Professional Documents
Culture Documents
VESSEL: YZJ2007-776
Rev:
Issued By: AH
Date: 06/01/09
TEL: +44 (0)1246 246700. FAX: +44 (0) 1246 246701. E-MAIL: technical@cathelco.com
C-SHIELD
MARINE IMPRESSED CURRENT
CATHODIC PROTECTION SYSTEM
NOTES:
a) Do not attempt to service or readjust the system operating levels without first reading
and understanding this manual.
b) The system operates at low d.c. voltage levels and may be severely damaged by high
voltage test equipment such as 500V Megger. Read the relevant section in this manual before
carrying out any tests.
c) Should any information be required which is not covered by this manual, please contact
Cathelco immediately. (Address on cover)
C-SHIELD MANUAL INDEX:
1.0 Introduction.
ELLIPTICAL
50-100A RECESSED ELLIPTICAL ANODE DETAILS DRG NO. C1202
50-125A RECESSED ELLIPTICAL ANODE ASSY (PLAIN OUTLET) DRG NO. C1186
6” COFFERDAM DETAILS M20 GLAND DRG NO. C1191/M20
50-125A DIELECTRIC SHIELD AREA DETAILS DRG NO. C1196
50-125A DIAGRAM RECESSED ELLIPTICAL ANODE ASSY. DRG NO. M1000
K6 JUNCTION BOX DRG NO. M1047
REMOTE MONITOR
TWO WAY DRG NO. M1238
TYPICAL WIRING DIAGRAM FOR TWO WAY MONITOR DRG NO. C1204
Section 0.1
Page 1 of 2
GENERAL INFORMATION DRAWINGS:-
SPARE PARTS LIST DRG NO. C1273
PORTABLE REFERENCE ELECTRODE DETAILS DRG NO. C1606
ELECTRICAL SPARE PARTS CH PANEL DRG NO. C1288/CH
SYSTEM LAYOUT
SYSTEM EQUIPMENT LAYOUT (FWD & AFT) DRG NO. C1849
Section 0.1
Page 2 of 2
1.0 INTRODUCTION:
Active or Anodic
Magnesium
Zinc
Mild Steel
Wrought Iron
Cast Iron
Ni-Resist
18.8.3 % Molybdenum SS, Type 316 (Active)
Lead
Tin
Manganese Bronze
Naval Brass
Aluminium Bronze
Copper
70 Copper 30 Nickel
Nickel (Passive)
Monel, 70% Nickel - 30 % Copper
18.8.3 % Molybdenum SS, Type 316 (Passive)
Noble or Cathodic
Note Some metals and alloys have two positions in the series, marked Active
and Passive; the active position is equivalent to the position if corrosion is
occurring and approaches the electro-chemical series position for the material.
The passive position relates to a non-corroding situation where the material is
protected by a self forming surface film. For example, type 316 stainless steel in
sea water is more likely to be passive than type 304 and is therefore generally
preferred for immersed marine applications.
Section 1
Page 1 of 3
If two metals are placed in an electrolyte (e.g. sea water or damp soil) and are in
direct electrical contact, a current will pass through the electrolyte from the
more active metal onto the least active metal. The least active metal does not
corrode and is termed the cathode. The more active metal, the anode, passes
into solution and the flow of electrical current increases. This is a metal ion and
electron transfer process i.e., it corrodes.
The Anodic and cathodic areas in a corrosion cell may be due to the electrical
contact of two dissimilar metals, termed galvanic corrosion. Anodic and
cathodic areas may be formed on a single metal surface as micro-cells for
instance by rain drops on uncoated steel. Alternatively, they may be close but
discrete cells found when accelerated corrosion occurs at uncoated Anodic areas
on a generally coated cathodic structure. In addition there are long line type
cells that occur on pipelines that pass through aggressive low resistivity soils.
These sections form Anodic areas and corrode in preference to cathodic areas in
less aggressive higher resistivity soils.
Large currents can occur at small Anodic areas and lead to rapid corrosion of
marine structures such as ship's internal tanks, external hull plates, sheet steel
piling in harbours and tubular structures common in jetties and petrochemical
drilling and production platforms.
Section 1
Page 2 of 3
As described above, a galvanic corrosion cell occurs when dissimilar metals are
in contact with each other within an electrolyte. Care should be taken in the
construction of structures that will be buried or immersed in an electrolyte to
ensure a galvanic cell is not created.
a) Steel or cast iron water boxes in contact with non ferrous (often copper
based) tube plates in condenser water boxes in ships or generating
plant. Rapid corrosion of the ferrous water box occurs close to the tube
plate.
The potential, or measure of activity, between the structure and the electrolyte is
a relatively easily measured indication of whether the structure is Anodic or
cathodic. For steel under normal non anaerobic conditions it can be shown
theoretically, and is accepted practically, that a steel/electrolyte potential more
negative than -0.85 volts measured against a standard copper/copper sulphate
electrode indicates that cathodic protection is achieved. This is equivalent to -
0.80 volts measured against silver / silver chloride electrode and + 0.24 volts
against a zinc electrode as indicated in figure 1.3.
Section 1
Page 3 of 3
2.0 GENERAL DESCRIPTIONS:
Section 2
Page 1 of 6
Generally, for a given current demand, less impressed current anodes than
sacrificial anodes are required for protection, as high anode currents are
feasible. Impressed current systems of cathodic protection are more
sophisticated in design than sacrificial systems.
The function of the anode is to conduct the d.c. protective current into the sea
water. C-Shield anodes have been designed to perform this function whilst
maintaining a low electrical resistance contact with the sea water. Standard
surface mounted anodes are available with from 50 to 300 Ampere ratings. For
forward mounted systems and for special applications 50 and 75 Ampere
recessed anodes are available.
Materials now used by C-Shield for Anodes have now gone beyond lead alloy
with specialist coated titanium based Anodes now available. All C-Shield anode
designs utilise a tough, chlorine resistant, but slightly flexible plastic carrier.
Section 2
Page 2 of 6
The use of a 24 volt system reduces the number and length of the anodes from
that required with a 12 volt system. The increased anode/sea water resistance
resulting from this decrease in anode size is overcome by the additional voltage.
Recommended cable sizes for various run lengths are tabulated in section 3.4.
The potential of the hull steel to the sea water is unaffected by this increase in
driving voltage, as the resistive effects are local to the anode and the hull/sea
potential is a function of the current flow, the sea water and the coating
condition, not the driving voltage.
The electrical connections to the active surface are made at the back of the
anode and are fully encapsulated and protected by the hull penetration.
Recessed anodes of essentially similar construction are provided for bow
section applications.
All hull penetrations are provided with substantial doubler plates and
cofferdams. The penetrations themselves are made watertight with heavy duty
packing glands, the cofferdams are fully sealed and provided with watertight
cable glands, all conforming to the requirements of Classification Societies.
The high purity, high stability, zinc reference electrodes are designed to give a
stable reference against which the hull/sea potentials can be measured and a
small current flow that is used in the closed loop circuit to maintain the pre-set
levels of protection.
The construction and the quantity of zinc employed within the electrodes are
such that a minimum life of fifteen years is available without maintenance or
replacement.
The minimum number of reference electrodes per power supply is one although
normally two will be fitted. Ideally, these should be located a minimum of 7.5
metres distant from the anodes. In the case of a stern only installation with the
anodes more than 150 metres from the bows, one reference electrode may be
located in the bows.
A novel feature of the C-Shield closed circuit is that additional reference cells
may be placed at areas that may be susceptible to over-protection such as
adjacent to the anode dielectric shields. These additional reference cells provide
a permanent check, thus preventing any coating damage due to over-protection
if conditions of operation change from those anticipated. This feature is offered
as an optional extra to the standard schemes.
All hull penetrations are provided with substantial cofferdams. The penetrations
themselves are made watertight with heavy duty packing glands. The
cofferdams are fully sealed and provided with watertight cable glands all
conforming to the requirements of the Classification Societies.
Section 2
Page 3 of 6
Section 2
Page 4 of 6
2.2.3 Power Supply Unit:
DISPLAY:
This allows the operator to control and monitor the running and set
parameters of the system. It comprises of a 2 line 16 character backlit LCD
display, 4 push button switches and an Alarm LED. This is mounted on the
door of the cabinet.
This board controls the operation of the system. It provides control signals
to the thyristor driver PCB, which allow control over the output current and
voltage of the system. This is mounted on the back of the cabinet door.
THYRISTOR PCB
This board monitors and conditions the signals supplied to the thyristor
unit.
Section 2
Page 5 of 6
2.2.4 Bonding
To allow protection of the bare propeller and any exposed shafting and to
prevent electrical arcing between shaft and bearings the propeller shaft is
fitted with a slipring assembly. A set of brushes provide the completion of a
low resistance path to allow current to flow to the propeller blades along
the shaft and back to the hull. The slipring is formed from a copper strip
clamped around the shaft with high copper content heavy current capacity
brushes held in geared brush holders. The C-Shield slipring track is silver
plated as standard and in addition silver graphite brushes are used to
minimise contact resistance.
Section 2
Page 6 of 6
3.0 INSTALLATION OF EQUIPMENT:
3.0.01 Description:
3.0.02 Locations for components are shown on the C-Shield drawings supplied for
the particular vessel, but are normally subject to final confirmation between
the C-Shield engineer on site and the yard/owner.
3.0.03 It is very important that the installation instructions given are followed. The
biggest cause of future problems found with the running of impressed
current systems is incorrect installation. Should any problems occur during
installation of this system or should any instruction appear unclear please
contact Cathelco for advice.
Section 3
Page 1 of 1
3.2 SURFACE MOUNTED LINEAR LOOP ANODES.
1) 250 Amp to 300 Amp output units to Drg no. M1074 with stud fixing
and di-electric shield areas shown on Drg. No. M1064.
2) 125 Amp to 200 Amp output units to Drg no. M1073 with stud fixing
and di-electric shield areas shown on Drg. No. M1076.
3) 50 Amp to 100 Amp output units to Drg no. M1072 with stud fixing and
di-electric shield areas shown on Drg. No. M1075.
3.2.1 For single anode cable type cut a 40mm diameter hole in the hull at each
anode location or for the double type cut a 100mm diameter hole to receive
either the single hull boss (Drg. C1177) or the double hull boss (Drg.
C1178).
3.2.2 Grind off any surplus metal to ensure that the hull boss will locate flat to the
internal shell plating at the inboard side of the hole and radius the external
edge of the hole.
3.2.3 Locate the hull boss centrally in the hole, inside the hull, in the case of the
double boss ensure that the centre line of the two threaded holes are
Vertical and weld it in place using continuous fillet welds both inside and
outside. Take care when welding externally to prevent weld spatter
damaging the thread.
3.2.4 Locate the cofferdam (single type Drg. C1191 or double type C1192)
centrally over the hull boss and position it such that the cable entry pipe(s)
is orientated to suit the installation. Secure it in place by a continuous fillet
weld internally and a full penetration weld externally to give a weld section
at least equal to the plating thickness.
3.2.5 Externally in way of the area to be covered by the anode clean off any weld
spatter from the surface, and grind flat all welds.
3.2.6 Using the stud fixing and di-electric shield area drawing as noted in 3.2.0
above. Weld a series of M10 x 1.5p x 37mm long studs directly to the hull
plate. Protect the stud threads with tape or rubber sleeves.
3.2.7 Before proceeding further, ensure that ALL other welding work, either
inboard or outboard has been completed for the entire area to be covered by
the di-electric shield. Any welding carried out after application of the di-
electric shield will damage the shield material even if the welding is not
associated with the cathodic protection system.
3.2.8 The dimensions of the di-electric shield are shown on the drawing as noted
in instruction 3.2.0
Section 3.2
Page 1 of 4
3.2.9 Inspect the area to be covered and grind off all weld spatter and surplus
weld material to a smooth profile.
3.2.10 Remove all oil and grease from the areas using clean, dry, oil free rags
soaked in a hydrocarbon solvent such as Xylol, Toluene or white spirit, do
not use petrol or paraffin. Change the rags frequently to avoid merely
spreading contamination.
3.2.11 Ensure that the mounting stud protecting sleeves are still in position and
plug the gland hole in the hull boss to protect the thread. Abrasive blast
clean the entire area to a white metal finish, SA2.5 Swedish standard SIS 05
59 00 using shot/grit that contains not less than 50% grit. Check the surface
profile height using test tape is within range to 50 to 75 micron.
3.2.13 Apply a coating of the epoxy mastic where the anode is to be sited, after
removing the gland hole plug but not the mounting stud protective sleeves.
Technical details and health protections for the anode mastic are available
on request from Cathelco.
Thoroughly mix the contents of each can before mixing the two parts
together. Follow the mixing instructions on the epoxy mastic material
packs, using a power driven mixer if possible and then apply by trowel.
3.2.14 Remove the mounting stud protective sleeves and degrease the studs.
3.2.15 Apply thread tape to one anode cable gland. Fit the gland to the inside of
the hull boss within the cofferdam recess and fully tighten the main body of
the gland, but fully slacken the compression ring. Two glands will be
required for the double hull boss.
3.2.16 Apply spare epoxy mastic ( as used for the di-electric shield ) around the
mounting studs forming a conical shape 25 mm high and 50 mm wide at the
base of the studs, working the compound well into the threads of the studs.
3.2.17 The anode must now be fitted onto the studs within one hour of the sealing
compound / mastic being applied.
3.2.18 Fit the M 10 threaded eye bolts into the two sockets provided on the outer
surface of the anode carrier, ensuring that they are inserted at least 15 mm.
3.2.19 Using the eye bolts hoist the anode to a position just in front of or above the
stud positions
3.2.20 Ensure that the cable sheath is not damaged at the back of the anode and
that the neoprene compression ring and slip washer are in the cable gland
previously fitted to the cofferdam assembly.
Section 3.2
Page 2 of 4
3.2.22 Fit the anode into position on the studs taking care to pass the free cable in
the cofferdam recess without it becoming trapped.
3.2.23 Inside the ship tighten the gland fully onto the cable.
3.2.24 Caulk around the mounting studs with the sealing compound so that the
recesses in the anode are filled up to the bearing surface for the washers and
nuts.
3.2.25 Fit the washers and nuts supplied and tighten the anode fixings evenly from
the centre. Tighten fixings to 4.8kg/metres (35ft lbs).
3.2.26 On completion of tightening the fixings, further caulk around the mounting
studs and the nuts and washers with the sealing compound, ensuring flow of
the compound into the compound previously applied below the nuts and
washers and entirely filling the recess in the anode carrier to present a
smooth, uniform surface.
3.2.27 Form the primary di-electric shield by applying the epoxy mastic within 4
hours of blasting and before the formation of any visible rust bloom. After
mixing the contents (instructions as previously mentioned) apply by trowel
to produce a film 4mm thick at the edge of the anode tapering to 1.0
minimum thickness at a distance of 850mm from the anode. A one coat
application is essential.
3.2.28 Inside the ship, remove the blank flange from the cofferdam and check the
cable for damage.
3.2.29 Pass the cable through the side entry hole in the cofferdam and apply thread
tape or sealing compound to the second anode cable gland, and pass the
gland over the anode cable to fit it into position outside the cofferdam in the
side entry hole. Note that two glands will be required for the double hull
exit cofferdam.
3.2.30 Tighten the main body fully into position, then tighten on to the cable
leaving 400mm of slack cable between inner and outer glands.
3.2.31 Fit a yard supply junction box at some convenient point adjacent to the
cofferdam and connect the anode cable to the power supply unit via
shipyard supplied cable (see power supply unit instructions).
3.2.32 Check the insulation of the anode connection circuit to the hull using a
500V earth insulation test meter. Note, if the anode is submerged then this
test will show a short circuit.
Disconnect from the power supply unit before this test, or permanent
damage may occur.
Section 3.2
Page 3 of 4
3.2.33 Refit the cover on the junction box.
3.2.34 Make a final visual check of all connections and finally fit the blind flange
and gasket to seal the cofferdam.
Section 3.2
Page 4 of 4
3.3 ELLIPTICAL RECESSED ANODE:
3.3.01 Select the required area and mark out using a template the steelwork
location. Make sure that the internal stiffening will not be touched.
Ensure the ellipse will be located within a steel plate and not
interfere with existing weld seams.
3.3.02 Cut an elliptical hole. The ellipse may be easily marked out by
positioning the anode on the hull and scribing around it and allowing
a margin of 6mm around the anode periphery. Alternatively, a
template may be made using the doubler plate. Refer to drg. C1186.
3.3.03 Clean the profile of the elliptical hole and grind a nominal 3mm
radius on the outer edge and a weld preparation on the inner edge to
match the one provided on the doubler plate
3.3.04 Position the doubler plate internally and line it up with the ellipse.
Tack weld the doubler plate in position. When you are sure that the
doubler plate is correctly located and that the anode will fit cleanly
into the recess continuously weld the doubler plate to the inboard and
outboard surface of the hull plating. Grind the recess weld flush as
shown.
3.3.05 Place the cofferdam concentrically over the cable gland hole in the
rear of the doubler plate. Position the cable exit tube from the
cofferdam to suit site conditions and weld internally and externally in
position with penetration welds with single bevel full penetration
weld complete with a backing run.
3.3.06 Cover the anode holding studs with plastic tubing to prevent damage
from shot blasting.
3.3.07 Shot blast the doubler plate and recess to SA 2 1/2 minimum
3.3.08 Fit a suitable cable gland into the doubler plate from the inboard side
inside the cofferdam recess.
3.3.09 Mix equal quantities of the 2 part epoxy filler material supplied.
Apply epoxy to back of anode and spread evenly.
3.3.10 Prepare an Anode for installation. The dimensions of the Anode are
shown by drg.C1202. Carefully insert the Anode Cable through the
centre hole in the doubler plate and through the cable gland taking
care not to damage the insulation. Locate the anode over the six
fixing points in the backing plate.
3.3.11 Slowly draw anode into recess by tightening the Anode fixing nuts.
The epoxy filler will slowly ooze out of the sides as anode settles
into position, ensure the Anode cable does not become trapped.
When anode is flush with hull and the bolts are resting within anode
fixing point recess ensure the head of the holding nut is below the top
level of the anode. Fill stud holes with epoxy and smooth level.
Section 3.3
Page 1 of 3
3.3.12 Smooth epoxy at edge of anode so that gap between anode and
steelwork is completely filled.
3.3.13 Inside the Ship fully tighten the gland onto the cable.
3.3.14 Before proceeding further, ensure that all other welding work, either
inboard or outboard, has been completed for the entire area to be
covered by the di-electric shield. Any welding carried out after the
application of the di-electric shield will damage the shield material
even if the welding is not associated with the cathodic protection
system.
3.3.15 The dimensions of the di-electric shield are shown on drg. C1196.
3.3.16 Inspect the area to be covered and grind off all weld splatter, and
surplus weld material to a smooth profile.
3.3.17 Remove all oil and grease from the area using clean, dry, oil free rags
soaked in a hydrocarbon solvent such as Xyol, Yoluene or white
spirit, do not use petrol or paraffin. Change the rags frequently to
avoid merely spreading contamination.
3.3.18 Ensure that the anode face is protected with masking tape or similar.
Abrasive blast clean the entire area to a white metal finish, SA 2 1/2
Swedish standard using grit or sand. Check the surface profile height
using test tape and that it is within the range 50 - 70 micron.
3.3.19 Form the primary di-electric shield by applying the anode epoxy
mastic within four hours of blasting and before the formation of any
visible rust bloom. Fill the four threaded temporary anode retaining
mounting holes with mastic. Technical details and health precautions
for the anode mastic are available on request from Cathelco.
3.3.20 Thoroughly mix the contents of each can before mixing the two parts
together. Follow the mixing instructions on the epoxy mastic
material packs, using a power driven mixer if possible.
3.3.21 Apply by trowel to produce a film 4mm thick at the edge of the
anode surface tapering to 1mm thick at the shield edge. Form a
circular shield of mastic of 900mm diameter. A one coat application is
essential.
3.3.22 Ensure that the di-electric shield mastic covers the resin of the anode
but do not allow mastic on the metal anode face. Allow the mastic to
harden fully before painting over. Remember to remove the
protective tape from the surface of the anode.
3.3.23 Inside the ship, remove the blank flange from the cofferdam and
check the cable for damage.
Section 3.3
Page 2 of 3
3.3.24 Apply thread tape to the second anode cable gland, make sure the
neoprene 'O' ring is fitted and pass the gland over the anode cable to
fit it into position as detailed below. Tighten the main body fully into
position, then tighten on to the cable.
3.3.25 Dry Compartment Installation. Pass the cable through the side entry
hole in the cofferdam and fit the cable gland in the same way as
before, to the outside of the cofferdam, leaving slack cable between
inner and outer glands.
3.3.26 Fit the junction box at some convenient point adjacent to the
cofferdam and connect the anode cable to the transformer/rectifier
via shipyard supply cable, see power supply unit instructions.
3.3.27 Wet Compartment Installation. Pass the shipyard cable through the
side entry hole into the cofferdam. Note that any cables running in
tanks should be in heavy wall conduit pipe. Fit the cable gland in the
same way as before, to the inside of the cofferdam side entry, over
the shipyard cable.
3.3.28 Connect the anode cable tail to the shipyard cable internally in the
cofferdam. Use a recognised splice kit or a C-Shield splice kit can be
provided. Refer to drg. M1043 for full instructions. Where cables
are spliced in a cofferdam it is recommended that the cofferdam be
filled with paraffin wax or similar. Connect the shipyard cable to the
power supply unit.
3.3.29 Check the insulation of the anode connection circuit to the hull using
a 500V earth insulation test meter. Note, if the anode is submerged
then this test will show a short circuit. Disconnect from power supply
unit before this test or permanent damage may occur.
3.3.30 Make a final visual check of all connections and finally fit the blind
flange and gasket to seal the cofferdam. Do not over paint the anode
when painting over the dielectric shield area.
3.3.31 Note all welds used during installation should meet the Yard or
Classification Society rules.
Section 3.3
Page 3 of 3
3.4 REFERENCE ELECTRODE CELLS
3.4.01 Cut a 170mm diameter hole in the hull at each electrode location.
This is to enable installation of the cell mounting cofferdam as
shown by drawing C1190
3.4.02 Grind off any surplus metal to ensure that the cofferdam body will
locate flat to the internal shell plating at the inboard side of the hole.
3.4.03 Locate the cofferdam centrally over the hole, inside the hull.
3.4.05 Clean off all weld splatter from the surfaces including the cofferdam
recess, and grind flat all welds in the area to be occupied by the
reference electrode.
3.4.06 Ensure that the neoprene sealing gasket is on the back of the
reference electrode assembly and that the inside of the cofferdam
recess into which the electrode will fit is clean and dry.
3.4.08 From the outboard of the shell thread the cable through the gland
plate at the back of the cofferdam recess.
3.4.09 Apply sealing compound to the recess and screw the reference
electrode firmly into place in the cofferdam using the spanner
provided to fit the recesses in the front face of reference electrode
carrier. Do not Over Tighten !!
3.4.10 Inside the ship, remove the blank flange from the Cofferdam and
check the cable insulation for any possible damage.
3.4.11 On completion of the inspection caulk the gap between the reference
electrode carrier and the outer shell with sealing compound, to leave
a smooth uniform surface.
3.4.12 From the inboard of the shell fit the neoprene washer within the
dished steel washer and locate over the reference electrode mounting
sleeve within the cofferdam. Ensure that the neoprene washer faces
outboard and is in contact with the gland plate in the cofferdam.
Section 3.4
Page 1 of 2
3.4.13 Fit the M20 full locking nut on the reference electrode mounting
sleeve and tighten until the neoprene washer is fully compressed and
the dished washer is in contact with the gland plate.
3.4.14 Pass the cable through the side entry hole in the cofferdam.
3.4.17 Wet Compartment Installation: Pass the shipyard cable through the
side entry hole into the cofferdam. Any cables, which run through
tanks, must be housed in heavy walled conduit pipe. Fit the cable
gland in the same way as before but to the inside of the cofferdam
over the shipyard cable.
3.4.18 Connect the anode cable tail to the shipyard cable using a cable
splice kit. Use an industry recognised kit or a C-shield splice kit as
shown by drawing M1043. After splicing in submerged cofferdams it
is recommended that the cofferdam recess void be filled with
paraffin wax or similar. Connect the shipyard cable to the Power
Supply Unit see section 3.5
Disconnect from the power supply unit before this test or permanent
damage may occur.
3.4.20 Make a final visual check of all connections and finally fit the blind
flange and gasket to seal the cofferdam.
3.4.21 Please ensure that if the vessel is going to be stood in water for a
long period of time during the outfitting period, the reference cells
are NOT to be connected to panel until the ICCP system is
commissioned.
Section 3.4
Page 2 of 2
3.5 POWER SUPPLY UNIT:
3.5.1 The units are designed for bulkhead and plinth mounting,
typically using the mounting holes provided.
45M 16MM2
Section 3.5
Page 1 of 2
3.5.5 Provide and install a cable between the Hull negative
terminal on the equipment and the main ship structure on a
stud of minimum M12 welded to a plate on not less than
100 X 100 X 20mm. It is recommended that these cables be
able to carry the full rated output capacity of the Power
Supply Unit. Cathelco will supply a suitable cable size to
suit the capacity of the power unit.
Section 3.5
Page 2 of 2
3.5A REMOTE MONITORING UNIT: FLUSH MOUNTED
3.5.09 For details of remote monitor panel please see below. This
type is designed for flush mounting:
3.5.12 Once installed the unit will display the same text
information as shown on the actual power supply unit it is
connected to.
Section 3.5A
Page 1 of 1
Iss 2 19.08.05
3.6.01. The propeller shaft bonding kit comprises a split slipring and brush
assembly that must be fitted close to the final shaft bearing, ideally
between the bearing and and stern seal (where space permits). A
mounting bracket or support pillar for the brush holder should be
supplied by the yard and mounted to a suitable frame or bearing
pedestal, Ensure that the mating faces are cleaned to bright metal before
fixing in position. For the General Arrangement of the Shaft Earthing
Assembly see Drg.M1191.
3.6.02. The brushgear unit is shown on Drg C1181 or C2144 dependant on the
type supplied (See Drg list in this manual). Weld into position on the
support pillar a brushgear support bar of the correct size at the correct
distance from the centre of the bar to the the outside diameter of the slip-
ring (See Drg). The centre of the bar should be parallel to the axis of the
shaft in both planes.
3.6.03. Mark a line around the shaft at approximately 60mm spacing from the
bearing block, ensuring that this is perpendicular to the axis of the shaft.
Thoroughly clean the shaft down to bright metal to a distance of 80mm
from this line away from the bearing block.
3.6.04. The slipring is made up of two matching bi-metal strips that are rolled to
the required shaft diameter. All sliprings are supplied slightly oversized
to allow some degree of tolerance for final fitting. All excess material
shall be removed by filing down at the joint faces, see Drg. M1191 for
details.
3.6.05. Ensure the shaft surface & inside face of the slip ring are clean and free
from raised imperfections. Loosely fit the clamps to the shaft and fit the
2 halves of the slip ring inside the clamps. Ensure the end of one of the
slip rings is butted tightly to the other half, allowing the other end to
overlap the adjacent half ring.
3.6.06. Tighten the clamps carefully, ensuring the two halves of the ring remain
in alignment. Do not overtighten the clamps at this stage. Using the edge
of the overlapping ring as a guide, mark the cutting line onto the surface
of the other half ring.
3.6.07. Carefully remove the excess material, taking care not to distort or mark
the ring, and remove all sharp edges. Re-assemble and recheck,
adjusting the fit by filing the ends of the half rings as necessary.
3.6.08. Once completed, thoroughly re-clean the inside of the slipring and shaft
and immediately fit to the shaft to ensure that no further contamination
of the cleaned surfaces takes place. Refer to Drg M1191. Carefully
check that there is no gap between the shaft and the slip ring, as this
would adversely affect the functioning of the system.
Section 3.6A
Page 1 of 4
Iss 2 19.08.05
3.6.09. It is essential that there is no step or gap at the joints between the 2
halves of the slip ring. To ensure that the brushes can ride smoothly over
the slipring joint, it may be necessary to lightly tap the strips into the
best form with a rubber or hide mallet, or a piece of soft wood, followed
by very light polishing of the surface. If necessary any small gaps can be
infilled with soft electrical solder and polished flush after checking
continuity as below.
3.6.10. Check the continuity between the shaft and the silver strip inlay with a
calibrated multimeter. The reading should be a maximum of 0.1 ohms.
3.6.11. Fit the brush holder as shown on the drawing to the support bar and
align the assembly so that the brushes will run centrally on the silver
track of the slipring. Check that the brushgear assembly will be clear of
the slipring securing brackets when the shaft rotates. Secure the
assembly in this position by tightening the hexagon headed bolt at the
top of the brushgear body.
3.6.12. Ensure that each brush is mounted tangentially to the shaft to avoid
uneven wear. Adjustment is provided by means of alignment bolts – see
appropriate drg of Brush holder for details.
3.6.13. Pull back the pressure spring on the brush holders and fit the brushes
into position. Recheck & adjust the brush gear as necessary until the
brushes sit correctly on the slipring. Ensure the brushes are free to move
in the holder.
3.6.14. Connect the wires from the brushes to the two hexagon headed bolts on
the brushgear.
3.6.15. Check the continuity between the shaft and the brush holder body with a
calibrated multimeter. The reading should be a maximum of 0.7 ohms.
3.6.17. Check the continuity between the shaft and the final hull earthing point
with a calibrated multimeter. The reading should be less than 1.0 ohms.
Section 3.6A
Page 2 of 4
Iss 2 19.08.05
3.6.19. The brush holder is insulated from the main hull structure and is
connected to one side of the meter, the other side of the meter is
connected to the main ships structure. The meter has a high internal
resistance that restricts current flow in the circuit to minimal levels and
thus minimises the volt drop between the slipring and the monitor brush.
The meter therefore accurately displays the potential difference between
the shaft and hull.
3.6.20. For ease of interpretation the display meter has high and low switchable
scales up to 250mV. The shaft mV meter is shown on either Drg
M1100, M1101 or M1106 dependant on type supplied (See Drg list in
this manual)
3.6.23. Fit the monitor brush holder as shown on drawing C1157 over the
plastic sleeve such that it runs centrally on the silver track of the
slipring. Check that the brush gear assembly will be clear of the slipring
securing brackets when the shaft rotates. Secure the assembly in this
position by tightening the hexagonal headed bolt at the top of the
brushgear body.
3.6.24. Ensure that the brush is mounted tangentially to the shaft to avoid uneven
wear. Adjustment is provided by means of an alignment bolt – see drg of
Brush holder for details.
3.6.25. Pull back the pressure spring from the brush holder and fit the brush into
position. Recheck & adjust the brush gear as necessary until the brush
sits correctly on the slipring. Ensure the brush is free to move in the
holder.
3.6.26. Connect the wire from the brush to the hexagon headed bolt on the brush
gear.
3.6.27. Check the continuity between the shaft and the brush holder body with a
calibrated multimeter. The reading should be a maximum of 0.7 ohms.
3.6.28. Using a megger tester, check that the brush holder is isolated from the
mounting post. NB: Ensure that the brush is not in contact with the shaft
by removing from the holder, and that the cable from the brush holder to
the meter (if fitted) is disconnected at the holder. Refit the brush into the
holder after checking.
Section 3.6A
Page 3 of 4
Iss 2 19.08.05
WIRING OF METER
3.6.31. Install a flexible cable of cross sectional area minimum 1mm2 from the
second terminal within the monitor panel connecting the other end to the
main ships structure at a suitable point adjacent to the panel. Ensure the
mating faces are cleaned to bright metal before fixing. See Drg.C1159
for further wiring details.
3.6.32. Using a calibrated multimeter, check the continuity between the brush
gear earth terminal inside the meter and the earth connection at the hull.
The reading should be a maximum of 0.1 ohms.
OPERATION OF SYSTEM:
a) Electrical Continuity between Shaft & Hull earth point less than 1.0
ohms.
d) Clean and check brushes for wear and check freedom of movement in
holders.
3.6.35. Please note that the silver graphite brushes are a consumable item, and
depending on the rpm of the shaft, shaft diameter and the running hours,
the brushes will wear and require replacing on average at 4 to 6 monthly
intervals. Ensure that the brushes are regularly inspected and replaced
before they are totally consumed, otherwise the shaft earthing assembly
will not operate correctly.
Section 3.6A
Page 4 of 4
3.7 RUDDER BONDING
3.7.1 The rudder stock must be grounded using the flexible cable
provided
3.7.2 Securely fix one end to the hull or overhead frame work .
3.7.3 Weld or braze a suitable lug to the top of the rudder stock and
securely fix the other end to this .
Section 3.7
Page 1 of 1
4.0 POWER SUPPLY UNIT OPERATING INSTRUCTIONS:
CTRL, ENT, ⇑, ⇓.
or
1) STAND-BY MODE,
2) MANUAL MODE,
3) AUTOMATIC MODE
4) CONFIGURATION MODE
Section 4
Page 1 of 11
In addition there is 1 functional mode1 :-
ACCESS CODE
NOTES:
STANDBY MODE:
STAND-BY V????V
EL1 ????mV
stepping to:-
STAND-BY V????V
EL2 ????mV
stepping to:-
STAND-BY V????V
EL3 ????mV
stepping to:-
Section 4
Page 2 of 11
STAND-BY V????V
EL4 ????mV
stepping to:-
STAND-BY V????V
MANUAL I £££%
EL1 ????mV
stepping to:-
MANUAL I £££%
EL2 ????mV
stepping to:-
MANUAL I £££%
EL3 ????mV
stepping to:-
MANUAL I £££%
EL4 ????mV
stepping to:-
Section 4
Page 3 of 11
MANUAL I £££%
V ???V
stepping to:-
MANUAL I £££%
I ???A
stepping to:-
MANUAL I £££%
Where ??? is the measured value and the £££ is the value
that has been set. The set value is altered by pressing the ⇑
⇓ buttons. The initial value is the one stored as the system
default. A new system default can be stored by setting the
current output to the desired value and then pressing the
ENT button.
AUTOMATIC ££££%
EL1 ????mV
stepping to:-
AUTOMATIC ££££%
EL2 ????mV
stepping to:-
Section 4
Page 4 of 11
AUTOMATIC ££££%
EL3 ????mV
stepping to:-
AUTOMATIC ££££%
EL4 ????mV
stepping to:-
AUTOMATIC ££££%
V ???V
stepping to:-
AUTOMATIC ££££%
I ????A
stepping to:-
AUTOMATIC ££££%
SYSTEM FAILURE
MODULE FAILURE
ELECTRODE FAILURE
UNDER-PRO FAIL
OVER-PRO FAIL
Section 4
Page 5 of 11
4.0.7 ACCESS CODE
ACCESS CODE
0000
Section 4
Page 6 of 11
4.1 CHANGING CONTROLLER SET POINTS:
CONFIGURATION
ZZZZZZZZZZZZZ
SYSTEM SIZE
ELECTRODE TYPE
ELECTRODE NUMBER
ELECTRODE SET mV
OVER PROTECT
UNDER PROTECT
CURRENT LIMIT
QUIT CONFIG
Section 4
Page 7 of 11
4.1.3 ELECTRODE TYPE
ELECTRODE TYPE
ZINC ELECTRODE
or
ELECTRODE TYPE
SILVER ELECTRODE
ELECTRODE NUMBER
Section 4
Page 8 of 11
4.1.5 ELECTRODE SET mV
This parameter will allow the user to define the set point
about which the AUTOMATIC MODE will maintain a
constant potential at the electrodes. The display will be as
follows, during which time using the ⇑⇓ buttons will vary
the setting.
ELECTRODE SET mV
xxx mV
This parameter will allow the user to define the set point at
which the OVER PROTECTION alarm triggers. The
display will be as follows, during which time using the ⇑⇓
buttons will vary the setting.
This parameter will allow the user to define the set point at
which the UNDER PROTECTION alarm triggers. The
display will be as follows, during which time using the ⇑⇓
buttons will vary the setting.
Section 4
Page 9 of 11
where xxx is the set value in the range OFF, 0 to 995 mV in
the case of Zinc Electrode and OFF, -75 to -1070 in the
case of Silver Electrode. To store the set value, the ENT
button is pressed.
Section 4
Page 10 of 11
4.2 SELF CHECKING:
4.2.1 Every 8 hours & upon entry to manual & automatic modes,
timed from the last power up, the system automatically
enters a self test mode. This mode checks the correct
function of anodes and electrodes and lasts approximately
10 seconds. During this time the display reads:-
SELFTEST
PLEASEWAIT
Signals from electrodes that have not passed the test are
suspended from the control function for the next 8 hour
period and an alarm generated to indicate an electrode
fault. The test is repeated automatically on all electrodes
(including those that have previously been suspended) after
an 8 hour interval.
Section 4
Page 11 of 11
5.0 ROUTINE OPERATING PROCEDURE
Check that the LCD of the Power Supply unit display is illuminated,
and that the ON/ALARM LED is lit. If either of these are incorrect
then refer to the fault finding section.
Record the O/P Current & Voltage and the 4 electrode voltages on
the C-Shield log sheets provided. Refer to figure 5.1 for an example
of how to complete the log sheet.
NOTES:
1. If the O/P Current is set to display % then press the 'ENT' button
to toggle to Amperes.
Once weekly the slipring should be checked for cleanliness, for wear
on the brushes and to confirm that the brushes both move freely in
their holders and are held firmly onto the slipring by the brush holder
spring. Check the rudder stock bonding cable for any fraying of the
conductor at the connection points.
Each log sheet has space for a complete month after which the copies
should be returned to Cathelco, Chesterfield for scrutiny and
comment.
Section 5
Page 1 of 3
5.0.4 EVERY 3 MONTHS:
Replace all covers provide power and operate the mains switch to the
On position and shut the front door.
One month before the dry docking ensure that daily log sheets have
been maintained and forwarded to Cathelco for assessment with
information that dry docking is expected. This will ensure that any
necessary spares can be despatched in good time. Continue to log
the system readings up to the time the vessel enters the dry dock. It
is advised that an Engineer from Cathelco (Chesterfield) be in
attendance during drydocking to check and service the C-Shield
System.
At times when the vessel enters a river estuary where the water may
be fresh or brackish the effect will be to limit the spread of current
from the anodes because of the much higher electrical resistivity of
water. Normally this will cause the automatic control to increase the
transformer rectifier output voltage to the maximum but this will be
accompanied by a very low level current and the reference electrode
potentials may indicate under protection. However, this has been
taken care of by our computer and is explained in a separate
paragraph in 6.1 The system will return the hull to the optimum
protective level as soon as the vessel returns to the sea water.
Section 5
Page 2 of 3
Cathelco Limited
Marine House
18 Hipper Street South
Chesterfield S40 1SS
United Kingdom
Telephone (01246) 207702
Fax (01246) 206519
_____________________________________________________________________________
Daily log for C-Shield Impressed Current Cathodic Protection System.
Vessel SHIP NAME Aft system capacity 400 amps 24 volts
Voyage number 23A Forward system capacity 100 amps 24 volts
Date from 01/05/97 To 31/05/97
Complete in triplicate and distribute as follows: 1st copy to owner’s file, 2nd copy to Cathelco,
3rd copy to ship’s file. Slip ring/brush gear operation and condition to be checked weekly.
Ring to be clean, brushes in contact.
Slipring check Wk1 √ Wk2 Wk3 Wk4
Month Area of operation Sea Aft output Sensing For’d output Sensing Notes
temp. electrode (mV) electrode (mV)
o
2 C
Amp Volt S1 S2 Amp Volt S3 S4
1 Pacific 26 15 2.8 210 220 5 2.8 221 215 light draft
2 Coral Sea 29 15 2.8 212 220 5 2.7 220 215 light draft
3 " " 29 15 2.7 212 220 4 2.7 221 214 light draft
4 Torra St 28 14 2.7 210 220 4 2.7 220 214 light draft
5 Arufura Sea 28 14 2.7 211 220 5 2.8 220 214 light draft
6 Serum Sea 27 15 2.8 212 220 5 2.8 221 215 light draft
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Figure 5.1: Typical LogSheet with Entries
Section 5
Page 3 of 3
6.0 SERVICE AND FAULT FINDING:
6.0.2 From consideration of section 1 it will be appreciated that the d.c. output
current of the system is the factor that provides the Cathodic Protection of
the hull. In a correctly functioning system the level of current output gives
an indication of the state of the paint system.
6.0.3 The voltage or potential reading on the reference electrode circuit is the
voltage of the hull with respect to the reference electrode. Application of
protective current changes this potential in a negative direction as indicated
in figure 1.3 to a level of +0.20 volt for optimum protection. This example
gives levels with respect to zinc electrodes.
6.0.4 The d.c. output voltage is the driving potential that produces the protective
current. The standard Cathelco C-Shield Marine Impressed Current System
has a maximum voltage output of 24VDC but this is automatically
regulated according to the current requirement and with a newly painted
vessel at low current output the DC voltage will normally be around + 3.5
volts.
6.0.7 Do not megger, or high voltage test this equipment. The DC and control
circuits are low voltage only and will be seriously damaged if high voltage
test equipment is used. To check insulation of any cables outside the Power
Supply Unit disconnect them at both ends.
6.0.8 If the LCD display is not illuminated then first check the mains supply to
the cabinet and that the system is switched on. If no fault can be found then
report conditions to Cathelco (Chesterfield).
6.0.9 If the Power Supply Unit On/Alarm LED is not lit, then note any of the
alarm conditions that are found to be displayed and contact Cathelco
(Chesterfield) giving full details of the alarm.
ICCP systems have experienced problems in the past when the vessel has to
enter a harbour or estuary where the water is either fresh or brackish. The
C-Shield computer controller has been programmed to identify this
situation by analysing the voltage reading, the amperage reading and the
reference electrode inputs. The ICCP system remains in automatic mode
and endeavours to provide the maximum available protection level around
the hull in this water condition. In fresh water conditions it is normal for the
output voltage from the system to increase and for current outputs to
decrease. This is caused by the increase in resistivity of the sea water
solution. When the vessel returns to normal sea water the output voltage
should begin to decrease and current outputs should begin to increase.
Section 6
Page 1 of 1
7.0 C-SHIELD COMMISSIONING CHECK LIST
Section 7
Page 1 of 7
C - Shield Commissioning Check List
Vessel : ________________________
Shipyard : ________________________
Owner : ________________________
6. Check panel holding bolts and frame. Make sure panel is rigid. ______
8. Make a physical check of the unit for any possible transit damage. ______
Section 7
Page 2 of 7
C - Shield Commissioning Check List Cont'd
A - B A - C B - C
Section 7
Page 3 of 7
C - Shield Commissioning Check List Cont'd
On completion of all the tests as detailed in the above check list you can switch the
system on.
CATHELCO CSHIELD
* * * A SYSTEM
The unit will then automatically go into the standby mode indicating as follows:
Manual Mode.
Press "CTRL" button once and unit will go into Select mode. Press "Up arrow"
to choose Manual Mode. When this appears Press "ENT".
The unit will show the following statement. SELF TEST
PLEASE WAIT.
The unit then does a self analysis of all its circuits and modules checking reference
electrodes and all relevant electrical data. On completion of the self test the unit
goes into Manual Mode.
The bottom half of the display is a continuous read out of Ref 1 & 2 & 3 & 4
followed by the voltage followed by the current.
Section 7
Page 4 of 7
C - Shield Commissioning Check List Cont'd
By pressing the "UP arrow" you will be able to increase the I %. This will result in
the reference cell readings reducing and the voltage and current increasing. To
avoid applying too much current to the hull at this stage we recommendthat this
test is carried out to a maximum of " I 25% ".
I = 10% I = 15%
EL 1 ______mV EL 1_______mV
EL 2_______mV EL 2_______mV
EL 3_______mV EL 3_______mV
EL 4_______mV EL 4_______mV
Voltage _____V Voltage_____V
Current_____A Current_____A
I = 20% I = 25%
EL 1 _______mV EL 1______mV
EL 2_______mV EL 2______mV
EL 3_______mV EL 3______mV
EL 4_______mV EL 4______mV
Voltage _____V Voltage____V
Current_____A Current____A
This establishes the correct operation of the manual mode. Reduce I % back to
zero by continuously pressing the "down arrow". When the I % is zero press
"CNTL" this takes it back to STANDBY then press "ENT"
Section 7
Page 5 of 7
C - Shield Commissioning Check List Cont'd
Automatic Mode.
Press the "CNTL" button once and the unit will go into the Select mode.
Press the "Up arrow" until Automatic Mode appears. Press "ENT".
EL 1 _____ mV
EL 2 _____ mV
Amps ____ A
Volts ____ V
After One (1) Hour record readings. After Two (2) Hours record readings.
EL 1 _____ mV EL 1 _____ mV
EL 2 _____ mV EL 2 _____ mV
Amps ____ A Amps ____ A
Volts ____ V Volts ____ V
Section 7
Page 6 of 7
C - Shield Commissioning Check List Cont'd
After six (6) Hours record readings. After twentyfour (24) Hours record readings.
EL 1 _____ mV EL 1 _____ mV
EL 2 _____ mV EL 2 _____ mV
Amps ____ A Amps ____ A
Volts ____ V Volts ____ V
The system can now be left permanently in "AUTOMATIC MODE" and the
readings should be taken daily. These should be filled in on the C - Shield log sheet
which has been provided and then returned to Cathelco head office monthly for
analysis.
If there are any problems relating to these instructions or else the computer
control unit does not function as it should then please immediately contact
Cathelco head office for further instructions.
C - Shield Systems
Cathelco Limited
Marine House
18 Hipper Street South
Chesterfield
S4O 1SS U.K.
Section 7
Page 7 of 7
C - SHIELD COMMISSIONING CHECK LIST
SHAFT EARTHING SYSTEM
Vessel : ________________________
Shipyard : ________________________
Owner : ________________________
Confirm Slip ring and Brush gear are installed correctly as follows – refer to Drgs M1191,
C1159 & C1181.
2. Slip ring a tight fit to the shaft over its entire length with
no gap between ring and shaft. ______
6. Brush holder and mounting are solid and will not be affected
by vibration. ______
9. Check Electrical continuity (Shaft-Slip ring track max 0.1 ohms) ______
Section 7.1
Page 1 of 2
C - SHIELD COMMISSIONING CHECK LIST
SHAFT EARTHING SYSTEM
OPTIONAL mV METER
2. Brush holder and mounting are solid and will not be affected
by vibration. ______
Section 7.1
Page 2 of 2
8.0 WORLD WIDE AGENCIES
8.0.1 Cathelco Ltd are world leaders in the supply of corrosion suppression and
control systems to the marine industry. Backed with over 35 years of
experience the C-Shield marine impressed current cathodic protection
system is second to none.
8.0.3 Please contact Cathelco UK in the first instance for details of your nearest
agent world-wide.
CATHELCO LTD
MARINE HOUSE
HIPPER STREET SOUTH
CHESTERFIELD
DERBYS
S40 1SS
UK
Section 8
Page 1 of 1