacement. 1.2 Preliminary Design All remaining anodes at junction boxes 1 thru 13 will be replaced, and new anode cable leads will be routed back to their respective junction box. 58 impressed current anodes will be replaced with new 84 long, 123 lbs. anodes. Additionally, 8 new anodes will be installed, for a total of 66 anodes. Placement will match their existing East/West location underneath the dock as shown in the project drawings. 2 Existing Conditions 2.1 Site Conditions Alaska Railroad s Seward Marine Terminal Passenger Dock is located at the North end of Resurrection Bay. It is 736 feet long and 200 feet wide. The deck of the dock is 24 feet above mean low-low water (MLLW) and is supported by uncoated vertical steel H-piling and uncoated 16-inch diameter batter pipe piling. There are two arrays of H piles totaling over 1800 H piles. There are two rows of batter piles with 59 piles in each row (total of 118 batter piles). The rectifiers for the impressed current system are located at the south side of the ARRC facilities building and the extreme south end of the dock. Anode junction boxes one through thirteen are located under the pier above the catwalk on bents 12, 16, 20, 24, 28, 33, 37, 41, 45, 49, 53, 57, and 61. In November 2013, condition assessments of the structural and cathodic protection (CP) components were completed on the Passenger Dock, by R&M Consultants and Taku Engineering respectively. In 2015 the following repairs were made to the passenger dock CP system: Sacrificial Anode Connection Repairs, Bents 1 4 (60 locations) New Sacrificial Anode Installation, Bents 5 9 (60 locations) Feeder Cable Reroute, Rectifier 9 (15 feet) 3

4 FINAL DESIGN PACKAGE Client: Alaska Rail Road Corporation Project: Seward Marine Terminal Passenger Dock 2018 CP System Repairs Feeder Cable Replacement, Rectifier 10 (~200 feet) Impressed Current Anode Replacement, Bents (63 anodes) Currently 52% of the impressed current anodes have been replaced and are functioning normally. 3 Scope 3.1 Scope Overview The ARRC Seward Passenger Dock s cathodic protection (CP) system is comprised of a sacrificial anode system on the first nine rows of piles closest to shore (Bents 1 9), and an impressed current cathodic protection system on the remaining rows of piles (Bents 10 63). The CP system repair scope will involve the replacement of the remaining impressed current anodes located in Bents (58 anodes). 8 new impressed current anodes will also be installed in the junction boxes with less than 5 anodes currently installed. Junction box 4 will have two anodes removed but not replaced. Repair methods are intended to have a minimal impact to dock operations and are replacement-in-kind in nature. 4 Implementation Instructions All anodes removed in junction boxes 1 thru 13 will be disconnected and removed from the boxes, electrically isolated, removed, and properly disposed of. New 84 long, 123 lbs. anodes will be placed to match their existing East/West location underneath the dock as shown in the project drawings CP3 and CP4. The location of new anodes is also shown on drawings CP3 and CP4. Anode conductors will be run in 1-1/2 conduit on the face of the existing H piles using the conduit support assemblies shown in the project drawing CP9. Anode wires will be run along the concrete beams in a workmanlike manner back to their corresponding junction boxes. Cables will be connected and terminated in the junction boxes as shown in project drawings CP5 thru CP8. 5 Codes and Standards The design for the installation of the 2018 Seward Marine Terminal Passenger Dock 2018 CP System Repairs was developed based on the following codes and standards listed below: The National Electrical Code, 2014 NACE SP ASCE Waterfront Facilities Inspection and Assessment Manual 6 Technical Specifications The CP system repairs will be in accordance with the Seward Cathodic Protection System Repair Specification included in Appendix A. 4

5 7 Materials FINAL DESIGN PACKAGE Client: Alaska Rail Road Corporation Project: Seward Marine Terminal Passenger Dock 2018 CP System Repairs All materials shall be procured by the contractor. 8 Construction Documentation Requirements 8.1 As-Built Drawings The Contractor is responsible for developing and maintaining a complete master set of redlined IFC drawings showing any design changes and deviations. At the end of construction, the Contractor will verify the installation against the master set of redlines and sign and date each drawing indicating that the redlined drawing is As Installed. If the installation did not deviate from the original design drawing, the Contractor will stamp Installed as Designed on that drawing. The As-Built package from the Contractor will include all issued drawings. 5

6 FINAL DESIGN PACKAGE Client: Alaska Rail Road Corporation Project: Seward Marine Terminal Passenger Dock 2018 CP System Repairs Appendix A: Seward CP System Repair Specification

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8 location of components to avoid interference with existing equipment or pile splints on the structure. C. Inspection: It is the Contractor s responsibility to perform work to the requirements of this Specification and to conduct the necessary inspections and tests to ensure proper installation and compliance. The Owner may conduct and or witness any inspection deemed necessary to verify compliance DELIVERY, STORAGE AND HANDLING A. Inspect all cathodic protection materials upon delivery to verify components are of the proper make, model and part number (as specified herein and on the project drawings); are free of damage; and are provided in sufficient quantities to complete the project as designed. B. Store all cathodic protection materials in a dry, protected location to prevent impact, spark and weather-related damage. PART 2 PRODUCTS 2.01 IMPRESSED CURRENT ANODES: HIGH SILICON CAST IRON A. Anodes shall be 84-inch tubular high silicon cast iron type and shall conform to ASTM A518, Grade 3 with the following metallurgical composition: Element Silicon (Si) Chromium (Cr) Carbon (C) Manganese (Mg) Copper (Cu) Molybdenum Iron (Fe) Percent Composition percent (min.) and percent (max.) 3.25 percent (min.) and 5.00 percent (max.) 0.70 percent (min.) and 1.10 percent (max.) 1.50 percent (max.) 0.50 percent (max.) 0.20 percent (max.) Remainder B. Anodes shall be high silicon cast iron, cast with a 200-foot lead wire of #6 stranded copper with HMW-PE black insulation. Anode nominal weight shall be 123 pounds minimum (Anotec Model 4884LZ or approved equal) CABLE Alaska Railroad Seward Passenger Dock CATHODIC PROTECTION Seward, Alaska / 05/ SYSTEM REPAIRS

9 A. All cables shall be continuous and splice free from their point of origin (anode or rectifier) to the designated termination point (junction box or structure connection.) PART 3 EXECUTION 3.01 PREPARATION A. Prior to commencing installation activities, the Contractor should review the Project Drawings and Specifications to become familiar with the scope of work and general location of the work to be performed. B. All cathodic protection materials shall be inspected for defect or damage prior to installation IMPRESSED CURRENT ANODE REPLACEMENT (BENTS 10 63) A. Anodes to be replaced have been identified by their wire lead landing locations in each junction box set as shown on the Project Drawings. The Contractor shall field verify the cable routing and location of each anode to be replaced. B. Depleted anodes and associated wiring shall be removed and properly recycled or disposed of. C. Care shall be taken during removal of existing anodes and wiring to salvage and reuse existing conduit attached to the H-piles running from concrete pile cap to sea floor. D. New anode placements shall match removed East/West locations and/or utilize adjacent locations between bents as specified in the Project Drawings. E. Replacement anode lead wires are to be routed through existing conduit and attached in a clean, orderly workman-like manner to the concrete pile cap for routing back to the associated junction box. F. Anode installation locations that have obstructed or damaged conduit, such that is cannot be re-used, shall install new materials that match the existing installations as shown in the Project Drawings. New/replacement conduit installations shall utilize 1-1/2-inch diameter, Schedule 80 PVC conduit in lieu of galvanized rigid metal conduit. G. After re-energizing the impressed current system, current (amperage) readings shall be taken and documented at each anode lead to ensure proper connection and system performance CATHODIC PROTECTION SYSTEM TESTING & COMMISSIONING Alaska Railroad Seward Passenger Dock CATHODIC PROTECTION Seward, Alaska / 05/ SYSTEM REPAIRS

10 A. Verify with the Contractor and Project Representative that all cathodic protection system installation have been completed and are solidly attached. As-builts of the new and existing installation locations shall be provided to the Project Representative after installation. B. Verify electrical continuity of installed components with dock structure. C. A full dock cathodic protection testing and commissioning survey shall be completed by others. END OF SECTION Alaska Railroad Seward Passenger Dock CATHODIC PROTECTION Seward, Alaska / 05/ SYSTEM REPAIRS

11 FINAL DESIGN PACKAGE Client: Alaska Rail Road Corporation Project: Seward Marine Terminal Passenger Dock 2018 CP System Repairs Appendix B: Seward CP System Repair Design Drawings

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13 ALASKA RAILROAD CORPORATION 2018 SEWARD MARINE TERMINAL PASSENGER DOCK ARRC - SEWARD DOCK DRAWING LIST DRAWING NUMBER REV DRAWING TITLE dt taku engineering 2018 SEWARD PASSENGER DOCK TABLE OF CONTENTS G2 4

14 GENERAL NOTES: dt taku engineering William R. Mott May 14, 2018 MM SEWARD PASSENGER DOCK GENERAL NOTES & FACILITY LAYOUT G3 4

15 BILL OF MATERIALS: William R. Mott May 10, 2018 MM dt taku engineering 2018 SEWARD PASSENGER DOCK BILL OF MATERIALS G4 4

16 JB-9 JB-8 JB-7 JB-6 JB-5 JB-4 JB-2 JB-1 JB-13 JB-12 JB-11 JB-10 JB-3 dt taku engineering William R. Mott May 10, 2018 MM LEGEND 2018 SEWARD PASSENGER DOCK REPAIR AREA OVERVIEW PLAN CP1 9

17 1 A TYPICAL DOCK CROSS SECTION dt taku engineering William R. Mott May 10, 2018 MM SEWARD PASSENGER DOCK TYPICAL ANODE CABLE CONFIGURATION CROSS SECTION CP2 9

18 TABLE 2 MATCH LINE SEE DWG: CP4 JB-6 2 JB-5 1 JB-4 4 JB-3 3 JB-2 2 JB-1 1 William R. Mott May 10, 2018 MM NOTES LEGEND SEWARD PASSENGER DOCK IMPRESSED CURRENT ANODE REPLACEMENT JB-1 THROUGH JB-6 dt taku engineering CP3 9

19 William R. Mott May 10, 2018 MM TABLE 1 JB-13 3 JB-12 2 JB-11 1 JB-10 4 JB-9 3 JB-8 2 JB-7 1 MATCH LINE SEE DWG: CP3 NOTES LEGEND SEWARD PASSENGER DOCK IMPRESSED CURRENT ANODE REPLACEMENT JB-7 THROUGH JB-13 dt taku engineering CP4 9

20 JB-2 ANODE REPLACMENTS 2 (PILE BENT 16) JB-1 ANODE REPLACMENTS 1 (PILE BENT 12) JB-4 ANODE REPLACMENTS 4 (PILE BENT 24) dt taku engineering JB-3 ANODE REPLACMENTS 3 (PILE BENT 20) William R. Mott May 14, 2018 MM SEWARD PASSENGER DOCK ANODE REPLACEMENT DETAILS JB-1 THROUGH JB-4 CP5 9

21 JB-5 ANODE REPLACMENTS 1 (PILE BENT 28) JB-6 ANODE REPLACMENTS 2 (PILE BENT 32) dt taku engineering William R. Mott May 14, 2018 MM SEWARD PASSENGER DOCK ANODE REPLACEMENT DETAILS JB-5 THROUGH JB-6 CP6 9

22 JB-8 ANODE REPLACMENTS 2 (PILE BENT 41) JB-7 ANODE REPLACMENTS 1 (PILE BENT 37) dt taku engineering JB-9 ANODE REPLACMENTS 3 (PILE BENT 45) William R. Mott May 14, 2018 MM JB-10 ANODE REPLACMENTS 4 (PILE BENT 49) 2018 SEWARD PASSENGER DOCK ANODE REPLACEMENT DETAILS JB-7 THROUGH JB-10 CP7 9

23 JB-11 ANODE REPLACMENTS 1 (PILE BENT 53) JB-12 ANODE REPLACMENTS 2 (PILE BENT 57) dt taku engineering JB-13 ANODE REPLACMENTS 3 (PILE BENT 61) William R. Mott May 14, 2018 MM SEWARD PASSENGER DOCK ANODE REPLACEMENT DETAILS JB-11 THROUGH JB-13 CP8 9

24 2 EXISTING CONDUIT A EXISTING CONDUIT C BOTTOM CONDUIT CONNECTION William R. Mott May 10, 2018 MM TYPICAL CONDUIT AND ANODE 1 INSTALLATION ELEVATION VIEWS B BOTTOM CONDUIT CONNECTION 2018 SEWARD PASSENGER DOCK IMPRESSED CURRENT ANODE CONDUIT INSTALLATION DETAILS dt taku engineering CP9 9