Download 1 Scope (regarding no. 1)

1. ------IND- 2012 0035 D-- EN- ------ 20120127 --- --- PROJET
Additional technical terms of contract - hydraulic engineering (ZTV-W)
for
cathodic corrosion protection in steel hydraulic engineering
(performance category 220)
Draft 2011 Edition
EU notification No. …..
TABLE OF CONTENTS
1
Scope (regarding no. 1) .................................................................................................................................. 3
2
Materials, components (regarding no. 2) ...................................................................................................... 3
2.1
General ............................................................................................................................................................. 3
2.2
Galvanic anodes ............................................................................................................................................... 3
2.3
Sacrificial anodes .............................................................................................................................................. 4
2.4
Rectifier units .................................................................................................................................................... 4
2.5
Electrical equipment.......................................................................................................................................... 5
2.5.1
General ............................................................................................................................................................. 5
2.5.2
Environmental requirements and conditions ..................................................................................................... 5
2.5.3
Switching devices ............................................................................................................................................. 5
2.5.4
Cables and conductors ..................................................................................................................................... 5
2.5.5
Overliad protection devices ............................................................................................................................... 6
2.5.6
Monitoring and measurement devices .............................................................................................................. 6
2.5.7
Housing ............................................................................................................................................................. 6
2.5.8
Mounting hardware ........................................................................................................................................... 6
2.5.9
Electronic and programmable electronic systems ............................................................................................ 6
3
Design (regarding no. 3) ................................................................................................................................. 7
3.1
General ............................................................................................................................................................. 7
3.1.1
Design ............................................................................................................................................................... 7
3.1.2
Final design documents (supplementary specific provisions for ZTV-W LB 202) ............................................. 7
3.2
Protective measures ......................................................................................................................................... 7
3.3
Housing and device installation ........................................................................................................................ 8
3.4
Connections ...................................................................................................................................................... 9
3.5
Line voltage and operating voltage ................................................................................................................. 10
3.6
Stray currents .................................................................................................................................................. 10
3.7
System software.............................................................................................................................................. 10
3.8
Completion of the performance ....................................................................................................................... 10
3.9
As-built documents (supplementary specific provisions regarding ZTV-W LB 202) ....................................... 11
4
Additional services, special services (regarding no. 4) ............................................................................ 11
4.1
Additional services .......................................................................................................................................... 11
4.2
Special services .............................................................................................................................................. 11
5
Billing (regarding no. 5) ................................................................................................................................ 12
Apppendix 1:
Appendix 2:
Summary of the documents cited ......................................................................................................... 13
Index ........................................................................................................................................................ 15
Note:
The obligations under Directive 98/34/EC of the European Parliament and of the Council of 22 June 1998
laying down a procedure for the provision of information in the field of technical standards and regulations (OJ L 204
p.37), as amended by Directive 98/48/EC of the European Parliament and of the Council of July 20 1998 (OJ L 217
p.18) have been met.
ZTV-W LB 220 2011 Edition
Page 1 of 16
Published by the Federal Ministry for Transport, Building and Urban Development
Department: Waterways, Shipping
All rights reserved.
Prepared by the "Standard specifications for hydraulic engineering" task force with the participation of:
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the Federal Ministry of Transport, Building and Urban Affairs and its subordinate agencies
the Lower Saxony Ministry for Economic Affairs, Labour and Transportation
the Ministry of Agriculture, Environment and Rural Areas in Schleswig-Holstein
the Senator for Economy and Seaports in Bremen
the Economic Authority of the Free Hanseatic City of Hamburg
Niedersachsen-Ports GmbH & Co KG
Federal Association of German Inland Ports e. V. (BÖB)
Duisburger Hafen AG
RMD Wasserstrassen GmbH
Emschergenossenschaft / Lippeverband
Linksniederrheinischen Entwässerungsgenossenschaft
Ruhrverbandes
Wasserverband Eifel-Rur
Wupperverband
Österreichisch-Bayerischen Kraftwerke AG
Lechwerke AG
Can be obtained from the
[German Maritime and Hydrographic Agency]
Bundesamt für Seeschifffahrt und Hydrographie (BSH)
Bernhard-Nocht-Straße 78
20359 Hamburg
ZTV-W LB 220 2011 Edition
Page 2 of 16
Preliminary remarks
The numbers in parentheses after the section headings refer to the “General technical terms of contract for building works
(ATV) General rules for all types of building works – DIN 18299”.
Products and goods originating from other Member States of the European Communities or Turkey, or an EFTA state which
is a Contracting Party to the EEA Agreement, which do not meet these technical specifications shall be treated as
equivalent, including the testing and inspections performed in the manufacturing country, if the required level of protection safety, health and suitability for use – is equally and permanently achieved.
1
Scope (regarding no. 1)
(1) The "Additional technical terms of contract - hydraulic engineering (ZTV-W) for
protection in steel hydraulic engineering" apply to the planning and construction of
protection systems for all fixed and moving parts on steel hydraulic structures and for
hydraulic structures. They may also be applied mutatis mutandis to the active corrosion
piling.
cathodic corrosion
cathodic corrosion
steel equipment in
protection of sheet
(2) In particular, DIN standard 19704-3, Steel hydraulic structures, electrical equipment and DIN-VDE
standards or the relevant European standards shall apply.
(3) The documents cited in the text are required for the application of these additional technical terms of
contract. The documents are listed in appendix 1.
2
Materials, components (regarding no. 2)
2.1
General
(4) Notwithstanding the following special rules, the cathodic corrosion protection (KKS) must be appropriate
for the use set out in the contract and the generally recognized rules of engineering.
(5) Special emphasis should be placed on uniformity in the contractor’s construction documentation. The
fewest possible number of different brands, types and sizes of materials and components are to be used.
2.2
Galvanic anodes
(6) The compositions must be evidenced by inspection certificate 2.2 in accordance with DIN EN 10204.
(7) The following anodes are to be used:
- Magnesium anodes in accordance with DIN EN 12438
- Zinc and aluminium anodes in accordance with VG 81257
(8) The galvanic anodes must have the following properties:
Anode material
Type/material
number
Magnesium
(Mg)
Az 63/2.1150
(Az 61/2.1140)
(Az 31/2.1130)
≥ 1,100
Aluminium
(Al)
A1
Zinc (Zn)
Comment
2.23012)
2.23023)
Practically
Ah/kg
≥ 2,700
≥780
contained current
Erosion loss
Kg/A∙a
≤ 8.0
≤ 3.25-3.3
≤ 11.2
Resting potential
mV*
-1200
-8501)
-800
∆U to structural mV
450-750
300-370
250-300
steel
Density
g/cm³
1.8-2.0
2.8
7.1
Water use
Internal
Brackwater
Sea water
*H electrode → Cu/CuSO4
1) Addition of gallium, indium or tin lowers the resting potential by 150 mV
2) Corresponds to materials in accordance with MIL-A 18001 K
3) Reduced Cd variant
in sea water
Voltage drive
(9) Anode holders made of construction steel S235JR in accordance with DIN EN 10025-2 (St 37-2) must be
supplied galvanized.
(10) Holder components made of galvanized construction steel that are not moulded into the anode bodies
must also be passively protected. The coating material must be compatible with the cathodic corrosion
protection (please refer to the list of approved BAW systems) and the galvanization.
ZTV-W LB 220 2011 Edition
Page 3 of 16
(11) The contact resistance must be < 1 mΩ both between the anode alloy and anode holder as well as
between the anodes the surface being protected, and this must be evidenced.
(12) Lock washers must be used as washers for screw connections. The screws must be secured using a
liquid single component adhesive.
(13) The galvanic anodes must be arranged in such a way that a shadow effect is avoided even on
components with a complicated design.
2.3
Sacrificial anodes
(14) The compositions must be evidenced by inspection certificate 2.2 in accordance with DIN EN 10204.
(15) The sacrificial anodes must have the following properties:
Sacrificial anode
Ironsiliconchrom1)
≤ 500
90
502)
None
Erosion loss
g/Aa
Minimum utilization
%
Max. current density
A/m²
Voltage limitation
V
1) Addition of chrome in sea water
2) In fresh water (iron-silicon) up to 150 A/m²
3) 8.4 V at the anode
Magnetite
≤ 20
90
70
None
Platinized
titanium/niobium/
tantalum
≤ 0.08
90
600
123)/40/80
Metal oxide-coated
titanium
≤ 0.04
90
600
123)
Magnetite [M-%]
FeO 28 - 32 M.-%, Fe2O3 60 - 64 M.-%, SiO2 M.-3 - 8%, remainder is special additives
Platinum on titanium
Titanium with an iron content of < 0.2% by mass is to be used in accordance with
material no. 3.7025 in accordance with DIN 17850. The thickness of the layer of
platinum coating must be at least 5 m and thoroughly coated on the side exposed to
water.
Platinum on Niobium
The thickness of the layer of platinum coating must be at least 5 m and thoroughly
coated on the side exposed to water.
Mixed oxide on titanium
Titanium with an iron content of < 0.2% by mass is to be used in accordance with
material no. 3.7025 in accordance with DIN 17850. The thickness of the mixed oxide
layer (oxide of iridium and ruthenium) should contain10 g to 40 g of precious metal per
m2.
(16) Rectifier drive voltages above the corresponding breakdown voltages for activated titanium and niobium
are permitted in media containing chlorine in accordance with VG 81259-3 as long as the breakdown voltages
of titanium and niobium do not exceed the values at the phase boundary anode/electrolyte solution.
(17) Anodes with a higher fracture risk (e.g. hollow anodes made out of iron silicon or magnetite) as well as
anodes that, because of their design, cannot be mounted without attachment and guide devices (e.g. spiral
anodes), must be given additional mechanical protection (e.g. perforated plastic pipe as a protective cover).
Mounting materials made of chlorine-resistant plastic must be used.
(18) The cable connection on the anode head must be manufactured in such a way that it is low-impedance
( 1) and water-pressure tight in accordance with the immersion depth (protection class IP 68 in accordance
with DIN EN 60529).
(19) The anode head insulation must be resistant against chemical and physical stresses in the electrolyte
solution (body of water).
2.4
Rectifier units
(20) Short-circuit protected power packs with a remaining voltage  5% must be used.
(21) Lightning and surge protection devices in accordance with DIN EN 62305 must be provided for the
rectifier units.
(22) A changeover switch and a connection for a meter must be provided in every secondary circuit /
measurement circuit in order to measure the ON/OFF switching potential.
ZTV-W LB 220 2011 Edition
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(23) Automatically regulating rectifier units must be used. The controlled variable is the protection potential,
which is maintained through the electronically regulating protection current within the minimal and maximum
selectable. The control has an inertia that must be adapted to the respective local conditions. Independent
protection areas must be controlled universally. Error messages are generated if the actual potential or the
anode current permanently fall outside the prescribed framework. In the case of protective equipment in
waters with constant conductivity values as well as relatively low temperature fluctuations (e.g. sea water
structures), it may be possible to dispense with automatic control.
(24) Anodic cleaning via a changeover switch must possible when using zinc electrodes.
2.5
Electrical equipment
2.5.1
General
(25) The mains connection (power supplies) for all distributions and switchgear cabinets ≥ 3 kW must be
designed as 230/400 V 50 Hz three-phase, four-wire mains.
(26) Rectifier units with a connection value ≥ 3 kW must be constructed as 3-phase for 400 V.
(27) The primary side of control transformers must be provided with tappings for + 5% of the nominal voltage.
2.5.2
Environmental requirements and conditions
(28) The equipment must be constructed for the following environmental requirements and conditions:
- Climatic conditions that fall under type C and creepage distances that fall under pollution index 3 in
accordance with DIN EN 50178 VDE 0160. If necessary, additional measures for meeting the aforementioned
requirements such as housings and heating should be considered.
- Electrical and electromagnetic requirements from the Basic Standard for electromagnetic compatibility DIN
EN 61000-6-2 for equipment in an industrial environment and for EMC interference emissions DIN EN 610006-3 for equipment in residential areas.
2.5.3
Switching devices
(29) Electrical position indicators must be installed for all circuit breakers.
(30) Toggle switches with lock cylinders must be installed as key control switches. The keys must be
removable in all positions. The same shutdown must be used for the same functions on a system, e.g.
ON/OFF for control voltage.
(31) Incoming circuit breakers must be designed as circuit breakers with the properties of a main breaker.
(32) Auxiliary circuits and other consumer loads must be protected using protect switches.
(33) All protect switches must be equipped with relay contacts.
2.5.4
Cables and conductors
(34) Power cables must have an externally concentric conductor as a protection conductor, e.g. NYCWY.
(35) The minimum requirements for flexible conductors in accordance with DIN 19704-3 apply to flexible
couplings.
(36) Cables and conductors must be laid in such a way that they can be exchanged and are protected, e.g.
on cable trays, anchor rails, in cable trenches, channels, protective tubes, wells and on cable ladders. The
cable carriers must have a space reserve of at least 20% in all areas.
(37) Cables and conductors by approximately 1.00 m must also have additional protection against
mechanical stress, e.g. using PE pipes, tubes or sheaths if they extend out of the ground or floor.
(38) Openings for cable ducts in floor slabs and in space-enclosing walls must be sealed in such a way that
they are resistant to the effects of fire according to dire resistance class S 90. These separations must be
easy to penetrate or open, however, for the subsequent laying of cable; see DIN 4102-9.
(39) Cables and conductors at the insertion points into buildings and at expansion joints should also be laid in
such a way that they can accommodate settling and shifting without being damaged. On site insertion points,
e.g. watertight joints, must be properly sealed after the cable has been laid.
ZTV-W LB 220 2011 Edition
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2.5.5
Overload protection devices
(40) No additional provision with regards DIN 19704.
2.5.6
Monitoring and measurement devices
(41) Voltmeters must be provided at main power supplies.
(42) Analogue measuring devices must at least correspond to class 1.5 (DIN EN 60051-1) and digital
measuring devices must have a four-digit display with a measurement precision of +/- 1% of the reading, +/- 1
digit.
(43) Current transformers for measurement displays, control etc. must be set up for a transformation ratio of
x: 1 A.
(44) Analogue data signals that are to be read and processed in other systems in accordance with the
performance descriptions, e.g. automation devices, process control systems, must be provided as a 4-20 mA
potential-free process signal (4-wire transducer).
(45) Circuits that are operated via control transformers, batteries and similar power sources must be designed
in such a way that each power source essentially has insulation monitoring.
(46) In KKS systems (power plant designation system), the “ON” operating state must be indicated using
appropriate feedback lights or display indicators on the control section.
At every control section, basic indicators must be provided for

Operational messages,

Fault messages,

Measured values, e.g. voltage, current and potential.
(47) The local control and signal circuits must be equipped with standardized, long-distance data
transmission interfaces, including disclosure and documentation of the communication protocols. The
interfaces enable the remote querying of conditions and measured values for the operation and maintenance
of the entire KKS system.
2.5.7
Housing
(48) Switchgear cabinets with a steel plate enclosed design must have the following plate thicknesses: Doors
> 2 mm, Walls > 1.5 mm. the plates must be dip-coat primed and powder-coated on the outside. Plastic
housings made of polyester fibreglass must have a polyurethane coating for outdoor use.
2.5.8
Mounting hardware
(49) Corrosion protected mounting hardware must be used for electrical equipment in housings.
(50) Cable laying hardware and mounting hardware must be galvanized (hot-dip); otherwise it must be
composed of plastic or stainless steel.
2.5.9
Electronic and programmable electronic systems
(51) Electronic systems include components containing semi-conductors in a parameterizable design, e.g.
transformers, multi-function displays or relays.
(52) Programmable electronic systems include components containing semi-conductors in a programmable
design, e.g. SPS, IPC or touch panels.
(53) The operating service life of electronic equipment must be at least 10 years. The manufacturer must
provide full support for the repair and replacement of components and must update the firmware and
programming software for this period of time, outside of warranty claims for defects.
(54) The entire system software that was created to fulfil the contractual obligations becomes the property of
the client. Software support for the system software must be guaranteed by the creator of the software for 5
years.
ZTV-W LB 220 2011 Edition
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3
Design (regarding no. 3)
3.1
General
(55) Construction documentation that is to be provided by the contractor must be created with due regard to
the findings from the preliminary studies and the “Fact sheet on cathodic corrosion protection in steel
hydraulic engineering (MKKS)” [Merkblattes Kathodischer Korrosionsschutz im Stahlwasserbau].
(56) The contractor must be certified in accordance with GW 11 field of activity S5P+S5I+S5Ü appropriate to
the scope of the contract.
(57) The components arranged in the water sector must be firmly attached so that they withstand the forces
from currents, and impact from drifting ice and floating debris.
3.1.1
Design
(58) The requirements in DIN VDE 0100 and DIN EN 60204 in particular apply to the design and construction of
the electrical equipment for steel hydraulic structures.
(59) The conductor cross section for anode and cathode cables is limited to a maximum of 70 mm2. In
addition, parallel cables must be laid.
(60) Voltage and current meters must be provided in the protection circuit.
(61) Measuring electrodes must be connected to the rectifier unit controller. They must determine the actual
potential, which triggers the control function based in its difference from the nominal potential.
(62) When using Zn 99.9 electrodes and Ag/AgCl/KCl (saturated), the measured value of the potential for
Cu/CuSO4 (saturated) must be standardised using the measurement transducer.
(63) Measurement electrodes must be positioned so that the voltage drop that could distort the potential (I x
R-component) in the actual potential remains < 5% of the display for all potentials within the operational
limits. A high-impedance voltmeter, R > 1 M should be used as a measuring device.
3.1.2
Final design documents (supplementary specific provisions for ZTV-W LB 202)
(64) The final design documents include:
– Comprehensive functional specification regarding the contracted performance, in particular including a
calculation of the service life of the anodes
– Plans with the arrangement of all components on the objects
and in addition for a procedure that uses an external power feed:
– Technical documentation in accordance with DIN EN 60204-1
– Schematics in accordance with DIN EN 61082-1 with schematic diagram and cabinet views
(65) The contractor must provide the assembly and workshop drawings needed for the implementation.
(66) The contractor must provide the client with all design documents needed for the unhindered installation
and proper operation of the facility 6 weeks before the start of workshop or assembly work.
3.2
Protective measures
(67) Main potential equalization and supplementary potential equalization must be established in electrical
operating areas; see VDE 0100-410.
(68) A main earthing bar must be placed in the area around each substation and distribution point. A test
disconnect terminal block must be installed in the supply line.
(69) PEN and PE busbars must be grounded at easily accessible points according to the mains and
protection conditions.
(70) Electrical and electronic systems and devices must be protected against unwanted external electrical
influences such as electromagnetic fields and power surges. The contractor must update the lightning
protection zone concept. The range of protection to be considered shall be specified by the client.
ZTV-W LB 220 2011 Edition
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(71) The functional measure, “functional low voltage with safe isolation” (PELV) in accordance with DIN VDE
0100-410 must be implemented on the DC side. With regard the remaining voltage of the DC voltage in the
case of a single-phase bridge circuit, the open circuit voltage may not exceed 90 V.
It is not necessary to protect cathodically protected objects against direct contact.
(72) In TN networks, the PEN or PE connectors may not be directly connected to the electrical equipment, the
housing of which is directly connected to the cathodically protected system and which cannot be electrically
separated. Due to the low ground resistance of PEN or PE connectors, this would have a strong adverse
effect on the effectiveness of the cathodic corrosion protection.
In these cases, protection against indirect contact is to be ensured through protective isolation or protective
low voltage in accordance with DIN VDE 0100–410.
(73) Cathodically protected system components may not be connected to the potential equalization and the
external lightning protection system. A connection via only spark gaps should be established as a protective
measure.
3.3
Housing and device installation
(74) Housings made out of insulating material of an appropriate protection class are permitted for small
partitions.
(75) Cables and conductors must be introduced from the bottom in switchgear cabinets, partitions and
encapsulated electrical equipment.
(76) Screw connections or equivalent sealing elements should be used for cable and conductor glands. They
may not reduce the required type of housing protection (DIN EN 60529). Reserve lead-ins (ca. 20%) must be
provided.
(77) For switchgear cabinets (standing), the gland plates are divided and removable constructed with sealing
elements. The required protection class must be ensured.
(78) Cables and conductors must be attached to cable catch rails and cable conductors using cable clamps.
(79) Cable catch rails and N and PE busbars should be arranged below. Only one wire may be connected to
each terminal point of the N and PE busbars.
(80) Head runners that run the entire width of the housing are to be provided on the switchgear cabinet
housing above the doors for attaching labelling.
(81) Arrangements must be made to ensure adequate ventilation and heat dissipation and this must be
demonstrated within the construction documentation.
(82) All substations, including individual switchgear cabinets and partitions, must be equipped with incoming
circuit breakers that can be operated externally. These breakers are to be labelled as such.
(83) In each substation and for sub-distributions, a fused outgoing circuit must be provided in front of the
incoming circuit breaker for measurement purposes and for the connection of cabinet lamps, electrical
sockets etc., and run to the terminal blocks. The connected electric equipment and the terminals must be
specifically enclosed and designed to be fingersafe, and it must be labelled with warning labels; see BGV A3.
(84) Electrical equipment must be grouped according to function, be easily accessible, and installed in such a
way that it can easily be replaced. The side walls on switchgear cabinets and partitions may not be occupied
with equipment. A 20% space reserve must be provided for additional equipment.
(85) Busbars are to be installed at the top in substations and partitions in such a way that they are touchproof.
(86) In the case of partitions that have a box design, the busbars should be provided with their own boxes.
(87) Support rails for terminal blocks are to be installed below in a horizontal position along the entire width of
the housing and cabinet. A space reserve of ca. 20% must be provided for the installation of additional
terminals.
(88) The wiring of the auxiliary circuits should be done in wiring ducts in switchgear cabinets and partitions,
and in protective hoses in moving parts. In the case of electrical equipment that is accessible in the rear, the
wiring must be accessible from the front.
(89) Multiple-strand or fine-strand copper conductors should be used. The minimum cross-section for
auxiliary circuits must be 1.5 mm².
ZTV-W LB 220 2011 Edition
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(90) In the case of assemblies/devices with a limited terminal cross section, these should have a minimum of
0.5 mm².
(91) The wiring should basically be done in black with the exception of external voltage and special power
circuits (e.g. orange). Ferrules with insulation must be used without exception.
(92) Switchgear cabinets and partitions must be lab led with plain text as well as with system and location
designations.
(93) Nameplates should be engraved in dual-layer plastic – white with black lettering. The exceptions are
signs for which a specific colour coding is prescribed. The signs should be permanently attached. Gluing is
only permitted in dry spaces.
(94) Electrical equipment and their installation locations in switchgear cabinets and partitions must be
provided with permanent markings (code).
(95) Operating and display elements, monitoring devices, circuit breakers and external electrical equipment
must also be lab led with plain-text name plates.
(96) Messages should be displayed using LED indicators unless otherwise provided in the specifications, and
test switches should be provided.
(97) Fault and hazard alarms must be indicated separately. Acknowledgement must be made using buttons.
(98) Terminal blocks are to be arranged left to right with continuous numbering.
(99) Terminal blocks for special power circuits, external power etc. must be specially marked.
(100) N and PE conductors must be lab led at the connection point with the associated cable number in
accordance with DIN EN 62491 VDE 0040-4 method R.
(101) The wiring, cable and conductor cores in switchgear cabinets and housings on all electrical equipment
are to be permanently labelled with connection identifiers (e.g. with marking collars that cannot be lost) in
accordance with DIN EN 62491 VDE 0040-4 method CL.
(102) Cables and conductors are to be permanently labelled on both ends and in cable ducts (with one-piece
cable markers made of plastic and captivated identification labels with perforated identifying text or the
equivalent) in accordance with DIN EN 62491 VDE 0040-4 method R.
(103) The labelling of the electrical equipment and the execution of the mimics shall be determined within the
context of the design review with the client.
(104) Switchgear cabinets should be installed with a wall distance of approximately 50 mm on a steel frame
(base frame) approximately 100 mm in height.
(105) When the installation is made on an elevated double bottom, independent substructures should be
provided in accordance with the local circumstances.
(106) Surface-mounted partitions must be mounted on support rails (e.g. Z profile) with a wall distance of
approximately 50 mm.
3.4
Connections
(107) All cable and connector cores must be connected to terminal blocks in switchgear cabinets and
partitions with the exception of the power cables, which are directly connected in accordance with the
performance specifications.
(108) Only one core may be connected at each terminal point of a terminal block.
(109) Terminal blocks must be constructed to accommodate the diameter of a 2.5 mm² multi-stranded
conductor. Spacer plates or spacers should be provided between the groups, depending on their assignment.
(110) Terminal blocks for external voltages must be confined using spacer plates.
(111) Test disconnect terminal blocks must be provided for control measurements on current transformers
and similar electrical equipment.
ZTV-W LB 220 2011 Edition
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(112) Fibre optic cables must be connected at both ends with all fibres in splice boxes. Other connections are
made using patch cables.
3.5
Line voltage and operating voltage
(113) A TN-C network should be assumed when taking measurements; see DIN VDE 0100-100. In the
performance specifications, the client determines at which node a TN-C-S network should be established.
The line voltage is: AC 3 x 400/230 V 50 Hz.
(114) The control and signal voltages are selected in agreement between the contractor and client from the
following voltage ranges: AC 230/115/48/24 V 50 Hz or DC 110/48/24 V
3.6
Stray currents
(115) An adverse effect on adjacent systems must be expected, where the voltage between the adjacent
system and a non-polarizable measuring electrode (e.g. Cu/CuSO4 saturated) that is placed on the ground is
changed, on average, by 0.1 V (incl. an ohmic voltage drop in the ground) in the positive direction by the
corrosion protection system.
This effect must be prevented using the following measures:
- Adequate distance between the sacrificial anodes and adjacent systems.
- Installation if insulating plates between anodes and external installations.
- Establishment of a potential connection between the protected and the adjacent system; the balancing
resistor must be set in such a way when the cathodic protection is switched on, there is no change in
potential in the positive direction in the adjacent system.
(116) The possible influence on adjacent systems (e.g. earthing and lightning protection) by the cathodic
corrosion protection is to be checked and documented.
3.7
System software
(117) In accordance with DIN EN 50128 VDE 0831-128, software for railway control and monitoring systems,
when using programmable logic controllers, the system software must be created using appropriate
procedures.
(118) It must be possible to analyse, test, verify and maintain the software being created. Every software
module must be tested. It must be documented that the intended function has been fulfilled.
3.8
Completion of the performance
(119) In terms of the commissioning and monitoring of the cathodic corrosion protection, the DVGW
worksheet GW 10 "Cathodic corrosion protection (of underground storage tanks and pipelines made of steel commissioning and monitoring" must be taken into consideration.
(120) Proof of the protective potential must be provided by mobile control measurements and recorded after
the installation of the cathodic corrosion protection systems.
(121) Cathodic protection is achieved when the entire surface that is to be protected has a potential that falls
between - 730 and - 930 mV Ag/AgCl/KCl (saturated) or + 236 and + 36 mV corresponding to zinc - 850 and 1050 mV Cu/CuSO4 (saturated). Violations of these limits should be avoided because of possible coating
damage.
(122) Constant electrodes, e.g. zinc 99.5, Ag/AgCl/KCl (saturated) should be used as reference electrodes for
determining the resting potentials as well as for monitoring of the potential distribution and the protective
effect. Cu/CuSO4 (saturated) electrodes can be used for short-term use in monitoring the function and
calibration of the measuring electrodes. The limiting values in accordance with DIN EN 12473 apply to sea
water. The potential of the reference electrodes used relative to standard hydrogen electrodes at 20°C should
be indicated.
(123) The trial run should be conducted in all operating modes after the functional tests have been performed
without objection under operating conditions and time period as specified by the client.
(124) The trial run must be attended by personnel of the client.
ZTV-W LB 220 2011 Edition
Page 10 of 16
(125) The operating and maintenance personnel of the operator should be trained in the system components
before the trial run. Appropriate training documents should be created for this training and distributed to the
personnel. The training must be documented.
(126) A successful trial run is a prerequisite for acceptance.
3.9
As-built documents (supplementary specific provisions regarding ZTV-W LB 202)
(127) The as-built documents specifically include:
- Functional description of the cathodic corrosion protection system
- Testing, measurement and setting protocols for cathodic corrosion protection systems
- Maintenance instructions, documents for scheduled maintenance
In addition, for external power procedures:
- Testing, measurement and setting protocols for electrical equipment
- Flowchart of the functional relationships
- Printout of the software programme with comments and cross references and with a list of all process
parameters
- Software programme on digital media as specified by the client, with labelling and factory label
- Licenses for the software used
- Installation plans (locations of the equipment in rooms)
- Electrical engineering calculations (e.g. selectivity, short circuit current, voltage drop calculations)
- Cable layout outdoors, cable laying systems in the building
4
Additional services, special services (regarding no. 4)
4.1
Additional services
In addition to ATV DIN 18299, paragraph 4.1, these specifically include:
(128) Marking slots and openings, even if these are made by another contractor.
(129) Assembly and disassembly as well as provision of scaffolding on which the work platform is no more
than 2.00 m above the ground or floor.
(130) Drilling, chiselling and milling work for placing dowels and installing installation hardware, e.g. flush
boxes.
4.2
Special services
In addition to ATV DIN 18299, Paragraph 4.2, these specifically include:
(131) Provision of accommodation and storage areas if the clients rooms, which can easily be locked, are not
made available.
(132) Assembly and disassembly as well as provision of scaffolding on which the work platform is no more
than 2.00 m above the ground or floor.
(133) Supply and installation of special mounting structures, e.g. brackets, support structures.
(134) Drilling, chiselling and milling work for attaching brackets and supports. Creation and sealing of slots as
well as openings.
(135) Supply and attachment of function, name and notification labels that go beyond the scope of
paragraphs 2.1.2 and 3.3.
(136) Provisional measures for early operation of the system or system components prior to acceptance on
the orders of the client including necessary maintenance and overhaul services.
(137) Operation of the system or system components prior to acceptance at the order of the client.
(138) Conduit planning and planning slots and openings.
(139) Cable carriers in accordance with item 36, mechanical protection in accordance with item 37 and
firewalls in accordance with item 38.
ZTV-W LB 220 2011 Edition
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(140) Additional systems for data acquisition in accordance with item 44 and insulation monitoring in
accordance with item 45.
(141) Planning documents in accordance with item 64.
(142) Potential equalization in accordance with item 67.
(143) Splice boxes, connection work and patch cable in accordance with item 112.
(144) System software in accordance with items 117 and 118.
(145) Training measures and instruction go beyond item 125.
(146) As-built documents in accordance with item 127.
5
Billing (regarding no. 5)
In addition to ATV DIN 18299 paragraph 5, the following applies to billing:
(147) Testing of the performance – regardless whether based on the drawing or measurements – should be
based on the actual dimensions of the system components.
(148) Cables, conductors, wires, pipes and ducts should be billed according to the actual length laid, e.g.
from terminal point to terminal point. Clippings are not taken into account.
ZTV-W LB 220 2011 Edition
Page 12 of 16
Appendix 1: Summary of the documents cited
ATV DIN 18299
VOB Regulations on contract awards for public works - Part C: General technical
terms of contract for building works (ATV) - General rules for all types of building
works
BGV A3
Occupational Health and Safety Regulations of the trade associations for electrical
systems and equipment
DIN 1961 VOB/B
Regulations on contract awards for public works – Part B: General terms of contract
for the execution of construction works
DIN 4102-9
Fire behaviour of building materials and elements seals for cable penetrations;
concepts, requirements and testing
DIN 17850
Titanium; chemical composition
DIN 19704-3
Steel hydraulic structures; electrical equipment
DIN 43781
Measurement, control, regulation; electrical measuring equipment; Direct acting
recording electrical measuring instruments and their accessories
DIN EN 10025
Hot rolled products of structural steels; Part 2: Technical delivery conditions for
unalloyed structural steels
DIN EN 10204
Metallic products - Types of inspection documents
DIN EN 12438
Magnesium and magnesium alloys - magnesium alloys for anode castings
DIN EN 12473
General principles of cathodic corrosion protection in sea water
DIN EN 50128
(VDE 0831-128)
Railway applications – Telecommunications technology, signal technology and
Data processing systems - Software for railway control and monitoring systems
DIN EN 50178 (VDE 0160)
Electronic equipment for use in power installations
DIN EN 60051
Direct acting indicating analogue electrical measuring instruments and their
accessories – Measuring devices with analogue display
DIN EN 60204 (VDE 0113)
Safety of machines - Electrical equipment of machines
DIN EN 60529 (VDE 0470)
Protection class as a result of housing (IP code)
DIN EN 61000-6-2
Electromagnetic compatibility (EMV) - Part 6-2: Basic Standards - Immunity for
industrial environments
DIN EN 61000-6-3
Electromagnetic compatibility (EMV) - Part 6-3: Basic Standards – Electromagnetic
interference for residential, commercial and light industry areas
DIN EN 61082-1
(VDE 0040-1)
Electrical engineering documents – Part 1: Rules
DIN EN 62305 (VDE 0185)
Lightning protection
DIN EN 62491
(VDE 0040-4)
Industrial systems, installations and equipment and industrial products–
labelling cables/conductors and cores
DIN VDE 0100
Construction of low-voltage systems
DIN VDE 0100-100
Construction of low-voltage systems - Part 1: General principles, provisions general
characteristics, terms
DIN VDE 0100-410
Construction of low-voltage systems - Part 4-41: Precautionary measures –
Protection against electrical shock
DVGW GW 10
Cathodic corrosion protection (KKS) of buried steel tanks and pipelines commissioning and monitoring
ZTV-W LB 220 2011 Edition
Page 13 of 16
DVGW GW 11
Qualification requirements for the certification by specialist firms of cathodic
protection
MIL-A-18001K
Military Specification Anodes, Sacrificial Zinc Alloy
MKKS
Fact sheet on cathodic corrosion protection in steel hydraulic engineering
VG 81257
Cathodic corrosion protection of ships - Galvanic anodes - Dimensions, measurements,
parameters and materials
VG 81259-3
Cathodic corrosion protection of ships; External protection by impressed current,
anodes, shields, electrodes, instrumentation
ZTV-W LB 202
Additional technical terms of contract – hydraulic engineering (ZTV-W) for technical
processing (performance category 202)
Zugelassene Systeme
List of approved systems; www.baw.de
Additional literature:
DIN EN 12473
General principles of cathodic corrosion protection in sea water
DIN EN 12495
Cathodic corrosion protection of fixed offshore steel installations
DIN EN 12954
Cathodic corrosion protection of metal installations in soil and water
Sources:
DIN standards, VG standards, VDE regulations:
Beuth Verlag GmbH,
Burggrafenstraße 6, 10787 Berlin
DVGW worksheets:
Deutsche Vereinigung des Gas-und Wasserfaches e.V.
Josef-Wirmer-Str. 1-3, 53123 Bonn
MKKS:
Bundesanstalt für Wasserbau
Bibliothek
Postfach 210253
76152 Karlsruhe
ZTV-W LB 220 2011 Edition
Page 14 of 16
Appendix 2: Index
A
Equipment
Acceptance
Acknowledgement
Alarms
Anchor rails
Anode alloy
Anode body
Anode current
Anode head
Anode head insulation
Anode holder
Anodes
- External current
- Galvanic
- Magnetite
Auxiliary circuits
(125)(135)(136)
(96)
(23)
(36)
(11)
(10)
(23)
(18)
(19)
(9)(11)
(7)(11)(17)(63)(117)
(15)(114)
(8)(13)
(15)(17)
External voltages
(28)(49)(53)(71)(74)(82)(83)
(87)(93)(94)(100)(102)(110)
(98)(109)
F
Firewall
Fuses
(138)
(94)
G
H
Hazard alarms
Hollow anodes
Housing made out of
insulating material
(96)
(17)
(73)
(32)(87)
I
B
Busbars
(84)(85)
C
Cable
- carriers
- channels
- core
- duct
- inlet
- protective tubes
- trays
- trenches
- wells
Cable ladders
Cathode cable
Circuit breaker
Commissioning
Conductor cores
Conductor inlets
Conductors
Contact resistance
Control device
Control measurements
Control transformer
Current transformers
(31)(81)(82)
(95)
(92)(101)
(47)
J
(36)(138)
(36)
(100)(106)
(38)
(75)
(36)
(36)
(36)
(36)
(36)
(58)
(29)(31)
(118)
(100)(106)
(75)
(35)(36)(37)(39)(74)(77)(88)
(101)(147)
(11)
(60)
(110)(119)
(27)(45)
(43)(110)
D
DC side
Display element
Incoming circuit breaker
Indicator lamp
Inscription labels
Interface
K
Key control switch
(30)
L
Labelling
Line voltage
(79)(102)(126)
(112)
M
Magnetite
Main earth bar
Main power supplies
Mains connection
Measurement display
Measurement
electrodes
Minimum cross-section
Mixed oxide
Mounting hardware
(15)(17)
(67)
(41)
(25)
(43)
(60)(62)(121)
(88)
(15)
(17)(49)(50)
N
(70)
(94)
Niobium
(15)(16)
O
E
Electrodes
Electrolyte solution
ZTV-W LB 220 2011 Edition
(61)(121)
(16)(19)
Open circuit voltage
Overvoltage
Overvoltage protection
device
(70)
(69)
(21)
Page 15 of 16
P
Partitions
Plate thickness
Platinum
Position indicator
Potential
Potential equalization
Power cables
Power requirement > 3 kW
Power supplies
Protection circuit
Protection potential
Protective measures
(25)(67)(73)(74)(81)(83)
(84)(85)(87)(91)(93)(106)
(48)
(15)
(29)
(23)(46)(60)(61)(62)(120)(121)
(72)(141)
(34)(106)
(26)
(25)
(59)
(23)(119)
(70)(72)
Spiral anode
Steel frame
Sub-distribution
Substructures
Support rails
Surface distributions
Switchgear
Switchgear cabinets
System software
(17)
(103)
(82)
(104)
(86)(105)
(105)
(67)(81)(82)(84)
(25)(48)(74)(76)(81)(83)
(87)(91)(93)(100)(103)(106)
(55)(116)(143)
T
Terminal blocks
Test switch
(82)(86)(97)(98)(106)(108)
(109)
(95)
Q
U
R
V
Rectifier drive voltage
Rectifier units
Reference electrodes
Remaining voltage
Resting potentials
(16)
(21)(23)(26)(60)
(121)
(20)(70)
(8)(121)
S
Screw connections
Screw joints
Signal circuits
Signal voltage
Spacer plates
Spark gaps
Special power circuit
ZTV-W LB 220 2011 Edition
(75)
(12)
(47)
(113)
(108)(109)
(72)
(90)(98)
Voltage ranges
Voltmeter
(113)
(41)
W
Wiring
Wiring cores
Wiring ducts
(87)(90)
(100)
(87)
Y
Z
Zinc measuring
electrodes
(24)
Page 16 of 16