K.C. LTD.

DRAWING TITLE WORKING DRAWING

IMPRESSED CURRENT CATHODIC

ITEM
PROTECTION (I.C.C.P) SYSTEM

SHIPYARD JIANGDONG SHIPYARD

HULL No. JD1000TEU-1/2/3/4/5/6/7/8/9/10/11/12

VESSEL TYPE 1000 TEU CONTAINER CARRIER

K.C.LTD. REF. No. 4014

K.C.LTD. MODEL No. KC1T 720

0 ORIGINALLY PREPARED H.W.H. JUN.27,08

REV DESCRIPTION DWN. APP. DATE

K.C. LTD.
1589-6, Songjung-dong, Kangsu-ku, CAUTION
THIS DOCUMENT CONTAINS CONFIDENTIAL
Busan 618-818, Korea AND PROPRIETARY INFORMATION OF
K.C. LTD.
Tel : +82 51 831 7720 THIS DOCUMENT ALWAYS REQUIRES PRIOR
WRITTEN CONSENT OF K.C. LTD.
FOR
Fax : +82 51 831 7726 (1)ITS REPRODUCTION BY ANY MEANS,
(2)ITS DISCLOSURE TO A THIRD PARTY,
E-mail : kcind@iccp-mgps.com (3)ITS USE FOR ANY PURPOSE OTHER THAN

Web : http://www.iccp-mgps.com THOSE FOR WHICH IT IS SUPPLIED

K.C. LTD.

INDEX
List Page No

1 Specification & Scope of Supply 1-2

2 Installations of Anode 3-5

3 General arrangement of Anode assembly 6

4 Di-electric shield area for Anode 7

5 Exploded diagram of Anode installation 8

6 Installations of Ref. Electrode cell 9-11

7 General arrangement of Ref. Electrode cell assembly 12

8 Exploded diagram of Ref. electrode cell installation 13

9 Power Supply Unit 14-15

10 Power Supply Unit details 16

11 Ground arrangement for Rudder stock 17

12 System Position details 18

13 System wiring & terminal details 19

14 Spare parts list 20

K.C. LTD.
SPECIFICATION & SCOPE OF SUPPLY
SHIPYARD JIANGDONG SHIPYARD

PROJECT NO JD1000TEU-1/2/3/4/5/6/7/8/9/10/11/12

DESIGN 1. TOTAL WETTED SURFACE AREA :

BASE HULL : 4,500 ㎡
RUDDER : 50 ㎡
PROPELLER : 15.5 ㎡
2. TOTAL SYSTEM REQUIRED :
HULL : 4,500 ㎡×35 mA/㎡(mean current density) = 157.5 Amp
RUDDER : 50 ㎡×120 mA/㎡(mean current density) = 6.0 Amp
PROPELLER : 15.5 ㎡×600 mA/㎡(mean current density) = 9.3 Amp
TOTAL 172.8 Amp

3. TOTAL SYSTEM PROVIDED BY K.C. LTD. : 200 Amp

QUANTITY DESCRIPTION FOR THE SYSTEM :

ONE (1) 200 AMPERE KC1T 720 POWER SUPPLY CONTROL UNIT :
INPUT : AC 440V/60HZ/3PH
OUTPUT : 200A/24V DC
PAINTED : MUNSELL NO. 7.5 BG 7/2
SUPPLIED COMPLETE WITH EARTHING CABLE

TWO (2) 100 AMPERE TITANIUM CIRCULAR ANODE ASSEMBLY

EACH COMPLETE WITH :
DI-ELECTRIC SHIELD EPOXY PUTTY
CIRCULAR DOUBLER PLATE
COFFERDAM
CABLE GLANDS

TWO (2) PURITY ZINC REFERENCE ELECTRODE CELL ASSEMBLY

EACH COMPLETE WITH :
COFFERDAM
CABLE GLANDS

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K.C. LTD.
SPECIFICATION & SCOPE OF SUPPLY
SHIPYARD JIANGDONG SHIPYARD

PROJECT NO JD1000TEU-1/2/3/4/5/6/7/8/9/10/11/12

QUANTITY DESCRIPTION FOR ASSOCIATED EQUIPMENT

ONE (1) SYSTEM SPARES WITH BOX

ONE (1) EPOXY PUTTY

ONE (1) RUDDER STOCK GROUNDING ASSEMBLY (2m)

ONE (1) LOG SHEET

SIX (6) OPERATION / INSTRUCTION MANUALS IN ENGLISH

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 K.C. LTD. ICCP DOCUMENT
REV(1) : 20/02/06

INSTALLATION PROCEDURE FOR I.C.C.P SYSTEM

1. INSTALLATION
The anodes should be installed in the positions indicated on the installation drawing
supplied by K.C. LTD. If, for some reason it is found impractical to fit any component in
the specified positions the K.C’s representative will advise on the necessary re-location.

2. DESCRIPTION
The Impressed Current System consists of anodes and electrodes for installation through
the hull using penetration/cofferdam arrangements, a power supply unit for location
internally and bonding arrangements for appendages such as propeller and rudder. The
standard cofferdams for the reference electrodes are longer than those for the anodes so that
there is a necessity to differentiate between cofferdams before starting assembly.

Locations for components are shown on the drawings supplied for the particular
vessel, but are normally subject to final confirmation between the engineer on site
and the yard/owner.

3. RECESSED ANODE (WITH EPOXY PUTTY DI-ELECTRIC SHIELD )

3.1 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 circle will be located within a steel plate and not interfere with existing
weld seams.

3.2 Cut an circular hole as shown in drawing.

Alternatively, a template may be made using the doubler plate.

3.3 Clean the profile of the circular hole and grind any surplus metal on the outer
edge and weld preparation on the inner edge to match the weld prep provided on
the doubler Plate.

3.4 Cover the anode holding studs with plastic tubing to prevent damage during
welding work.

3.5 Position the doubler plate internally and line it up with the circle.
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.

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K.C. LTD. ICCP DOCUMENT
REV(1) : 20/02/06

3.6 Before proceeding further, ensure that ALL other welding work, either inboard or
outboard, has been completed. Any welding carried out after application of the
dielectric shield will damage the shield material even if the welding is not
associated with the cathodic protection.

3.7 Shot blast the anode dielectric shield to SA 2 1/2 or shipyard’s standard surface
treatment. Apply di-electric shield by epoxy putty around anode. The dimensions
of the dielectric shield are given on the manual drawings.

3.8 Remove the mounting stud protective sleeves.

3.9 Apply thread tape to one cable gland, making sure that this is fitted with a
neoprene 'O' ring over the entry thread. Fit the gland into the doubler plate from
the inboard side inside the cofferdam.

3.10 Apply epoxy putty on the back of the anode fully after mix equal quantities of the
2 part well. Thoroughly mix the contents of each can before mixing the two parts
together. Follow the mixing instructions on the epoxy putty material packs, using
a power driven mixer if possible.

3.11 The anode must now be fitted onto the doubler plate within one hour or the epoxy
putty will cure before the anode is fitted.

3.12 Carefully insert the Anode assembly 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 eight (8) fixing points in the backing plate.

3.13 Slowly draw anode into recess by tightening the Anode fixing nuts.

3.14 The epoxy putty will slowly ooze out of the sides as anode settles into position.
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 putty and smooth level.

3.15 Smooth epoxy putty at edge of anode so that gap between anode and steel-work is
completely filled.

3.16 Fit the washers and nuts supplied and tighten the anode fixings evenly.

3.17 Tighten fixings to 2.5 kgf.m (25 Nm).

3.18 Caulk around the mounting studs with the epoxy putty so that the recesses in the
anode are filled up to the bearing surface for the washers and nuts.

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K.C. LTD. ICCP DOCUMENT
REV(1) : 20/02/06

3.19 Inside the ship, remove the cofferdam cover.

3.20 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.

3.21 Fit the cofferdam cover and gasket to seal the cofferdam.

3.22 Then carry out air test for more than 1 hour.

Test air pressure (P) should be applied as below ;

Distance between cofferdam and scantling draft

P= X 1.5
10

3.23 Remove the cofferdam cover after air test and pass the cable for anode
through the side entry hole into the cofferdam.

3.24 Fit the cable with cable terminal using nuts and connect the anode cable to
the power supply unit.

3.25 Tighten the cable gland.

3.26 Finally fit the cofferdam cover and gasket to seal the cofferdam.

Do not paint the anode.

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K.C. LTD. ICCP DOCUMENT
REV(2) : 03/05/08

4.0 RECESSED REFERENCE ELECTRODE CELL

The reference electrodes should be installed in the positions indicated on the installation
drawing supplied. See drawing. If, for some reason it is found impractical to fit any
component in the specified positions the K.C’s representative will advise on the necessary
re-location.

4.1 Cut correct diameter hole in the hull at each electrode location to suit out diameter
of cofferdam tube.

4.2 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.

4.3 Locate the cofferdam centrally over the hole, inside the hull.

4.4 Secure the cofferdam in the position by a continuous fillet weld internally to give
a weld section at least equal to the plating thickness. Protect the stud bolts with
tape or rubber shields.

4.5 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.

4.6 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.

4.7 From the outboard of the hull insert the reference electrode through the mounting
plate inside the cofferdam recess. Be sure to put neoprene sealing gasket on the
back of reference electrode.

4.8 Fit the washers and nuts supplied and tighten the reference electrode fixing nuts.
Tighten fixings to 2.5kg.m (25 Nm).

4.9 On completion of the inspection caulk the gap between the reference electrode
and the cofferdam inside with epoxy putty, to leave a smooth uniform surface.
And fill stud holes with epoxy putty and smooth level.

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K.C. LTD. ICCP DOCUMENT
REV(2) : 03/05/08

Epoxy putty application;

Mix epoxy putty very well till grey color is secured and use. Don’t use
when black or white color is seen. Refer to the below table.

Mix Ratio EAA820 : EAA821 = 1 : 1

Caution 1. Think about waste before mixing the using volume.

2. Use immediately the mixed volume within POT life before
getting solid as follows.
Ambient Temp 5℃ 10℃ 23℃ 35℃
Drying time after Mix 4 HR 3 HR 1 HR 20 min
(POT life)

It will be easier to put epoxy putty a little bit (partly) inside cofferdam just before
reference electrode is mounted for installation.
Then after complete installation of reference electrode do fill in as above.

4.10 Inside the ship, remove the cofferdam cover.

4.11 Check the insulation of the reference connection circuit to the hull using 500 Volt
earth insulation meter. If the electrode is submerged then this test will show a
short circuit.

Disconnect from the power supply unit before this test, or permanent damage may
occur.

4.12 Fit the cofferdam cover and gasket to seal the cofferdam.

4.13 Then carry out air test for more than 1 hour.

Test air pressure (P) should be applied as below ;

Distance between cofferdam and scantling draft

P= X 1.5
10

4.14 Remove the cofferdam cover after air test and pass the cable for ref.cell through
the side entry hole into the cofferdam.

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K.C. LTD. ICCP DOCUMENT
REV(2) : 03/05/08

4.15 Fit the cable with cable terminal using nuts and connect the ref.cell cable to the
power supply unit.

4.16 Tighten the cable gland.

4.17 Make a final visual check of all connections and finally fit the blind flange and
gasket to seal the cofferdam.

Do not paint the ref.cell surface.

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K.C. LTD. ICCP DOCUMENT
REV(2) : MAR.03,04

5.0 POWER SUPPLY UNIT

5.1 The units are designed for bulkhead mounting or deck mounting on request

5.2 To ensure adequate ventilation it is recommended that an air gap be maintained

around the bottom and sides of the equipment for all units.

5.3 Provide and install appropriate input power supply cables, terminating them at the
terminals provided. Check that the supply source conforms to the voltage and
frequency specification given on the rating plate of the equipment.

5.4 Provide and terminate single core cables with a voltage rating in excess of 24V
D.C. from the anode cofferdams to the appropriately labelled connection studs on
the terminal board. Equivalent area multi-core cables may be used with all cores
connected. The cables should be sized according to the following table to ensure
that the maximum voltage drop in each cable is equal and does not exceed 3 volts.
Table of cable lengths for different anode size to maintain 3 volt drop.

CONDUCTOR
50A 75A 100A 150A 175A 200A 250A 300A SIZE SINGLE
CORE CABLE

65m 25mm2

90m 60m 35mm2

122m 81m 61m 50mm2

176m 118m 88m 58m 50m 70mm2

244m 162m 122m 80m 70m 61m 49m 95mm2

310m 206m 154m 102m 88m 76m 62m 51m 120mm2

378m 252m 188m 126m 108m 94m 76m 63m 150mm2

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K.C. LTD. ICCP DOCUMENT
REV(2) : MAR.03,04

5.5 Provide and install a cable of minimum 400mm between the Hull-ve terminal on
the equipment and the main ship structure by welding. Be sure to install correct
system negative cable as recommended in wiring diagram. These cables will carry
the full rated output capacity of the power unit.

5.6 Provide and terminate single core screened cables with a sectional area minimum
2.0mm from the reference electrode to the appropriately labelled terminals on the
distribution board within the equipment. The metallic braid screens of these
cables should continuous from connected to the 'Ground', terminal only on the
terminal panel within the power unit.

5.7 Provide and install a connection to the ship's earthing system from the cubicle
earth terminal, typically 1×5.5mmSq or 1×14mmSq Core Cable provided.

6.0 RUDDER BONDING

6.1 The rudder stock must be ground using the flexible cable provided.

6.2 Securely fix one end to the hull or overhead framework.

6.3 Weld or braze a suitable lug to the top of the rudder stock and securely fix the
other end of the cable to this.

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