6/6/2016

CathodicProtectionSystemsandtheNEC
Forum

Subscribe

AboutUs

MagazineIssues

Newsletters

Advertise

Shop

REGISTER LOGIN
ElectricalConstruction&ampMaintenance(EC&ampM)
NEC

Design

Ops&Maintenance

Contractor

Safety

PowerQuality

Training

Basics

Products

HOME > DESIGN > CATHODIC PROTECTION SYSTEMS AND THE NEC

CathodicProtectionSystemsandtheNEC
ConflictsandsolutionsforcomplyingwithgroundingrevisionsoftheNECfor
cathodicallyprotectedfacilities.
WhittL.TrimbleandEddieGuidry,FluorEnterprises,Inc.|ElectricalConstructionand
Maintenance
SHARE

Tweet

Recommend

Jun1,2008

COMMENTS 0

During the 2005 National Electrical Code (NEC) review cycle, a relatively simple revision was made that
created a significant change on the cathodic protection (CP) systems of petroleum and chemical facilities
(plants).

SpecialistsinIBMPower
Hardware,Licensing,
Maintenance,Consultancy
andManagedServices
www.maplecom.co.uk

Duringthe2005NationalElectricalCode(NEC)review
cycle,arelativelysimplerevisionwasmadethatcreateda
significantchangeonthecathodicprotection(CP)systems
ofpetroleumandchemicalfacilities(plants).The2005
NECmadeitclearthattheremustbeaninterconnectionof
allconcreteencasedsteelreinforcingbar(rebar)tothe
facilitygroundingelectrodesystem.

Howwouldyourateyour(primary)digital
multimeter(DMM)?
TipoftheWeek:StopShortCyclingThose
Motors
MotorWiring,Part2
TipoftheWeek:LessonsLearnedfromaTest
andMeasurementCaseStudy
HowGoodisGoodEnough?

Photo Galleries
CodeQuizofthe
Week:No.27
Takethisweeklyquizto
testyourknowledgeofthe

<b>Fig.1.</b>Cablestubbedoutofconcretefoundation.

Forfacilitiesusingcoppergroundingelectrodesystems(andalsohavingcathodic
protectionaspartoftheircorrosionmitigationandintegrityprograms),thisrevisionmay
requireafacilitytochangetheirentirecathodicprotectiondesignandoperating
philosophy.Itwilldefinitelyrequiregreatercoordinationandcooperationbetweenthe
variousengineeringandconstructiondisciplines.
2005Codechanges

InNECSec.250.50,itisrequiredthatallgroundingelectrodespresentbebonded
togethertoformthegroundingelectrodesystem.Thetypesofgroundingelectrodesthat
mustbebondedtogether,ifpresent,arelistedin250.52(A)(1)through(A)(6).They
include:1)metalundergroundwaterpipe,2)metalframesofbuildingsorstructures,3)
concreteencasedelectrodes(usuallyrebar),4)groundrings,5)rodorpipeelectrodes,
and6)plateelectrodes.Thisarticlewillfocusonconcreteencasedelectrodes,copper
groundrings,andthepotentialproblemsthismaycreatebybondingwithout
considerationofpotentialcorrosion.
http://ecmweb.com/design/cathodicprotectionsystemsandnec

2014NationalElectrical
Coderequirements.

Join the Discussion on EC&M Talk

HotTopics

Comments

NewTopics

EC&M White Papers

ElectricalServices
BoominSeniors
Market
Checkoutthiswhitepaper
tofindouthowelectrical
contractorscanbeapart
ofthisemergingandrewardingmarketshare,howthey

1/6

6/6/2016

CathodicProtectionSystemsandtheNEC

Priortothe2005editionoftheNEC,thefirstparagraphofSec.250.50startedwiththe
phrase:Ifavailableonthepremisesallofthetypesofgroundingelectrodeslistedin
theprecedingparagraphwererequiredtobebondedtogether.Moretimesthannot,
industriallyorientedengineersanddesignerstookthephraseifavailabletomeanthat
sincetheconcretestructureswereusuallypouredbeforetheelectricianswereonsite,then
therebarwouldn'tbeavailable.Therefore,theyassumeditwasn'tnecessarytobondthe
rebartotheothergroundingelectrodesandmaketherebarpartofthegrounding
electrodesystem.Inotherwords,thewaytheNECusedtobewordedseemedtogivethe
designersomelatitudeastowhethertobondallofthepotentialgroundingelectrode
typestogether.
Rightorwrong,thiswasandstillisthetypicalattitudewhendesigningplant
groundingelectrodesystems.Ifyou'readesignengineerwhotriestofollowtheNEC,
however,removalofthewords,Ifavailableonthepremiseshasaratherprofound
meaning.Nowitbecomesclearthatonemustbondthecoppergroundringtothe
concreteencasedrebar(andallotherelectrodes),unlesstherebarisinanexisting
structure.Withaliteralinterpretation,allconcretestructureswithinaprocessunit,with
theequivalentofmorethan20feetofinch(orlarger)rebarinit,mustbebondedto
thecoppergroundringandallotherelectrodes.Thisincludespumpfoundations,pile
caps,spreadfootings,concretepiers,andtankbottoms.Fornewprocessunits,thisadds
considerableinitialcostsandprobablyevenmoresolater,duetotheresultingcorrosion
currents.

canaddcredibilitytotheirprofession,andincrease
potentialforoverallprofitability....

VIEWMOREWHITEPAPERS

EC&MWebinars
SEP10,2015
SPONSORED

ONDEMAND:An
EffectiveElectrical
SafetyProgramthat
Delivers
JUL21,2015
SPONSORED

ONDEMAND:
MitigationMethodsfor
ArcFlashHazards
EnhancingPersonal
Safety
VIEWMOREWEBINARS

EC&M TV

Groundingphilosophies

IDEALPowerBlade
CableCutters

Intoday'srefineriesandpetrochemicalfacilities,avarietyofphilosophiesareused.Many
plantswantalargecoppergridorgroundingringsineachprocessunit.Theseground
grids,groundrings,orgroundloops,astheyareoftenreferredto,aretypically
installedwith10feetor20feetcoppercladrodsspacedatanaveragedistanceof50feet
to100feetwithacopperwirerunbetweentherods.Thecopperwirebetweentherodsis
usuallybare,althoughoccasionallyinsulatedcableisused.Theconductorsizesare
normallyatleast4/0AWGandcanbeaslargeas500kcmil.Equalorsmallersizetaps
fromthegroundringareusuallybondedtostructuralsteelabovegroundthroughoutthe
unitandtoallmotors,transformers,andotherequipmentsuchastanksandvessels.The
intentistocreateanequalpotentialplanewhilealsocreatingalowresistancetoearthfor
groundfaultsandlightningstrokes.Forthepurposeofthisarticle,thisring,grid,orloop
willbereferredtoasagroundring.

<b>Fig.2.</b>Groundingpadonconcretefoundation.

WhilemostplantinstallationsintheUnitedStatestodayhaveacoppergroundring,
therearesomefacilitiesthatpreferonlyanequipmentgroundingconductorrunwiththe
branchcircuitsandfeederstoelectricalequipment(eitherintheformofmetalconduit,
cabletrayorwire,oracombinationthereof),thinkingthatthecircuitequipment
groundingconductorscombinedwithstructuralsteelandpipingbeingincontactwith
eachotherisallthatisrequiredtokeepeverythingatanequalpotential.Forsystem
groundinginthesecases(atatransformersecondary,forinstance),theremaybeoneor
twogroundrodsinstalledtosupplementthegroundingelectrodesystem.

More

Bigenoughforanyjob...

More

BROWSEALLVIDEOS

EC&MLearningCenter
Understandingthe2014NEC,
Volume1(Articles90to480)
Thisresourcehasprovenitselfinthe
fieldandintheexamroom.Thislatest
editionwillprovideyouwitharocksolid
foundation...

UnderstandingNECRequirements
forGroundingvsBonding
Oneofthemostconfusingareasofthe

Thenthereareotherfacilitiesthatprefersomethinginbetweenthesetwomethods,like
small,partialgroundringsaroundspecificequipment,suchastransformersand
substations,bondedtogether,andequipmentgroundingconductorsrunwithbranch
circuitsandfeeders.Thisdiscussionwillfocusonlyonthosesystemswithlargecopper
groundingrings,becausethisiswheretheprobabilityforburiedsteelcorrosionisthe
greatest.
Bondingandgroundingmaterials
http://ecmweb.com/design/cathodicprotectionsystemsandnec

tradecontinuestobegroundingand
bonding,whichiswhythisbookneedsto
beinthehands...

ChangestoTheNEC2014
Don'tletthescaleofthecodechanges
intimidateyou,thisbookwillgetyouup
tospeedonthemostessential...

2/6

6/6/2016

CathodicProtectionSystemsandtheNEC

Whenbondingthecoppergroundringtotheconcreteencasedrebar,severalapproaches
canbeusedhowever,aneffectivepathmustbeprovided.Onemaychoosetouse
exothermicweldingontherebar(Photo)orlistedcompressionconnectorsandattach
acopperwirepigtailtotherebar.(It'simportanttonotethatallgroundingmustbe
donewitheitherexothermicweldingorlistedmaterialspertheNEC.)Thiswirecanthen
berunjustoutsidethefoundationformsandextendedatalatertimetothegroundring
(Fig.1).
Anothermethodistoinstallacoppergroundpadflushontopoftheconcreteslaband
bondittotherebarpriortothepour.Duringconstructionofthegroundring,tapscanbe
installedandboltedtothecoppergroundpad(Fig.2).
Anadditionaltechniqueistoleaveapieceofrebarprotrudingfromtheconcreteintothe
soiltotapontoduringgroundringconstruction(Fig.3).Dependingonthetypeofsoil
andmoisturecontent,however,theexposedrebarmaynotbepermanent,becauseit
mayrustanddeterioratefairlyquickly.
Yetanothermeansofbondingistoweldtheanchorbolts(whereused)tothesteelrebar
beforetheconcreteispoured.Then,duringconstructionofthegroundring,atapcanbe
runuptoasteeltabweldedtothestructuralsteelataconvenientlocationaboveground
(Fig.4).

BROWSEALLTITLES

Signuptoreceiveourfreenewsletters
eTrain(BiWeekly)ViewSample
ProductNewsWire(Monthly)View
Sample
ElectricalZone(Weekly)ViewSample
MROInsider(BiWeekly)ViewSample
PQNewsBeat(BiWeekly)View
Sample
IlluminationInsider(BiWeekly)View
Sample
CodeWatch(BiWeekly)ViewSample
GBiz(Varies)ViewSample
ElectricalTesting(Monthly)View
Sample
EMAIL*
COUNTRY*

UnitedStates

Enteryouremailabovetoreceivemessagesabout
offeringsbyPenton,itsbrands,affiliatesand/orthird
partypartners,consistentwithPentonsPrivacyPolicy.

ConnectWithUs
<b>Fig.3.</b>Rebarstubbedoutofconcretefoundation.

Regardlessofwhichmethodisused,theyallrequireeithermobilizingtheelectrical
contractorlongbeforeitwouldnormallyberequiredoraddingworkonthecivil
contractor'spart.Theadditionalcostsforsupplyingameanstobondthecopperground
ringtotherebarareconsiderednegligiblewhencomparedtothecorrosionthatwilloccur
intherebarwhentheconnectionismadewithoutmeanstopreventcorrosionofthe
buriedsteel.

TwitterFacebook
LinkedRSS

Grounding,corrosion,andtheIEEEGreenBook.

Anexothermicweldconnection.

InIEEEStd142GreenBook,Sec.4.2.3discussestheuseofrebarasagrounding
electrode.CorrosionisdiscussedinSec.4.4.5.Thissectionstates:Thebasicobjectivesof
asoundelectricalgroundingsystemaresafetyofpersonnel,reliabilityofequipment
operation,faultcurrentreturnandtolimittransientovervoltages.Aftertheseobjectives
havebeensatisfied,theeffectofthegroundinginstallationoncorrosionmustbe
considered.Systems,equipment,andlightingsometimesunknowinglycontributetothe
corrosionofundergroundconductors,structures,andpiping.Inthesamechapterofthe
GreenBook,italsoexplainshowcorrosionworkswhencopperandsteelareconnected.
Unfortunately,theNECdoesn'ttakematterssuchascorrosionintoaccount.Makingthe
steelrebarpartofthegroundingelectrodesystemisaverygoodideaforsafetyatleast
intheearlylifeofthesteelrebar.Afterafewyears,ifcorrosionisn'taddressed,corrosion
oftherebarmaycausecrackingandspallingoftheconcretestructuresuchthatits
integritymaybecompromised.Theintegrityoftherebargroundingsafetyelectrodeat
http://ecmweb.com/design/cathodicprotectionsystemsandnec

3/6

6/6/2016

CathodicProtectionSystemsandtheNEC

thispointbecomesquestionable.Thus,incaseswherelargeamountsofcopperwillbe
installedbelowgroundandbondedtotheburiedorconcreteencasedsteel,aCPsystem
shouldbeinstalledoradifferentmaterialthancoppershouldbeusedfortheground
ring.
Cathodicprotectionissues

TheNationalAssociationofCorrosionEngineersInternational(NACE)isanorganization
similartotheIEEE,exceptitdealsprimarilywithcorrosionissues.AccordingtoNACE,
Cathodicprotectionisachievedbymakingthestructurethecathodeofadirectcurrent
circuit.Inotherwords,cathodicprotectionisthepracticeofensuringthatallcurrent
flowbetweenaprotectedmetallicstructureanditselectrolyticenvironmentisfromthe
electrolytetothestructure.Nocurrentflowfromthestructuremeansnometallossfrom
thestructure.
ThemajorrootproblemoftherecentNECgroundingrevisionarisesfromthemodern
constructionpracticesofusingcopperforgroundingpurposesandsteelforstructural
purposes.Steelandcopperhaveverydifferentenergylevelswithsteelbeingthemore
negativeandanodicofthetwo.Thishasprobablycontributedtothepracticeofusing
copperforgroundingasthecoppercomponentsappeartolastforever,wheninactuality,
thecopperhasbeencathodicallyprotectedbythesteelanodetowhichithasbeen
connected.Bondingthetwotogethercreatesacorrosionbatterywithadrivingvoltageof
approximately0.5VDC.Onlythecircuitresistanceisvariableandcontrolstheamountof
current/resultingmetalloss.Iftheresistancetoearthofconcreteencasedelectrodesis
sufficientlylowtomakebondingtothemanimprovementtothefacilitygrounding,the
readercanbeassuredthationiccurrentwillflowfromthesteelanodetothecopper
cathode,andtherebarwilldeteriorate(Fig.5).

<b>Fig.4.</b>Rebarweldedtoanchorbolt.

Inadditiontothedissimilarmetalsproblem,thereareotherdesigncomplicationsfrom
thegroundingrevision.Forexample,thesurfaceareaofmetaltobecathodically
protectedwillbesubstantiallyincreased.Cathodicprotectiondesignersbasetheir
preliminarydesigncalculationsonneedingacertainnumberofmilliampsofCPcurrent
perunitareaofbaremetal.Whilerebarisconcreteencased,groundingcomponentsare
barebydesign.Eveniffoundationrebarand/orfacilitygroundingwereincludedinthe
CPschemebeforehand,whichisnotuncommon,thenewcombinationwillincreaseCP
currentrequirementsbyseveraltimes.Anotherproblemisthatofstraycurrents.CP
designersconstantlyfightthebattleofdistributingtheirintendedCPcurrentstothe
intendedstructures.Thisisanunappreciatedtask.Metallicpipingsystemssuchas
firewater,potablewater,deminwater,stormwater,andoilywaterdrainsystemsmaybe
routinelyconsidered.Oftenfallingthroughtheconsiderationcracksareplantairand
otherutilitygases,electricaltraysandducts,instrumentandcommunicationcables,
nearbyutilitygrounding,andevenfencing.Bondingrebartogroundrings(orother
groundingelectrodes)caninadvertentlyleadtonumerousunintendedstraycurrent
paths.
CPandrebar/groundingbondingsolutions

Thefirstandsimplestpracticalsolutiontothenewrebargroundingrequirementsisto
determineifthefacilitycanbedesignedand/oroperatedwithoutexternalCP.Thisisa
reasonableexerciseandcanhavefavorableresultsifpipingcanberoutedabovegradeor
canbeconstructedusingnonmetallicmaterials.(Theuseofcorrosionresistantalloysfor
pipingiscostprohibitiveandperfect,neverdeterioratingcoatingssimplydonotexist.)
Abovegroundstoragetanks(ASTs)willhavetobeconstructedonsolidconcreteslabsor
withdielectriclinersandconcretewillhavetobechloridefreeornonmetallic
http://ecmweb.com/design/cathodicprotectionsystemsandnec

4/6

6/6/2016

CathodicProtectionSystemsandtheNEC

reinforcementwillhavetobeused.Althoughitrarelyhappens,itshouldbementioned
thatthereistherarecasewhereCPcanbeeliminatedbecausethefacilityisbeingbuiltin
alocationwithextremelyhighsoilresistivity.Eventhen,eliminatingCPgenerallyrequires
thatnolowerresistivityfillbebroughtin,thatcoppergroundingequipmentbereplaced
withstainlesssteel,andthatpossiblefuturesoilcontamination,suchastheuseofde
icingsaltsinthewinter,beeliminated.Itshouldalsobementionedthatsometimesa
shortdesignlife10yearsorlesswilljustifytheeliminationofCPandprotective
coatingsandwillrelyinsteadoncorrosionallowancesandthesubstitutionofstainless
steelforcoppergroundingtoachievetheintegritygoal.
Thesecondsolutionactivityistodetermineifthefacilitycanbecathodicallyprotectedas
awhole.Withfewexceptions,thisisgenerallythecase.Again,ASTswillstillhavetobe
constructedonsolidslabsorwithdielectriclinershowever,steelreinforcementof
concretefoundationscanbecathodicallyprotected.Sometimes,unusualfacility
instrumentationrequirementsorlocationswithextremelyhighsoilresistancerequire
limitedareaCPsystems.WhenthefacilityissuitablefortotalCP,severalremoteordeep
anodebedscangenerallybeinstalledtoprovidesuitabletotalcurrentandcurrent
distribution.Sometimes,supplementallimitedlocaldistributedanodeswillhavetobe
installedincongestedareasorinareasofcorrosionhotspots.

<b>Fig.5.</b>Unintendedcathodicprotectionofcopper
groundingcomponents.

Whentheabovestrategicsolutionsarenotpossible,targetedsolutionsmustbe
employed.Thesewillinvolveacombinationoftheuseofnoncoppergrounding
materials,specializedisolationequipment,separategroundingsystems,nonmetallic
materialsforavarietyofpurposes,combinationsoflocalandareaCPsystems,and
possiblytheuseofautomaticallycontrolledrectifiers.Thistypeoffacilitytreatmentwill
requirecomplexstructuretosoilpotentialand/orvoltagegradientsurveystodetermine
theexistenceormitigationofstraycurrentsituations.Personnelsafetyandmechanical
integritycanbothbeaccomplished,butthemethodsmaybenontraditionaland
engineeringandproceduresmayneedtobesitespecific.
ProvidingCPtoallofafacilitywillinitiallyappeartobethemostexpensiveofthe
strategicsolutions.However,whenthelifetimemonitoringandmaintenancecostsof
targetedfacilityCPsystemsareconsidered,applyingCPtoonlywhatweneedorhaveto
havetomeetregulatoryrequirementsisoftenthemostexpensivecourseofaction.
TrimbleisaNACEInternationalCertifiedCathodicProtectionSpecialist,aninstructor
fortheNACECP1andCP2courses,andamemberofnumerousNACEtechnical
committees.HeisalsoamemberoftheASMEB31.4CommitteePipelineTransportation
SystemsforTransportationSystemsforLiquidHydrocarbonsandOtherLiquids.He
canbereachedatWhitt.Trimble@fluor.com.Guidryisaseniorelectricaldesign
supervisoratFluor,SugarLand,Texas.HeisalicensedmasterelectricianinTexasand
acertifiedICC/IAEIelectricalinspector.AnactivememberofCodePanel11since1999,
heisalsoamemberoftheInternationalAssociationofElectricalInspectorsandthe
NFPA.HecanbereachedatEddie.Guidry@Fluor.com.
BasedonTheConflictsandSolutionstoComplyingwiththeGrounding
Revisionsofthe2005NationalElectricalCodeforCathodicallyProtected
FacilitiesbyWhittL.TrimbleandEddieGuidry,whichappearedinthe
IEEE2007PCICRecordofConferencePapers.2007IEEE.

SHARE
PRINT

REPRINTS

FAVORITE

Tweet

Recommend

EMAIL

PleaseLogInorRegistertopostcomments.

Related Articles
http://ecmweb.com/design/cathodicprotectionsystemsandnec

5/6

6/6/2016
Related Articles

CathodicProtectionSystemsandtheNEC

UnderstandingtheDifferencesBetweenBonding,Grounding,andEarthing
GroundingvsBondingPart9of12
ObservationsonSupplementalGroundingandBondingSystems:Part1
IEEEStandard142:FoundationforGrounding
GroundingvsBondingPart2of12

Ecmweb.com
NEC Design Ops&Maintenance Contractor Safety PowerQuality Training Basics Products

Site Features

EC&M Corporate

AuthorGuidelines

PrivacyPolicy

RSS

TermsofService

Sitemap

AboutUs

SiteArchive

Advertise

Subscribe

ContactUs

ViewMobileSite

Follow Us

Search ecmweb.com

Subscribe to the print magazine

Related EC&M Sites

ElectricalWholesaling ElectricalMarketing Transmission&DistributionWorld

Copyright2016Penton

http://ecmweb.com/design/cathodicprotectionsystemsandnec

6/6