Storage Procedures

Storage batteries which are not in use will lose their strength
gradually (the rate of discharge depends upon the temperature) when left
on the shelf or stored in machines for an extended period of time, The
higher the temperatures, the greater the loss of energy. To keep them
up to strength and ready to use, recharge any batteries in storage when
their specific gravity drops to 1.240. A fully charged battery will
show a hydrometer reading of 1. 270-1. 280.

OK OK KO
EXPANDED METAL COVERS AND WALKWAYS

The use of expanded metal for the protection of operating per-
sonnel and the general public has been illustrated in the bulletin before,
but the more general use of the
material for safety has added
advantages,

The pleasing appearance as
well as the safety provided is well
illustrated in the photograph of the
protective cover on the distribu-
tion box in the suburban areas of
the Salt River Project, Arizona.

The operating walkway on
the structures shown below, pro-
vided by the Salt River Valley Water
Users' Association, are also pleas-
ing in appearance as well as functional,
and well suited to the populated Phoenix Area,



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11



A similar commercial dispenser is also distributed in the area.

Jaeco Hydrator

The Jaeco Hydrator has no moving parts. Jets of water from
nozzles on the manifold are directed into the hopper hydraulically erod-
ing the dry gypsum, which is returned with the water to the irrigation
stream. In the
installation of
this type of de-
vice as shown at
the left, a sump
pump is neces-
sary to pump the
treated water
into the stand-
pipe. When in-
stalled in a man-
ner similar to
that shown for
the Exeter model,
no power source
is required.

The unit
will operate
with as little
as one and one-
half pounds of
water pressure.
Delivery rates
of from 50 to 500 pounds of gypsum per hour can be obtained by changing
the size of the nozzle orifices. The hydrator is available in 1-, 2-,
and 3-ton capacities at a cost of about $140, $160, and $180, re-
spectively.

While the above machines vary somewhat in ability to handle
damp or lumpy gypsum, all work most satisfactorily with a finely proc-
essed material. Gypsum of a fineness that 85 percent will pass through a
100 mesh screen is widely used.

Since gypsum readily absorbs moisture from the atmosphere, and
tends to cake, the hoppers should be fitted with a tight top cover. Fair
weather application is generally a rule followed by the irrigators.

The above devices can be used to apply fertilizer or other
water soluble chemicals, With minor modifications they can be utilized
to continuously introduce copper sulfate into open ditch systems for
control of submerged aquatic weeds. Additional information regarding
the dispensers may be obtained by writing the Fresno Operations Field
Branch, U. S. Bureau of Reclamation, Fresno, California.

OR OK OK OK

21



Installations With and Without a Power Source

Direct current power for cathodic protection is supplied by a rec-
tifier, where alternating current is readily available. Where electric
power is not convenient to the structure, galvanic or sacrificial anodes can
be used. Magnesium or zinc are two types of anodes commonly used with-
out an external source of power. The magnesium or zinc anode and the
submerged steel surface to be protected constitute a galvanic cell. Since
the magnesium or zinc has a higher solution potential than the submerged
steel surface, a driving force of approximately one volt is obtained from
this combination and the necessary cathodic protection current flows through
the circuit. As this current flows, the anode gradually dissolves at a rate
proportional to the amount of current. A resistor is used when required to
regulate the current.

Cathodic Protection Supplements Surface Coatings

In most cases it is desirable to use cathodic protection supple-
mental to regular surface coatings both to increase the time between re-
coatings and to minimize the cost of cathodic protection. As a coating
begins to fail, the area requiring protection increases. Experience has
shown, however, that a current of approximately one milliampere per
square foot of submerged area to be protected is adequate. Experience
also has shown that for best results, the object being protected must be
grounded; i.e., connected to the negative pole of the rectifier.

Type of Anodes

The Bureau of Recla-
mation experimented with scrap
iron anodes which were satis-
factory except for their rapid
and irregular dissipation re-
quiring frequent replacement
and allowing chunks of metal to
fall into the desilting basins
plugging the underflow valves.
At the time the Imperial Irri-
gation District assumed respon-
sibility for care, operation and
maintenance of the All-American
trashrack, headworks and de-
silting basins in 1952, the Bu-
reau was experimenting with
graphite anodes, such as that
shown at left. These anodes
are available commercially,
and in 1953 were costing about
$16.00 for a 3-inch diameter
by 60-inch long anode, weigh-
ing 28 or 29 pounds. The
graphite anodes were a defi-
nite improvement over the



SAFETY LATCH FOR POWER TAKE-OFF LEVER
(Suggestion R2-58-99)

When the power take-off
lever on a 1}-ton truck was acci-
dentally tripped, damaging the
winch, Mr. Jacob Gobel, head-
quartered at Oak View, California,
on the Ventura Project in Region
2, suggested the simple device
shown in the photograph at left,
to prevent a similar accident in
the future,

The very ordinary
hinge, slotted to closely fit the
power take-off lever at floor
level, can be quickly fastened
in place.

Apparently the Ventura
Project experience is only one
of several similar accidents.
Others also were interested inthe
idea. Not only did the sugges-
tion bring an award from the
Bureau of Reclamation, Sug-
gestion Awards Program, but
one of the McGraw-Hill Pub-
lications sent Mr. Gobel a
check for a photograph and a
description of the device.

kk OR OK OR

AUTOMATIC DISPENSERS OF GYPSUM AND CHEMICALS

Continued irrigation of agricultural land with water having a
low soluble salt content tends to leach out electrolytes necessary for
desirable soil tilth and causes the soil to "puddle." Puddled soils tend
to pack readily, become relatively impervious to water, and are not well
aerated. In such a condition, water, air and root penetration into the
soil is diminished and most crops will not do well. The condition can be
prevented or improved by the addition of certain electrolytes to the soil.

Gypsum has proved to be the most practical soil conditioner for
agricultural use and may be applied in irrigation water or broadcast over
an area and disked into the soil. Most growers in the Southern San Joa-
quin Valley of California prefer to apply gypsum with their irrigation
water; using one of several devices available on the market for metering
dry, water-soluble, chemicals into open ditch or pipe line systems. The

18


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a capacity of 1,000 pounds. The commercially available machine sells

for approximately $500.

Water Powered Exeter Model

Growers in the Exeter Irrigation District, who wish to build
their own dispenser, can obtain particulars for the device shown on this
page from the Exeter Irrigation District, Exeter, California.

The homemade
device as shown has a
capacity for holding
700 pounds of gypsum,
and the machine uses
water bypassed through
the unit to operate a
simple mechanism to
meter gypsum from the
hopper.

Water entering
the unit alternately
fills two bucket like
containers mounted on
a shaft; turning the
shaft back and forth
to move a metering bar
at the bottom opening
of the hopper from one
side to the other. The
lower photograph at
left, shows the arrang-
ment of the two buckets
which power the shaft
and the water inlet
located above the buck-
ets. The hopper which
contains the dry gyp-
sum is located in the
upper left corner.

When the de-
vice is installed ina
pipe line system as
shown in the upper pho-
tograph, no other source
of power is required.
The rate of delivery
of the chemical can be
regulated by adjusting
the amount of water
entering the unit.


TIPS ON BATTERY CARE

(Reprinted from the December 1958 issue of
Western Construction. Copyright 1958, King
Publications, 609 Mission St., San Francisco
5, California; further reproduction prohibited. )

Robert H. Hawkins, Manager, Central Division, Service Depart-
ment, Caterpillar Tractor Company, in writing the 'Master Mechanic" sec-
tion of the December 1958 issue of Western Construction states that ma-
chine owners have come to expect convenience and dependability when start-
ing diesel engines in all weather, regardless of temperature extremes.
Some machines come equipped with gasoline starting engines, while others
depend on cranking the diesel with electric starting motors, Even gaso-
line starting engines often have their own direct electric starting sys-
tems. In fact, most electric starting systems are dependent on one source
of power--the storage battery.

A storage battery has a limited capacity (the quantity of elec-
tricity which can be taken from it in a given period of time) just as a
water storage tank can maintain a flow of so many gallons per minute for
only a certain number of minutes. The capacity of a battery (sometimes
called its electrical size) is usually listed in "ampere-hours." This
term is used to specify the amount of current a battery will deliver con-
tinuously for a definite number of hours or minutes. Capacity depends
on how well the battery is constructed, its age, the size of the plates,
and how many plates are assembled in each cell.

Why do storage batteries run down? Frequently the problem is
the same as with any storage system: If more is taken out than is put
back in, the reservoir for storage ultimately becomes empty. Added elec-
trical load, such as lights, heaters, two-way radios, sometimes impose
more drain on the system than can be replaced by the generator. There
are other reasons. The first is age. After many hours use, the storage
capacity is reduced. A second reason may be internal faults which con-
tinually drain off the electrical supply. Finally, improper maintenance
and operation make a battery "age" quickly.

Any battery requires some attention for continued satisfactory
service. Here are a few necessary rules for its care:

Periodic Check of Electrolyte or Water Level

A most important step in extending battery life is a periodic
check of the electrolyte or water level. Nearly all storage batteries
have a reserve space for water in the top above the plates, and most
battery manufacturers recommend that water be added until it is 3/8-inch
above the plates. Be careful not to overfill the battery because this
allows the electrolyte to splash out and corrode all metal it contacts.
Continued overfilling will result in so much loss of acid that the elec-
trolyte may no longer be strong enough for the battery to deliver the

15



lead primer and aluminum coating was in fair condition on the front of
the gates, but the ends and downstream portions were seriously cor-
roded. This was especially true of areas near the water surface sub-
jected to water spray from turbulence, The District sandblasted the
submerged portions and corroded areas of each gate and applied an
acid-cured zine, in inorganic vehicle, coating. The above water por-
tion of the gates was wire brushed and spotted with vinyl resin primer
followed by vinyl resin aluminum paint.

The use of cathodic protection for the upstream side of the
numerous radial gates on the All-American Canal is usually simplified
because the water surface elevations at the gates are constant and ap-
proach velocities are usually low. A typical installation at a check
is shown in the photograph on the following page in which the anodes are
centered in the middle of the gate bay and suspended a few feet up-
stream from the deck of the structure.

The downstream side of the radial gates is more of a problem.
The portion of the gate submerged by backwater is protected by the
normal installation except that the anodes may have to be placed far
enough downstream to avoid excessively turbulent water. Such an in-
stallation is shown in the photograph on page 4. To balance the current
between the front and rear of the gates, it is necessary to use resist-
ance in the leads to the anode lines.


Experience at Desilting Works

The coating on the desilting basin clarifiers is a coal-tar enamel.
The machines were exposed to the weather for about three years before
the Bureau of Reclamation began experimentation with cathodic protection.
At the time the Imperial Irrigation District assumed responsibility for
operation and maintenance of the facility, the coal-tar coating was in fair
condition, with fair bond to the steel, Extensive cracks were noted, but
no excessive corrosion.

Numerous failures had occurred in the underground sludge lines,
water lines, and metal conduits of the desilting basins. After the protective
system was expanded to include anodes buried in the basin floors, there
have been no additional failures in the underground piping for the past two
years.

The graphite anode dissipates evenly, tapering to a point at its
lower extremity; however, its useful life terminates at about 8 or 9 pounds
when it becomes quite thin and fragile. Thus, the graphite anode has an
effective weight of 20 pounds, and if efficiently employed should last from
three to seven years.

In 1955, a high-silicon, cast-iron, anode was marketed. These
were tried experimentally and
found to have a very low rate of
dissipation. One of the anodes of
this type is shown with an adjustable
chain suspension in the photograph
at left. These anodes are 2 inches
in diameter, 60 inches long, and
weigh about 48 pounds. Their cost
is about $19.00 per anode. For
comparison with the graphite
anode mentioned above; while the
graphite anode was dissipating at
the rate of 2.73 pounds per year,
an experimental high-silicon,
cast-iron, anode in the same half-
basin, lost only 0.75 pound. Be-
cause of their greater mechanical
strength and promised longer life,
the District is changing to high-
silicon, cast-iron anodes as re-
placement becomes necessary.

The desilting works for
the All-American Canal are com-
posed of three large basins, each
being divided in half by an in-
fluent channel. The 72 clarifiers
have a total submerged steel surface area estimated at nearly 200,000



scrap iron anodes, and the District converted to graphite as rapidly as
possible at Imperial Dam.

Location of Anodes

Experience has shown that to protect a given structure or group
of structures; e. g., one side of a desilting basin having 12 clarifiers
and considerable underground conduit and piping, that it was more effi-
cient to use additional anodes spacing them opposite the clarifiers rather
than equidistant from each other, Using 12 equally spaced anodes in one
half of a desilting basin, and an impressed current of 29 amperes, or
2.42 amperes per anode, certain anodes were weighed periodically,
for one twelve-month period. The rate of dissipation was 6.15 pounds
per year for a total of 73, 8 pounds for the half-basin, During another
twelve-month period using 20 anodes, including 13 suspended opposite
the clarifiers and 7 anodes buried in the sand floor, and an impressed
current of 26 amperes, 0.30 amperes per anode, the rate of dissipation
for a twelve-month period dropped to 2.73 pounds per anode for a total
of 54.6 pounds. Thus a 26 percent reduction in rate of anode dissipa-
tion was effected while providing more efficient protection to approxi-
mately 35,000 square feet of submerged and buried metal surface in
this half-basin. Suspension of the anodes in South half-basin No. 3

of the All-American Desilting Basin is shown in the left photograph
above. The rotary scrapers in South half-basin No, 2 in the right photo-
graph,



required energy to crank the engine. If the battery requires water more
often than once every two weeks, the charging rate is too high.

Keep Battery Clean

Wash the battery occasionally with a "baking soda" solution
(one pound of soda to one gallon of water) to neutralize the acid which
is present on the case, and then rinse it with a stream of cold water.
Cleanliness also includes the terminals. Wire brush them until corrosion
is removed and then coat them with petroleum jelly.

Keep Battery Charged

Maintain the battery in a normal state of charge--the specific
gravity should be above 1. 225--by keeping the generator output and volt-
age regulator in proper adjustment.

Never let a battery remain in a discharged condition for an ex-
tended period of time. The discharge action of a battery sulphates the
plates, but this can be driven off if the battery is charged soon after
discharge. However, if the battery is allowed to remain too long in a
discharged condition, the sulphate becomes hard and is very difficult,
if not impossible, to drive off the plates during charging.

Batteries have much longer service life if they are kept at or
very near full charge at all times. In normal operation of equipment,
some discharging and charging of the battery takes place continuously,
but the battery is not discharged to a great extent at any time. How-
ever, cycling a battery (regularly discharging it almost completely and
then recharging it) will seriously affect its service life.

Prevent Freezing

In cold weather, never add water at the end of a day's run.
Instead, add water in the morning just before starting or right after
starting. In this manner, the water will be thoroughly mixed with the
acid by the end of the day's run and freezing of the electrolyte will
be prevented.

Allow Rest

Never use the electric starter more than 30 seconds at a time
and then allow approximately 2 minutes between cranking cycles. The
brief "rest period" allows the battery plates to cool and allows the bat-
tery to recuperate sufficiently to again deliver a surge of power.

After emergency use or accidental energy loss, such as leaving
the lights on overnight, it might be necessary to “quick charge" the bat-
tery. No particular fault can be found with "quick charging" or "hot
charging" methods providing the manufacturers instructions are closely
followed.

16


In the installation of a pro-
tective system for a structure, the
main criterion is the placing of the
anodes to give an even distribution
of current, as evidenced by half-
cell voltages; however, existing
conditions for a given structure,
such as velocity of water flow, ac-
cess for maintenance, and struc-
tural design will require com-
promises.

The trashrack for the All-
American Canal headworks at Im-
perial Dam, as shown on the cover
of this issue of the bulletin, is an
example of a compromise. Here
anodes should be placed both in
front of and in the rear of the struc-
ture. The operation involved in
cleaning the trashrack prohibits
the use of anodes in front of the
rack; therefore, a compromise
was made by placing anodes only
in the rear of the rack, as shown
in the lower photograph, with
enough current applied to obtain a
fair protection of the front.

The original coal-tar enamel
coating on the trashrack and screens
is still in fair condition, although
the rack has been in service since
its completion in 1938.

The protective system for
the All-American Canal headgates,
as shown on the following page is a
typical installation for large gates.
Two anodes are suspended up- .
stream and downstream from each
of the four 75-foot wide gates.

The 3/8-inch messenger cable sup-
porting the anodes also serves as
the conductor for the rectified
current.

The Bureau has installed
only upstream anodes prior to the
District's assumption of responsi-
bility in 1952. The original red


OUTBOARD GEAR GREASE AS PUMP LUBRICANT

The Fort Sumner Irrigation District, which operates the Fort
Sumner Project in New Mexico, reports that some of their problems in the
operation of a hydraulic turbine-driven pumping plant have been allevi-
ated by the use of outboard gear grease. The grease is being used to
lubricate bearings which operate under water and, according to the water
users, has improved bearing life and thus, the service of the facility.

The Fort Sumner Project was completed early in 1951 and the
pumping plant with other projects works was turned over to the Fort
Sumner Irrigation District for operation and maintenance. The irrigation
water supplied this project direct from a diversion on the Pecos River
carries considerable silt and sand. Some of this material found its
way into the pump bearings causing undue wear and also caused the tur-
bine wicket gates control mechanism to freeze. Bearing troubles devel-
oped in the pump almost immediately after the plant had been placed in
service and continued for several seasons, Extensive overhaul was
required at the end of each irrigation season and the plant had to be shut
down for repairs during one or two irrigation seasons. The trouble
appeared to be primarily one of the water carrying granular material into
the bearings, but inadequate lubrication also was a contributing factor
in the difficulties encountered.

The equipment, as shown in the drawing on page 24, was orig-
inally installed with all bearings lubricated by drip cups using a light oil.
Consideration was first given to a more positive method of lubrication
with the light oil, hence, an electrically operated force-feed oiler was
installed. The change improved pump service, but did not solve the bear-
ing problem. Accordingly, during an overhaul of the pump following the
1955 irrigation season, the pump was modified by the Fort Sumner Irri-
gation District and use of outboard gear grease, as a lubricant, was
initiated.

During modification, the pump shafts were built-up and then
machined to fit the bearings and two new lubrication lines were added.
One line provided for the lubrication of the main bearing flange bushing
at the bottom of the main turbine bearing which was not previously lubri-
cated, and where excessive wear on the turbine shaft had occurred. The
second lubrication line extended to the gate ring which adjusts the tur-
bine wicket gates. Here, a channel was cut around the ring to receive
the grease and provide for lubrication of the ring which has always frozen
during the latter part of the season making gate adjustments impossible,

The equipment is lubricated regularly twice a day at twelve
hour intervals. A small quantity of the outboard gear grease works out
the ends of the bearings and forms a small ridge of grease which with-
stands the erosion of the flowing water. With the bearings sealed, sand
and silt is prevented from entering. The gate adjustment mechanism
has also remained free, since lubrication was supplied to the gate ring.

22


AST top

OPERATION

LAST COPY - BO NOT REMOVE

od > Department of the Interior
~ Hil AID
ba NOT RE of Reclamation

D MAINTENANCE

EQUIPMENT AND PROCEDURES

RELEASE NO. 28

April, May and June 1959

CONTENTS

Cathodic Protection of Submerged Metalwork
Pickup Mounted Boom and Hoist

Safety Conference Highlights-Region 1

Tips on Battery Care

Expanded Metal Covers and Walkways

Safety Latch for Power Take-off Lever

Automatic Dispensers of Gypsum and Chemicals
Outboard Gear Grease as Pump Lubricant

Plastic Protectors for Tables and Charts

T COPY - BO NOT REMOVE

§


and turnout ar-
rangement of the
anodes is shown
in the upper
photograph. The
anodes of this
protective system
are magnesium,

The method
used in suspending
the anodes and more
detail of the sus-
pension device and
attachment of the
anodes to the mes-
senger cable are
shown in the photo-
graph at left.

Judging from the number of inquiries relative to cathodic pro-
tection received in Denver, this interesting presentation by L. R.
McGlocklin and C. H. Youngstrom, Superintendent of the River Division
and Senior Electrical Engineer, respectively, of the Imperial Irrigation
District of the use being made of cathodic protection will be followed
closely by many.
KOK Ok OK Ok

9


“Sdevegeyp aa RRS ese A:

The portion of the gate above
normal water surface is subject to
spray due to turbulent water and leak-
age. The only protection against cor-
rosion in this area is the proper appli-
cation of paint.

Application of cathodic pro-
tection to the New River Siphon was
complicated by the large size of the
structure. This siphon consists of
two steel barrels, one of which is
shown in the lower photograph. Each
barrel is 15'-6" in diameter with an
overall length of 476 feet and the water
velocity is about 7 fps. Two types of
anodes are used. The anode in the
west barrel, the one shown in the
photograph, is of magnesium and de-
pends on galvanic action between the
magnesium of the anode and the iron
of the barrel for cathodic protection.
The second, or east, barrel has a
steel rod anode and cathodic protec-
tion is provided by a rectifier.

Both anodes extend throughout
the length of the barrel and are sus-
pended in the center on a steel mes-
senger cable covered by a plastic
tube. Regulation of cathodic protec-
tion current in the magnesium anode
installation is provided by an ex-
ternal resistor. District experience
shows that the protection afforded the
siphon barrels by either the impressed
current system with iron anode or the
galvanic system with magnesium anode
is equal and sufficient. The fouling
of anode supports by floating trash has
not been serious.

Smaller structures on the All-
American Canal system are also be-
ing protected by cathodic methods. An
example of some of the smaller in-
stallations is the check and turnout
illustrated in the photographs on the
following page.

A general view of the check


square feet, yet the cost of maintaining the desilting basin cathodic pro-
tection system for the year 1958 was less than $2,000. The estimated
cost of sandblasting and coating this complicated machinery would be
approximately $300,000, making evident economy effected by cathodic
protection,

Evaluation of Protection Provided

The Bureau of Reclamation employed the use of coupons, or test
plates of clean steel, strategically located on the structures and avail-
able for ready observation of effectiveness of the cathodic protection
system. The District has also cleaned test areas to bare metal, on the
individual structures, for observation. It became evident, however, in
order to design or improve a cathodic protection system to assure ade-
quate corrosion control that more refined methods of evaluating the sys-
tem should be employed.

Data obtained from the American Gas Association, the National
Association of Corrosion Engineers, and other organizations, clearly
indicated the need of instruments to assure adequate protection. A
"Rhodes" Potentiometer Voltmeter, one copper sulphate and one lead chlo-
ride half-cell were purchased. The copper sulphate half-cell is the
most convenient since it can be prepared and cleaned in the field. The
lead chloride cell with a jellied solution was used where long periods of
immersion were required,

The method of determining whether a structure is receiving ade-
quate protection is to attach the half-cell to a pole, and with leads con-
nected to the instrument, hold the cell 3 to 6 inches from the metal sur-
face about a foot below the water line. The rectified current is then
adjusted until the voltage of the copper sulphate half-cell is 0. 85-volts
positive to the steel surface. (A 0.70 -voltage between the copper sul-
phate half-cell and steel is considered as a minimum to assure protection. )

The lead chloride half-cell was useful where it was necessary
to leave the cell submerged for a long period. A 0. 2-volt difference of
the lead chloride half-cell to the steel surface was found to assure
protection.

Typical Installations

Many cathodic protection installations employ the dry dise or
plate type rectifier which converts the usual alternating current com-
mercial power to direct current. The rectifier unit usually contains a
transformer to reduce the input voltage to 20 volts or less, tap-changing
links or rheostats to adjust the voltage, and fuses or circuit breakers
to protect the equipment from overload. A voltmeter and an ammeter are
usually provided in order to assure proper operation. A rectifier unit
of a cathodic protection system at a check on the All-American Canal is
shown in the photograph at the top of the following page.


use of these devices has been described in an article prepared for the
bulletin by Glenn J. Berry, Irrigation Agriculturist, closely associated
with the work on the Central Valley Project, California, and following
the subject for the U. S. Bureau of Reclamation's Region 2, Sacramento,
California.

Each of the devices illustrated requires a small amount of
water circulating through the unit. Dry gypsum is metered from a hop-
per into this stream which is returned to the main irrigation flow.
Water for operation of the devices can be obtained by plumbing into a
pipe line system or by pumping from an open ditch,

The Deco Model

In the Delano and Bakersfield areas, where electricity is usu-
ally available nearby,
the Deco auger type
dispenser is widely
used. A typical in-
stallation is shown in
the upper photograph
at left.

A circular
plate, forming the
bottom of the hopper, is
revolved slowly bringing
the gypsum into contact
with an auger which
feeds the dry material
into a mixing basin
where it is mixed with
water and pumped back
into the irrigation
flow.

The lower
photograph shows the
mixing basin below the
motor and the location
of the notched revolving
bottom plate. The
auger extending into
the hopper is partially
enclosed and rate of
delivery can be con-
trolled by regulating
the size of the open-
ing of the auger box.
The gypsum can be
mixed at rates of from
25 to 800 pounds per
hour. The hopper has



CATHODIC PROTECTION OF SUBMERGED METALWORK
on the
All-American Canal System

Boulder Canyon Project

The protection of submerged metalwork against electrolytic dete-
rioration, or corrosion, is considered a major maintenance and economic
problem by the Imperial Irrigation District in its role of diverting and de-
livering Colorado River water via Imperial Dam and the All-American Ca-
nal, of the Boulder Canyon Project, for over half-a-million acres of the
Imperial and Coachella Valleys of Southern California,

Basically, the problem of corrosion or oxidation on a metal surface
submerged in water is an electro-chemical reaction in which the flow of an
electrical current from the metal to the water permits the pitting and rust-
ing of underwater steel. This phenomena can be reduced or eliminated by
stopping the flow of current.

Coating of the metal surface to insulate it from the water continues
to be the most widely accepted method of accomplishing the needed protec-
tion. The problems and costs involved in selecting correct coatings, sched-
uling work, preparing surface and applying coatings are well known to men
charged with the responsibility of protecting irrigation works.

Initial Installations

It was the inquisitiveness inherent in good maintenance men that
caused the Bureau of Reclamation to initiate in 1950, and the Imperial Ir-
rigation District to improve, a system of preservation known as cathodic
protection for submerged metalwork of the trashrack, headgates and de-
silting basin clarifiers for the All-American Canal at Imperial Dam. Cath-
odic protection is used generally at all checks, drops and turnouts on the
All-American Canal.

Corrosion and cathodic protection involve the electrochemical
principles of a primary battery, of which the common dry cell is an ex-
ample. In the cell, a direct current flows from the anode, which corrodes,
through the electrolyte to the cathode, which does not corrode. By making
the metal to be protected the cathode, of an electrolytic or galvanic cell
using an external anode, natural corrosion currents are neutralized, and
corrosion does not take place. This can be accomplished by impressing a
direct current between the external anode and the metal to be protected
with a rectifier or other direct-current source. Cathodic protection can
also be done by making the metal to be protected the cathode of a primary
battery by choosing the proper material for the external anode. Such
anodes are called galvanic or sacrificial anodes. When a submerged steel
surface is receiving cathodic protection, a protective film of hydrogen,
calcium carbonate, and other chemical forms on the surface of the metal,
and this film is being constantly renewed by keeping the metal surface
charged cathodically. An analysis of water being used for irrigation in the
system shows 163 parts per million of calcium carbonate, with a pH rang-
ing from 7. 2 to 8. 4.



SAFETY CONFERENCE HIGHLIGHTS
Region 1

On January 12 and 13, 1959, the Region 1 Safety Conference was
held in Boise, Idaho. Some 40 individuals participated in the conference --
safety engineers from all over the region, design and construction engi-
neers, Bureau attorneys, Bureau O&M people, and quite a number of
irrigation operators from water user operated projects. A number of
very excellent presentations were made and excerpts from some of these
will be of interest to operation and maintenance personnel.

Mr. W. Burpee, Field Solicitor, commented regarding the
handling of water:

". . . it is quite like handling dynamite --you

are not dealing with an ordinary substance. Any-
one who takes water out of its natural environ-
ment must recognize that he is dealing with a
dangerous substance. Certain decisions have been
given that he is responsible only if he is negli-
gent. . . The amount of care you take to be sure
that you are not incurring a liability, should be
done by any means to insure that you are hand-
ling the water safely."

Regional Engineer Don Walter in discussing the prevention of
accidents, stated:

"Cooperation in the prevention of accidents is
both a moral and personal obligation of each
employee. I like to consider that each employee
is a safety inspector, always exercising reason-
able precaution, promptly reporting unsafe work-
ing conditions and observing applicable safety
measures and procedures.

In view of the high frequency rate of accidents among Bureau
O&M people (their record is the poorest in the Bureau), the explanation
of why this might be true by the region's Chief of Irrigation Operation,
Mr. Ted Nelson, will be of interest. Mr. Nelson remarked that:

"Records reveal that 32 percent of all accidents

take place on the farm. . . Irrigation O&M work
in many ways is similar to farm work. . . many
of the (O&M) workers come from the local farms.

"There are many other reasons why it is difficult for
O&M employees to work safely. One is that he has

12


Ennis also stated:

", . . Unless we have the good will of the majority
of the people in our communities, we are going to
have a tough time selling safety.

"Our field irrigation personnel have been very help-
ful in not only promoting safety, but in creating
good will. We have tried to get the youngsters to
swim elsewhere, other than our canals, especially
if their chosen swimming hole happens to be near a
drop or the head of a siphon. We haven't tried that
by a 'get tough' policy. Rather, our ditchriders
and others get out of their cars and explain to the
kids why they shouldn't be swimming or fishing where
they are. This seems to be paying off. When we
find the occasional exception, we try to see his
parents--tell them the dangers--the whys-- and
usually we get cooperation.

"Don't be afraid to toot your horn a little. Radio
--the press--TV--(the people responsible for these
publicity mediums) are always willing to givé safety
coverage. Of course they want something that catches
the eye--that appeals to the public. For instance,

+ . . a husky young farmer fell into a check drop and
really got churned up in the stilling pool. Just

about didn't get out. Made a good story; first, he

was a husky man; second, he was an experienced irri-
gator; third, he was a responsible member of the com-
munity. .; and, fourth, he readily admitted that he
nearly drowned. “The angle we played up was this--

if this type of man can accidentally fall into a
lateral--nearly drowns--then what would happen if a
youngster fell in."

Harold T. Nelson, Regional Director, Region 1, in welcoming
those in attendance at the conference called attention to the fact that
it was the first such conference held in Region 1. He also stressed
that the conference was to provide an interchange of ideas from the
field men present and that from this should come a coordinated plan for
dealing with the variety of problems encountered.

All agreed that the conference was productive and thought pro-
voking, that we must think "safety," preach "safety," practice "safety,"
and as Mr. Nelson stated in summing up the accomplishments of the con-
ference:

"A well developed and coordinated (safety) program
will save us money. . ."

* OR OK KOK

14


OPERATION AND MAINTENANCE

EQUIPMENT AND PROCEDURES

Release No, 28
April, May and June - 1959
INTRODUCTION

We are indebted to Mr. G. E. Tank, General Manager, Impe-
rial Irrigation District, Imperial, California, and to two of his opera-
tions men, L. R. McGlocklin, Superintendent, River Division, and
C. H. Youngstrom, Senior Electrical Engineer, who have prepared the
excellent article included in this issue of the bulletin describing the use
of cathodic protection of submerged metalwork on the All-American
Canal System, Boulder Canyon Project, California. The protection of
submerged metalwork is of major concern on all projects, but more
particularly in the corrosive water used in the irrigation of the Imperial
and Coachella Valleys of Southern California, and other areas in the
Southwest.

This bulletin, published quarterly, is circulated for the bene-
fit of irrigation project operation and maintenance people. Its prin-
cipal purpose is to serve as a medium of exchanging operation and
maintenance information. Reference to a trade name does not consti-
tute the endorsement of a particular product, and omission of any
commercially available item does not imply discrimination against
any manufacturer. It is hoped that the labor-saving devices or less
costly equipment developed by the resourceful water users will be a
step toward commercial development of equipment for use on irri-
gation projects in a continued effort to reduce costs and increase op-
erating efficiency.

To assure proper recognition to those individuals whose
suggestions are published in this and subsequent bulletins, the sug-
gestion number as well as the person's name is being given. All
Bureau offices are reminded to notify their Suggestions Awards Com-
mittee when a suggestion is adopted.

KOK OK KOK

Division of Irrigation Operations
Commissioner's Office
Denver, Colorado



The plant has now operated three seasons and is beginning the
fourth without excessive bearing wear. The equipment has been inspected
at the end of each irrigation season and only minor adjustments have
been necessary. If further details are desired on the modification and
use of the outboard gear grease, write the Regional Director, U. S.
Bureau of Reclamation, Amarillo, Texas.

OR kk *

PLASTIC PROTECTORS FOR TABLES AND CHARTS
(Suggestion R2-58-188)

Especially helpful to ditchriders, hydrographers, and others,
who must frequently refer to rating tables, charts, and other documents
in the field, -are plastic protectors for these documents. Mr. Jesse F.
Esque, Fresno Operations Field Branch, Central Valley Project, Califor-
nia, reminds us that the protectors are available in clear plastic, visible
from both sides, and obtainable from the General Services Administration
as follows:

Catalog No. 7530-286-1407. . . 11"x 83" (punched for
3-ring binder) $0.06 ea.

Catalog No. 7530-286-1410. . . 8" x 103", $0.08 ea.

OR OK Ok O&

23



All-American Canal Trashrack at Imperial Dam
is protected cathodically by anodes shown
attached to downstream side of structure.
Photo No, 212-A-9673.


PICKUP MOUNTED BOOM AND HOIST
(Suggestion R-5-APO-58-8)

The small boom equipped with a 3/4-ton chain hoist, shown here,
mounted on the rear of a pickup truck, was an idea of John W. James, Jr.,
Maintenance Equipment Opera-
tor, of the San Marcial Field
Branch of the Middle Rio
Grande Project, New Mexico.
The boom has been very effi-
cient in handling parts as-
semblies that weigh in excess
of 1, 200 pounds.

Although designed and
built for handling large pieces
of equipment, it has been most
useful in loading and unloading
with fewer men, heavy items
of steel, lumber, chemicals,
etc.

The boom was construc-
ted of 14-inch pipe and 14-inch
steel stock tapered to fit into
the pipe. The boom is held
in position for operation by
one-half inch cable attached to

a pipe standard fitted into the stake welds in the sides of the bed. The
boom can be quickly assembled and dismantled at the site of the work and
can be fastened to the sides of the truck bed for transportation from one
job to another. Details of construction are shown in the drawing on the
facing page.

kK OR KOK

10


to be a jack-of-all trades. Let us follow the
working foreman of a small repair crew through

the process of installing a small concrete struc-
ture in a lateral. First he has to load his truck

so that he can have tools, equipment and material.
Sometimes (he must drive) through difficult high-
way traffic to the job and it is not unusual that
behind the truck he is trailing a concrete mixer.
When he gets to the work site, the truck has to be
unloaded so he can haul water and aggregate. Forms
have to be built and the mixer set up. As work pro-
gresses, concrete is placed, forms are removed, the
structure backfilled, props replaced and metalwork
secured to the concrete and painted. In the process
this small crew has in addition to using numerous
hand tools, used the truck they rode to work in, a
dragline or 'cat' to excavate and backfill the
structure, the concrete mixer, water pump and pos-
sibly an air compressor. Following the completion
of the job this same crew may be called upon to as-
sist in the repair of a leak or break in a lateral,
burn weeds, 'puddle-in' a washed out structure, and
perform many other duties."

The truth of Mr. Nelson's remarks will be easily recognized by
operation and maintenance organizations; that the great variety of duties
irrigation O&M personnel are called upon to perform exposes them to a
great variety of hazards. This means a much greater effort must be ex-
erted in the safety training of O&M crews than would be necessary with
a crew following a more or less set routine from day to day, if we are
to better our safety record.

Mr. E. E. Ennis, Safety Engineer of the Columbia Basin Project
spoke on the safety of the public on an irrigation project:

", . . getting influential people--and others--
to go along with you (on matters of community
safety) isn't a matter of occasionally walking

in on some of them and giving them a sales pitch.
You have to be an active participant in various
community organizations and activities, the
majority of which are not primarily interested

in or connected with safety. By so doing you

can make your contacts--your friendships --upon
which to build your campaign of safety."

By assisting in the organization of the County Farm Safety
Council, Mr. Ennis has been invited to provide speakers on safety for
their meetings and through this organization's connections with the
county agent, that official has been able to secure radio and TV time
for the dispensing of safety information to the general public. Mr.

13