CATHELCO: C-SHIELD ICCP

MARINE IMPRESSED CURRENT CATHODIC PROTECTION

SYSTEM INSTALLATION & INSTRUCTION MANUAL

VESSEL: NB 938

CATHELCO REFERENCE: CA 337581AA

Rev:

Issued By: AH

Date: 14104108

MARINE HOUSE, HIPPER STREET SOUTH, CHESTERFIELD, DERBYS. S40 ISS, UK

TEL: +44 (0)1246 246700. FAX: +44 (0) 1246246701. E-MAIL: technical@Cathelco.com

FINISHED PLAN
DWG
NO. ])2:3 3/0 0 I
F-50
 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 SOOV 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-SIDELD MANUAL INDEX:

0.0 List of drawings.

1.0 Introduction.

2.0 General Descriptions.

3.0 Installation of Equipment.

4.0 Power Supply Operating Instructions.

5.0 Routine Operating Procedure.

6.0 Service & Fault Finding

7.0 C-Shield Commissioning Check List.

8.0 World Wide Agencies.

 LIST OF DRA WINGS:
ANODE DETAILS:
LINEAR LOOP
125-200A SURFACE MOUNTED LINEAR LOOP ANODE DETAILS DRG NO. MlO73
STUD FIXING & DIELECTRIC SHIELD DETAILS DRG NO. MlO76
INSTALLATION SECTION OF 50-200A ANODE DRG NO. Cl504
6" COFFERDAM DETAILS FOR 50-200A ANODE DRG NO. Cl19J1M20
SINGLE HULL BOSS DETAILS FOR 50-200A ANODE DRG NO. Cll77IM20
EXPLODED DIAGRAM OF 50-200A ANODE ASSY. DRG NO. Ml 109
K6 JUNCTION BOX (CSBC) DRG NO. Ml259

REFERENCE CELL DETAILS

ZINC REFERENCE CELL INSERT DRG NO. Cl 102
REFERENCE CELL ASSEMBLY DETAILS (PLAIN OUTLET) DRG NO. Cl 162
REFERENCE CELL COFFERDAM DETAILS (PLAIN OUTLET) DRG NO. Cl 190
EXPLODED DIAGRAM OF REFERENCE CELL ASSY DRG NO. Ml004
K4 JUNCTION BOX DRG NO. Ml046

SHAFT & RUDDER EARTHING DETAILS:-

SHAFT EARTHING GENERAL ARRANGEMENT DETAILS DRG NO. Ml191
SHAFT EARTHING BAND CLAMP DETAILS DRG NO. MJl92
SHAFT EARTHING BRUSH HOLDER DETAILS (STD) DRG NO. CJl81
MILLI- VOLT METER BRUSH HOLDER DETAILS DRG NO. CJl57
TYPICAL SHAFT EARTH HOLDER MOUNTING POST (STD) DRG NO. C2 158
MILLI-VOLT METER DETAILS (SWITCHABLE) DRG NO. Ml 100
SHAFT EARTHING WIRING (SWITCHABLE) DIAGRAM DRG NO. Cl l59
RUDDER BONDING CABLE DETAILS DRG NO. Cl 165

POWER SUPPLY UNIT DE TAILS:-

THYRISTOR CH TYPE
lOO-300A POWER SUPPLY UNIT (STD) DRG NO. C2l30
lOO-300A CABLE COAMING INLET DETAILS DRG NO. C229 1
TERMINAL LAYOUT DETAILS (2 ANODE) DRG NO. C2082
KEYPAD &DISPLAY DETAILS DRG NO. Cl623
SCHEMATIC CIRCUIT DIAGRAM FOR PSU DRG NO. C2083

GENERAL INFORMATION DRA WINGS:-

SPARE PARTS LIST DRG NO. C1273
PORTABLE REFERENCE ELECTRODE DETAILS DRG NO. Cl606
It
ELECTRICAL SPARE PARTS CH PANEL DRG NO. C12881CH

WIRING DIAGRAM (CH)

SYSTEM WIRING DIAGRAM THYRISTOR 2 ANOD, NO REMOTE DRG NO. C209 1

SYSTEM LAYOUT
SYSTEM EQUIPMENT LAYOUT (AFT) DRG NO. C2l03

Section 0.1
Page 1 of 1
1.0 INTRODUCTION:

1.0.1 PRINCIPLES OF CORROSION AND CATHODIC PROTECTION:

Metallic corrosion is an electro-chemical reaction in which the metal combines

with a non metal, such as oxygen, to form a metal oxide or other compound.
This depends upon the nature of the environment.

Different metals have different tendencies to corrode, termed activity or

potential. These potentials can be tabulated and form the electro-chemical
senes.

A more practical approach is the determination of the tendency of certain metals

to corrode in a particular electrolyte, such as sea water. This is termed the
galvanic series of which the following table is an abridged form.

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 of3
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.

This simple cell may be represented as:

§IlIIllUllll
or
IElOOIroly'ue

Figure 1.1 - Simple Corrosion Cell

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.

Cathodic Protection is a system ofpreventing corrosion by forcing all surfaces

of a structure to be cathodes by providing external anodes.

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

Section 1
Page 2 of3
 construction of structures that will be buried or immersed in an electrolyte to
ensure a galvanic cell is not created.

Typical examples of galvanic cells are:

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.

b) Brass or bronze valves fitted to immersed steel buoyancy tanks or

• flooding chambers on marine petrochemical structures. Accelerated
corrosion of the steel occurs near the valve.

c) The connection of steel pipes into an otherwise cast iron system.

Accelerated corrosion of the steel occurs near the cast iron sections.

Sacrificial anode cathodic protection achieves corrosion prevention on a

particular structure or component by forming a galvanic cell where an
additional anode of zinc, magnesium or aluminium corrodes in preference to the
structure. The galvanic corrosion current (see simple cell before) available from
this anode / electrolyte / structure combination should be sufficient to overcome
the local surface corrosion currents on the structure until no current flows from
Anodic areas of the structure i.e the structure is entirely cathodic or under
complete cathodic protection.

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.

SACRIFICIAL ANODE CATHODIC PROTECTION:

As indicated previously, a metal can be made cathodic by electrically

connecting it to a more Anodic metal within the electrolyte. The most
commonly used Anodic metals are alloys of aluminium, zinc and magnesium.
Anodes of these metals corrode preferentially; the corrosion current of the
anode achieving cathodic protection of the structure to which they are
connected. The anodes deteriorate as an essential part of their function and they
are therefore termed sacrificial.

Section 1
Page 3 of3
 2.0 GENERAL DESCRIPTIONS:

2.1.1 IMPRESSED CURRENT CATHODIC PROTECTION:

A metal also can be made cathodic by electrically connecting it to another

metallic component in the same electrolyte through a source of direct electric
current and directing the current flow to occur off the surface of added metallic
component (anode), into the electrolyte and onto the metal (cathode). This can
easily be visualised by reference to the simple cell and assuming yet another
• electrode with a power source is introduced and that the current flow from this
electrode is sufficient to overcome the natural corrosion current.

Because an external current source is employed, this type of protection IS

termed 'IMPRESSED CURRENT CATHODIC PROTECTION'.

Figure 1.2 - Cathodic Protection Applied to a Simple Corrosion Cell

A source of direct current is required, this is generally obtained from mains

power units that contain a transformer and rectifier. The magnitude of this
current may be automatically controlled in response to a continuous monitor of
the cathode / electrolyte potential or may be manually controlled after
intermittent measurement.

The impressed current anode material is ideally non-consumed by the passage

of current from it into the electrolyte, in practice the materials used are a
compromise between this ideal and the cost and physical properties of available
materials. Impressed current anodes are made from graphite, silicon iron, lead
• alloys some with platinum bi-electrodes, platinised titanium or more exotic
combinations such as platinum clad niobium. The selection of the correct anode
material is critical in the formulation of an effective and economic cathodic
protection scheme.

Section 2
Page 1 of6
 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.
Tyjpe of
Refeli\elllltCe
lEll«%:IDrOOe

-1.2 -Uli ...(l.1l

~.2
:lIDrnC
(ZIlll)

-Uli -O.S
§illveli/§illveli Clhloridle
,§ea Wa1telr
(Ag/AgCL)
NlOrte: Ornret IOf lPrefel!1iOO
Over lP'lrorectllilOll R!ilI1lge 1Oj[
i!l!epelllldimt IOn lP'lrortec1tJiOIll
oo:rndlitllilD .&
oj[ ooatlliJrng

Figure 1.3 - Comparison of Reference Electrodes & Interpretation

2.2.0 MARINE IMPRESSED CURRENT SYSTEM:

The C-Shield Marine Impressed Current System compnses the following

components, as illustrated in figure 1.4.

2.2.1 Impressed Current Anodes

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 of6
 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.

2.2.2 Impressed Current Reference Electrodes.

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 stem 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 0[6
 AFlI' §Y§'][']EM lFORWAJID §Y§1'lEM (OlPTIONAJL)

;PVl Power SUJIlply Unit Power Slllpply UIllia

0
(]Q
o (")
~ g.
o ;:l
~N
]Reference !Electrode
2.2.3 Power Supply Unit:

. The C - Shield impressed current Cathodic protection power supply unit is a

thyristor system housed in a range of different sized cabinets. The specific
power supply unit supplied is illustrated on the drawing included with this
manual. The system comprises of a control PCB, a Thyristor PCB and a
Thyristor unit (consisting of a transformer, a choke and a thyristor bridge)
ranging in size from 100 Amperes upto 800 Amperes. The supply
requirements are 415 Vac +1-10%, three phase, 50/60 Hz.

The control PCB is a micro-processor based system having a 2 line 16

character backlit LCD display which is located in the top centre of the
cabinet door. The display is used to monitor and allow control of the
system. Below the LCD are four push buttons, which are the controls for
changing the system parameters. To the right of the LCD is a power on
indicator, which also acts as an alarm indicator. On the reverse side are a
rotary switch and a potentiometer. The switch toggles between manual
override and normal operation. This allows the operator, in the event of a
fault, to disable the micro-processor control system, and to control the
output current with the potentiometer.

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.

MAIN CONTROL PCB

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 of6
 2.2.4 Bonding

To enable the rudder to receive protection it is provided with a dedicated

electrical bond in the form of a flexible cable from the top of the rudder
stock to the main ship structure. In the same way any stabilisers are bonded
to allow protective current to these surfaces.

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 of6
 3.0 INSTALLATION OF EQUIPMENT:

3.0.01 Description:

The C-Shield Impressed Current System consists of anodes and electrodes

for installation through the hull using penetration and cofferdam
arrangements, a power supply unit for location internally and bonding
arrangements for appendages such as propeller and rudder. The system uses
identical cofferdams for both surface mount linear and recessed anodes. The
. 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.

3.0.02 Locations for components are shown on the C-Shield drawings supplied for
the particular vessel, but are normally subject to fmal 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.

3.2.0 There are three (3) types of Linear Loop Anode.

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. MI072 with stud fixing and
di-electric shield areas shown on Drg. No. M1075.

3.2.1 F or 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. C 1177) or the double hull boss (Drg.
Cl178).

3.2.2 Grind off any surplus metal to ensure that the hull boss wi11locate 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. Cl191 or double type Cl192)
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 ofM10 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 of4
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 paraffm. 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, SA3 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.

3.2.12 Remove residual dust with a clean dry brush.

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.

3.2.21 Pass the anode cable through the gland.

Section 3.2
Page 2 of4
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 Ibs).

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 of4
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.

Do not paint over the anode surface.

Section 3.2
Page 4 of4
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.

3.4.04 Secure the cofferdam in the position by a continuous fillet weld

internally to give a weld section at least equal to the plating
thickness. Drawing C1162 gives a rough guide for welding and
electrode cell installation.

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.

3.4.07 Apply thread tape or sealing compound to the M20 threaded

mounting sleeve of the reference electrode. The reference electrode
cell is shown by drawing C 11 02. Remove the nut, dished washer and
neoprene washer from the M20 sleeve but leave the neoprene sealing
ring in place.

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 of2
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.

3.4.15 Dry Compartment Installation: Apply thread tape to the reference

electrode cable gland, and pass the gland over the anode cable to fit
it into position outside the cofferdam as shown in the drawing.
Tighten the main body fully into position then tighten onto the cable
leaving slack cable inside the cofferdam.

3.4.16 Fit a junction box at some convenient point adjacent to the

cofferdam and connect the reference electrode cable to the power
supply unit via shipyard supplied cable see the Power Supply Unit
instructions in section 3.5

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 MI043. 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

3.4.19 Check installation 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.

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 of2
 3.5 POWER SUPPLY UNIT:

3.5.1 The units are designed for bulkhead and plinth mounting,
typically using the mounting holes provided.

3.5.2 To ensure adequate ventilation it is recommended that an

air gap be maintained all around the equipment for all
units .
•
3.5.3 Provide and install appropriate input power supply cables,
terminating them at the terminals provided. Check that the
supply source conforms to the voltage, phase and frequency
specification given on the rating plate of the equipment.

3.5.4 Provide and terminate single core cables with a voltage

rating in excess of 24V d.c. from the anode junction box or
cable splice 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 MINIMUM 3-VOLT DROP

50A 75A lOOA 150A 175A 200A 300A CONDUCTOR

SIZE SINGLE
CORE CABLE

45M 16MM2

70M 47M 25MM2

100M 67M 50M 35MM2

125M 83M 62M 41M 50MM2

180M 120M 90M 60M 5lM 45M 70MM2

250M 167M 125M 83M 71M 62M 41M 95MM2

315M 210M 158M 105M 90M 79M 53M 120MM2

Section 3.5
Page 1 of2
 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 Ml2 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.

3.5.6 Provide and terminate single core screened cables with a

sectional area of minimum l.Omm from the reference
electrode junction boxes to the appropriately labelled
terminals on the distribution board within the equipment.
The metallic braid screens of these cables should be
continuous and be connected to the 'Ground' terminal only
on the terminal plate within the power unit. Do not connect
the screen at the junction box end.

3.5.7 The reference electrode connection block IS earthed

internally in the Power Supply Unit.

3.5.8 Provide and install a connection to the ship's earthing

system from the cubicle earth stud, typically 1 X 16mm
Core Cable.

3.5.9 PLEASE ENSURE THAT WHEN WELDING WORK

IS BEING CARRIED OUT ON THE VESSEL THAT
THE PANEL IS SWITCHED OFF AND THE
SYSTEM NEGATIVE EARTH CABLE IS
DISCONNECTED.

Section 3.5
Page 2 of2
 Iss2 19.08.05

3.6 PROPELLER SHAFT EARTIDNG ASSEMBLY

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 stem 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.MI191.

3.6.02. The brushgear unit is shown on Drg Cll81 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 [mal fitting. All excess material
shall be removed by filing down at the joint faces, see Drg. Ml191 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 halfrings as necessary.

3.6.08. Once completed, thoroughly re-clean the inside ofthe slipring and shaft
and immediately fit to the shaft to ensure that no further contamination
of the cleaned surfaces takes place. Refer to Drg Mll91. 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 of4
 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.

3.6.16. A length of 35mm2 flexible cable may be included in the C-Shield

Cathodic Protection package for connecting the brushgear to the hull.
Connect one end to the brushgear by the large hexagon headed bolt at
the top of the assembly, then securely bolt the other down to the hull at
some convenient point close by, ensuring contact faces are cleaned to
bright metal before fixing. Full wiring details for the assembly are
shown on Drg Cl159.

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.

3.6A SHAFT MONITORING

3.6.18. This extension to the standard shaft earthing system comprises a

bulkhead mounted panel that incorporates terminals, a scale switch and a
display meter and a separate monitor brush holder with brush. The
system requires no external power supply.

Section 3.6A
Page 2 of4
Iss 2 19.08.05

3.6.19. The brush holder is insulated from the mam 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
MllOO, MllOI or Mll06 dependant on type supplied (See Drg list in
this manual)

3.6.21. The monitoring brushgear is to be installed such that it runs on the

existing slipring track. See drawing Ml191 for general arrangement.

3.6.22. Using the dimensions shown on drawing C1l57 fabricate an additional

support for the monitor brush. The brush gear fitted to this support
MUST be insulated. This may be best achieved by using a mounting bar
of 12mm diameter sleeved with an insulating plastic to produce a
fmished diameter of 16mm. This bar should be typically 125mm long.
Mount the bar as detailed in section 3.6 above.

3.6.23. Fit the monitor brush holder as shown on drawing Cl157 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 of4
 Iss 2 19.08.05

3.6.29. At a convenient location adjacent to the slipring install the mV meter

panel. See the appropriate drg for hole diameters and centres (Refer to
3.6.13). The location chosen should ensure that the meter is clearly
visible to the ships operating staff.

WIRING OF METER

3.6.30. Connect a length of flexible cable of cross sectional area minimum

&
1mm2 between the monitor brush gear and the terminal inside the
monitor panel using the bottom entry cable gland provided.

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 ftxing. See Drg.Cl159
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:

3.6.33. Upon completion of the installation the complete assembly should be

checked in accordance with the Checklist in Section 7.1 Shaft
Commissioning.

3.6.34. For ease of interpretation the display meter is scaled up to 250mY.

Every week or if the meter reading rises above 50mV it is recommended
that the following checks are carried out:

a) Electrical Continuity between Shaft & Hull earth point less than 1.0
ohms.

b) Clean and degrease slipring track.

c) Slipring free from indentations.

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 of4
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 .

3.7.4 Please refer to drawings C 1165 .

Section 3.7
, Page 1 of!
4.0 POWER SUPPLY UNIT OPERATING INSTRUCTIONS:

4.0.1 The system is controlled by the four push buttons on the

front panel, with the information displayed on the 2 line 16
character display above them.

The four buttons are marked from left to right

CTRL, ENT, 11, U.

At power up, achieved by operating the MCB switch

mounted on the side or front of the cabinet, the system
displays

" CATHELCO C - SIDELD X X X A SYSTEM"

for approximately 3 seconds and then displays

" CATHELCO C - SHIELD ZINC ELECTRODE"

or

" CATHELCO C - SHIELD SILVER ELECTRODE"

for approximately 2 seconds. The system then reverts to

the last operational mode prior to power down.

4.0.2 OPERATING MODE SELECTION

There are 4 Operating modes :-

1) STAND-BY MODE,

2) MANUAL MODE,

3) AUTOMATIC MODE

4) CONFIGURATION MODE

Section 4
Page! of1!
In addition there is 1 functional model :-

ACCESS CODE

To change to another operating mode, press the CTRL

button. The display will change to read SELECT MODE
on the top line and one of the above 4 operating modes on
the bottom line. The ft U. buttons can then be pressed to
scroll through the operating modes until the desired mode
is displayed. The ENT button is then pressed to enter that
mode. To exit any mode, press the CTRL button to return
to the SELECT MODE menu and then select the desired
mode.

NOTES:

1. Pressing the CTRL button to enter the SELECT MODE

menu does not exit the mode until a new mode has been
selected.

2. Configuration mode is only accessible when a valid pass

number has been entered. See PASS NUMBER mode
below.

4.0.3 MODE DESCRIPTIONS:

STANDBY MODE:

In this mode all output current from the equipment is shut

down to zero. The display indicates the output voltage and
automatically steps through indicating electrode values and
alarms (if any) thus:-

STAND-BY V????V

ELI ????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

ALARMS (see 4.0.6)

stepping back to the start.

Where ???? is the measured value. Note that in the case of

the Anode voltage the display will be the back emf of the
anode system

4.0.4 MANUAL MODE

In this mode the output current from the equipment is set

and maintained at a constant level. The display indicates
the set value of current as a percentage of the total system
capacity and automatically steps through indicating
electrode values, anode voltage and system current in
Amperes and alarms (if any). Thus:-

MANUAL 1£££%

ELI ????mV

stepping to:-

MANUAL 1£££%

EL2 ????mV

stepping to:-

MANUAL 1£££%

EL3 ????mV

stepping to:-

MANUAL 1£££%

EL4 ????mV

stepping to:-

Section 4
Page 3 ofl!
 MANUAL 1£££%

V???V

stepping to:-

MANUAL I U£%

I ???A

stepping to:-

MANUAL I U£%

"ALARMS" (see 4.0.6)

stepping back to the start.

Where ??? is the measured value and the £££ is the value
that has been set. The set value is altered by pressing the ft
JJ 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
ENTbutton.

4.0.5 AUTOMA TIC MODE:

In this mode the output current from the equipment is

varied to maintain a constant electrode potential. The
display indicates the value of current as a percentage of the
total system capacity and automatically steps through
indicating electrode values, anode voltage, system current
in Amperes and alarms (if any). Thus:-

AUTOMATIC ££££%

ELl ????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 ££££%

"ALARMS" (see 4.0.6)

stepping back to the start. Where ??? is the measured value

and the £££ is the set value

4.0.6 ALARM STATUS:

This mode is embedded in the above 3 operational modes

and displays the status of any alarm, thus:-

SYSTEM FAILURE

MODULE FAILURE

ELECTRODE FAILURE

UNDER-PRO FAIL

OVER-PRO FAIL

Section 4
Page 5 of11
4.0.7 ACCESS CODE

This mode provides access to the service functions

provided in the CONFIGURATION mode. To gain access
to this mode a valid pass number needs to be entered.
Initially the display shows the following:-

ACCESS CODE

0000

The first digit will be flashing, which indicates the active

digit. Pressing the ft button will increment the flashing digit
by one. When the correct number is displayed, pressing the
JJ will move the active digit to the next digit on the right (or
back to the first digit if it was the last digit). Once the
correct numbers have been entered, pressing the ENT
button will allow access to the service functions. If the
number entered was incorrect then the message ACCESS
CODE 1NVALD will be displayed.

Section 4
Page 6 of 11
4.1 CHANGING CONTROLLER SET POINTS:

4.1.1 Upon entering this mode will access a configuration menu,

which will allow access to the setting of the system
parameters. The display will read :-

CONFIGURATION

ZZZZZZZZZZZZZ

where ZZZZZZZZZZZZZ is one of the following:-

SYSTEM SIZE

ELECTRODE TYPE

ELECTRODE NUMBER

ELECTRODE SET mV

OVERPROTECT

UNDER PROTECT

CURRENT LIMIT

QUITCONFIG

The fl' U buttons allow scrolling through the menu items,

and pressing the ENT button will enter the displayed
configuration mode, as follow:-

4.1.2 SYSTEM SIZE

This parameter will allow the user to defme the size in

steps of 50Amps. The display will be as follows, during
which time using the fl' U buttons will vary the setting.

SYSTEM SIZE xxx A

where xxx is the set value in the range 50A to 800A. To

store the set value, the ENT button is pressed.

Pressing the CTRL button will return to the configuration

menu.

Section 4
Page 7 of 11
4.1.3 ELECTRODE TYPE

This parameter will allow the user to defme the electrode

type. The display will be as follows, during which time
using the 11.lJ buttons will vary the setting.

ELECTRODE TYPE

ZINC ELECTRODE

or

ELECTRODE TYPE

SILVER ELECTRODE

To store the set type, the ENT button is pressed.

Pressing the CTRL button will return to the configuration

menu.

4.1.4 ELECTRODE NUMBER

This parameter is used to define the number of electrodes.

The display will be ad follows, during which time using the
11.lJ buttons will vary the setting.
ELECTRODE NUMBER

where x is the set value in the range of 1 to 4. To store the

set value, the ENT button is pressed.

Pressing the CTRL button will return to the configuration

menu.

Section 4
Page 8 ofll
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 1I'.ij buttons will vary
the setting.

ELECTRODE SET mV

xxxmV

where xxx is the set potential range of -100 to +400 mV in

the case of Zinc Electrode and -1,170 to -670 mV in the
case of Silver Electrode. To store the set value, the ENT
button is pressed.

Pressing the CTRL button will return to the configuration

menu.

4.1.6 OVER PROTECT

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 1I'.ij
buttons will vary the setting.

OVER PROTECT, xxx mV

where xxx is the set value in the range OFF, -995 to 0 mV

in the case of Zinc Electrode and OFF, -2,065 to -1,070 in
the case of Silver Electrode. To store the set value, the
ENT button is pressed

Pressing the CTRL button will return to the configuration

menu.

4.1.7 UNDER PROTECT

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 1I'.ij
buttons will vary the setting.

UNDER PROTECT, xxx mV

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.

Pressing the CTRL button will return to the configuration

menu.

4.1.8 SYSTEM CURRENT

This parameter will allow the user to defme the current

limit that will restrict the maximum output current in either
MANUAL or AUTOMATIC modes. The display will be
as follow. during which time using the 1IU, buttons will vary
the setting.

SYSTEM CURRENT, xxx %

where xxx is the set value in the range 0 to 100%. To store

the set value, the ENT button is pressed.

Pressing the CTRL button will return to the configuration

menu.

4.1.9 QUIT CONFIG

This mode will allow the user to exit from the

configuration menu. The display will read :-

QUIT CONFIG, ENT TO CONFIRM

Pressing the ENT button will then exit from the

configuration mode, resetting the whole system. If the
CTRL button is pressed, then it will cancel the quit request
and return to the configuration menu.

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

The power output is shut down to zero and the potential

from each of the system electrodes is measured. Output
current is the ramped to 50% of system capacity over a 5
second period. At the start (OA) and at every 1 second
interval the potential from each of the system electrodes is
measured. During this test the output voltage required to
deliver the current is also monitored. If the output voltage
at 50% current output exceeds 20V, then the system is
deemed to be operating in non-standard sea water and the
results of the test are ignored, with the test repeated after a
further 8 hour period. Any electrode that returns a
potential of less than 100mV at zero current output and
does alter its potential by at least 30mV when 50 % output
is achieved is deemed to have failed.

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

4.2.2 ERROR CHECKING

The equipment is provided with a number of built in self

checking functions. These functions ensure the correct
running of the equipment.

Section 4
Page 11 oftl
5.0 ROUTINE OPERATING PROCEDURE

The Cathelco Marine impressed Current System is completely automatic with

little maintenance required and will normally require no adjustments during
routine operation of the vessel. However, careful attention on a routine basis
should be given to the following points, by the ships staff to ensure that the
system is kept operating at maximum efficiency at all times.

5.0.1 EVERY DAY:

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 OIP 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 OIP Current is set to display % then press the 'ENT' button
to toggle to Amperes.

2. Pressing either the up or down buttons will toggle the display to

read either electrodes 1 & 2 or electrodes 3 & 4.

3. If the electrode readings appear to be erratic (ie going positive &

negative) then the readings unit has become confused. Turning the
unit off then on with the front mounted switch will solve this
problem. This switch also acts as an isolating switch should the
system need to be turned off.

5.0.2 EVERY WEEK:

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.

5.0.3 EVERY MONTH:

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 of3
5.0.4 EVERY 3 MONTHS:

Every 3 months switch off the equipment isolate the power

externally to the unit remove the covers and inspect the power supply
unit internally for signs of loose wires or other visual defects. The
power supply unit is, under normal operation, fan cooled, and
depends on free circulation of cooling air through the vents to
maintain safe working temperature of components. Check that the
ventilation grilles in the sides and top are not obstructed in anyway.
Clean any dust and dirt from the unit paying particular attention to
the cooling fan.

Replace all covers provide power and operate the mains switch to the
On position and shut the front door.

5.0.5 30 DAYS PRIOR TO DRY-DOCKING:

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.

5.0.6 FRESH WATER OPERATION:

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 of3
 Cathelco Limited
Marine House
18 Hipper Street South
Chesterfield S40 1SS
United Kingdom
Telephone (01246) 207702
Fax (01246) 206519

Daily log/or C-Shield Impressed Current Cathodic Protection System.

Vessel SIDP NAME Aft system capacity 400 amps 24 volts
Voyage number 23A Forward system capacity 100 amps 24 volts
Date from 01105/97 To 31105/97
nd
Complete in triplicate and distribute as follows: 1st copy to owner's file, 2 copy to Cathelco,
rd
3 copy to ship's file. Slip ringlbrush gear operation and condition to be checked weekly.
Ring to be clean, brushes in contact.
SliIpnnJ ch eck Wk1 ...j Wk2 Wk3 Wk4
Month Area of operation Sea Aft output Sensing For'd output Sensing Notes
temp. electrode (mV) electrode (mV)
2 °C
Amp Volt SI 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 of3
6.0 SERVICE AND FAULT FINDING:

6.0.1 RECOGNITION OF A PROBLEM:

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.

6.1 VESSEL IN FRESH WATER

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-SmELD COMMISSIONING CHECK LIST

7.0.1 Upon completion of the system installation, after allowing a minimum of 48

hours for the di-electric shield areas to harden, commissioning may now be
carried out.

7.0.2 Follow the attached check list entering readings as requested.

7.0.3 It is recommended that completed check lists be copied and submitted to

Cathelco for analysis. Keep the original copy with the ships manual.

Section 7
Page 1 of7
 C - Shield Commissioning Check List

Vessel

Shipyard

Newbuilding No.

System Size

Owner

1. Check shipyard cable connections to panel fuse terminals.

2. Check shipyard cables to reference electrode inputs.

3. Check ground connection at terminal in panel.

4. Check shipyard mains input cables are connected.

5. Check any auxiliary circuit input cables if applicable.

6. Check panel holding bolts and frame. Make sure panel is rigid.

7. Locate shipyard mains input voltage supply point.

8. Make a physical check of the unit for any possible transit damage.

Section 7
Page 2 of7
 C - Shield Commissioning Check List Cont'd

Before switching unit "ON". Check mains input voltage.

A - B A - C B - C

A- Ground B- Ground C - Ground

Disconnect Shipyard anode input cables from fuse terminals in panel.

Measure anode open circuit potential. ( Anode - ground) 1.

2.
3.
4.
For a new installation where the anodes have never had power applied to them readings should
be in the range of 0.400 V - 0.600 V. For anodes that have had current applied then readings
will vary but will be in excess of 1.6 V up to 2.0 V.

Re-connect anode cables to panel terminals / fuses.

Disconnect shipyard reference electrode wires from panel input terminal.

Measure reference cell potentials. 1.

2.
3.
4.
These reading will vary in accordance with the state ofthe hull paint coating adjacent to the
reference cell location. For a newly painted installation the readings will be in the range of
200 mV - 300 mV. For a hull in bad painted condition the readings will be higher i.e. 300 mV +.

Re- connect reference electrode cable inputs to terminal block.

Measure -v terminal to ground. ohms (Should be zero)

Section 7
Page 3 of7
 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.

Watch display and note unit will indicate the following:

CATHELCO csmELD
* * * A SYSTEM

The unit will then automatically go into the standby mode indicating as follows:

STANDBY VOLTS - - -
I ***mV 2 *** mV
(To obtain reference cells 3 & 4 if applicable press "up" arrow. Press "up" arrow to return
to 1 & 2).

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 following will appear on the display panel: MANUAL I %

ELI ***mV

The bottom half of the display is a continuous read out of Ref I & 2 & 3 & 4
followed by the voltage followed by the current.

At start up the I % should be "zero".

The unit is now ready for testing.

Section 7
Page 4 of7
 C - Shield Commissioning Check List Cont'd

Manual Mode Cont'd.

By pressing the "UP arrow" you will be able to increase the I 0/0. 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%" .

Log the data as follows: I = 5%

ELI mV
EL2 mV
EL3 mV
EL4 mV
Voltage V
Current A

I - 10% I - 15%

ELI mV ELI mV
EL2 mV EL2 mV
EL3 mV EL3 mV
EL4 mV EL4 mV
Voltage V Voltage V
Current A Current A

I - 20% I - 25%

ELI mV ELI mV
EL2 mV EL2 mV
EL3 mV EL3 mV
EL4 mV EL4 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
PageS of7
 C - Shield Commissioning Check List Cont'd

Automatic Mode.

The unit is now ready for automatic operation.

Press the "CNTL" button once and the unit will go into the Select mode.
Press the "Up arrow" until Automatic Mode appears. Press "ENT".

The unit will show the following statement. SELF TEST

PLEASE WAIT

The following will appear on the display panel: EL 1 *** m V I *A

EL2 ***mV V *V

By pressing the "Up arrow" you can read EL 3 & EL 4 if applicable.

Record readings immediately. ELl - - - mV

EL2 _ __ mV
Amps_ __ A
Volts - - - V

After 30 minutes record readings again.

ELl mV
EL2 mV
Amps__ A
Volts V

After One (1) Hour record readings. After Two (2) Hours record readings.

EL 1--,--_ mV EL1 _ _ mV
EL2 _ _ mV EL2 _ _ mV
Amps __ A Amps __ A
Volts V Volts V

Section 7
Page 6 of7
 C - Shield Commissioning Check List Cont'd

After six (6) Hours record readings. After twentyfour (24) Hours record readings.

EL1 _ _ mV EL1 _ _ mV
EL2 _ _ mV EL2 - - 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.

Please review the instruction manual for "Alarm Conditions"

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
S40 ISS U.K.

Telephone: (01246) 246700

Fax: (01246) 246701
E-mail: technical@cathelco co.uk

Section 7
Page 7 of7
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.

8.0.2 In order to meet customers requirements world-wide, Cathelco have an

extensive agency network of Cathelco trained Engineers. These Engineer are
available to assist with installation and commissioning as well as providing
on site instruction for operating staff.

8.0.3 Please contact Cathelco UK in the first instance for details of your nearest
agent world-wide.

CATHELCOLTD
MARINE HOUSE
HIPPER STREET SOUTH
CHESTERFIELD
DERBYS
S401SS
UK

Tel: 0044 (0)1246246700

Fax: 0044 (0)1246246701
E-Mail: technical@Cathelco.co.uk

Section 8
Page 1 of 1
 -----------------'730 O/ALL------------------I

F 140 11--.----500-----1-1.----450----+-----500 1- 140 -

~ I
o /0 0
° 0
F ./ f )

/ /
i I
0 0 0
F
FOR CABLE DETAILS EYEBOLT LUGS FOR FOR STUD FIXINGS (11 OFF) & MIXED METAL OXIDE ANODE HOLDING
REFER TO VIEWS ANODE LIFTING AND DIELECTRIC SHIELD AREA COATED TITANIUM OR ENCAPSULA TlON
BELOW INSTALLATION DETAILS SEE DRG.Ml076 PLA TlNIZED TITANIUM RESIN
ANODE ELEMENTS

VIEW LOOKING ON END: EACH ANODE TO BE SUPPLIED VIEW LOOKING AT SIDE: SECTION A-A
WITH 1 x 5M CABLE LENGTH
UNLESS OTHERWISE STATED

/
~
A
~ CIRCULAR
TITANIUM
r 50 -I
ANOD[~ 00

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~ A
I
g [L[M[~~ ~

L~FL[XIBL[
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I 125-150A 35mm SO

I. I.
190
175-200A 50mm SO

190 I
J 45.0 CABLE
RESIN ENCAPSULA TlON

r ~
C-SHlfLD (ICCP)
CATHELCD LIMITED
MARINE HOUSE, 18 HIPPER STREET SOUTH,
CHESTERFIELD, DERBYSHIRE, 540 ISS, UK.
F 18.04.06

D 17:01:02
R[V: DAT[:
CABLE DIAS REMOVED TlTL[:

DIMNS CORRECTED
MODIFICATION:
PA NO:

TYP[ UN[AR WOP ANOO[ D[TAll DRAWN: CH~:: ~~~ Ml073

JRH
DAT[: SCALE:
-SHIELD 125A TO 200A OUTPUT ~;:-:----~:::-;-'5_:S[-,-;;-PT;o;o-:94-------L_N_OT_TO---,-SC_ALE--j
I---E-+-'-3:-":-03-l-2X-CA-BLE-S-IZE-S-AD-DED--1 C
REFV
 •

DIRECT STUD FIXING CENTRES:

: 1640 ±1 -I KEY TO DIAGRAM:

I1-':~-------1620 ±1 ·1
960 ±1 -I 400 HOL[ FOR INSTALLATION OF
: 820 ±1 ·1 0) SINGLE HULL BOSS AS SHOWN BY
DRGn 177
I
1-, :~- 680 ±I - - -

II x Ml0 STUD POSITIONS AS SHOWN

20 ±1-
I
o CATHELCO TO PROVIDE, YARD WELD TYPICAL
STUD DIR[CT TO HULL PLATE
CATHELCO LTD MAY PROVIDE A STUDDED
MOUNTING PLATE UPON REQUEST AT

~! -+- ~ -+- -+- -~

EXTRA COST

-:
.-'$---.------------------------~$--.-~
-+-1 USE CENTRE LINES OF HULL BOSS
~ POSITION AS A DATUM FOR SETTING
0)
.....~ ~
OUT THE STUD POSITIONS,

QY"! 1
-
ol-ELECTRIC SHIELD AREA: TYPICAL STUD DETAILS:
~ 5700 SECONDARY

I I 3400 PRIMARY -I g:
>--
C>::
~
--I I MIO x 1,5P
AREA OF PRIMARY DI-ELECTRIC SHIELD MASTIC
_""
USE SPECIALIST TWO PART PUTTY OR SIMILAR
COATING TO RUN FROM 4MM TO lMM THICK
~
~1
FULL WELD
BY YARD
+-r
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APPROX, OVER AREA SHOWN >--
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2§
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" is
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AREA OF SECONDARY DI-ELECTRIC SHIELD
MASTIC USE STANDARD HULL COATING TO
25
~

500 MICRONS MINIMUM THICKNESS, OVER

AREA SHOWN
t "*
HULL PLATE

o 16: 10:03 NOTE 3 ALTERED I PA NO: I DATE: I SCALE'

CATHELCD LIMITED TITLE'

I
C-SHiElD ~CCP)
MARIN[ HOUSE, 18 HIPP[R STR[ET SOUT~
CH[ST[RFI[LD, D[RBYSHIRE, S40 ISS, UK
C 116: 11 :95
B 26:09:95
IREV DATE'
1620 was 1630
STUD WAS 32 LG
MODIFICATION:
STUD flXINC &DiElECTRIC AREA fOR
!25A TO 200A LINEAR LOOP ANODE DRAWN:
JRH
18:SEPT:94
DRG
NO
M1076/D
NOT TO SCALE
 KEY TO ORA WING ITEMS:
I. DIELECTRIC SHIELD AREA TO DRG. No.:-
50-100A MI075
HULL BOSS TO HULL PLATE
125-200A MI076
WELDS BY YARD
2. 50-100A LINEAR LOOP ANODE
TO DRG. No. MI072
125-200A LINEAR LOOP ANODE
TO DRG. No. MI073

3. MASTIC INFILL IN CABLE RECESS

4. SINGLE ENTRY HULL BOSS

TO ORG C1177/M20 (50-150A)
6 DRG CII77/M25 (175-200A)
5. BRASS CABLE GLANDS TO SUIT CABLE
COFFERDAM TO HULL PLA TE
WELDS BY YARD
6. HULL PLATE

7. CABLE TO JUNCTION BOX x 5M LONG

UNLESS OTHERWISE STATED

8. 6" NOM BORE COFFERDAM

7 TO DRG C1191 /M20 (50-150A)
DRG C1191/M25 (175-200A)

Iii
~
IT
CATHELCD LIM b
'D1)
MARINE HOUSE, 18 HIPPER STREET SOUTH,
0
C
B
120406
11:0;04
11.02.04
NOTES MODIFIED
DETAILS MODIFlEO
NOTES MODIFIED
TITLE:
TYPICAL INSTALLATION SfCTlON
fOR 50 TO 200A liNEAR WOP ANODE
PA NO:
DRAWN
MDA'
DATE: I SCALE:

C-SHI£LO (ICCP) CHESTERFIELD, DERBYSHIRE, S40 ISS, UK. REV: OA TE: MODIFICA nON:
 I- 245 APPROX LENGTH .. I 1- 285 APPROX DIAMETER
K[Y TO COFF[RDAM DRAWING IT[MS:
ITEM: I DESCRIPTION: REQD:
EXIT L--t_ _ _
CXSW006
PIPE0--~
2 r-
a
:<:
~
_____
o NEOPRENE
IGASKET
\, .'
6" NOMINAL BORE SCH 80 TUBE
OF SIZE 168.3 % x 10.97 WALL
x 200 LG WITH 40.5 HOLE CUT
TO ALLOW ENTRY OF BOSS ITEM 2

-11
CXSWCI191M20
40;1 EXIT PIPE DRILLED THROUGH &
1
2 TAPPED EACH END M20 x 1.5 PITCH
1 x 20 DEEP. PIPE IS 90 LONG
0 140 CRS - a TO DRG CI947 ITEM 3
1

i CXFL032
---------~------.-
0")
~ 6" ST[[L PLAT[ FLANG[ FOR W[LDING
~ TO 8S4504, CLASS 150, PN 16,
1 3
CODE 101, OF SIZE 285 % x

L,' _
1

i 170.5 I/O X 22 THICK WITH 8 X

i 22¢ HOLES ON A 240 PCO. NOTE
i FLANG[ HAS 212¢ x 3 RAIS[D FAC[
CXFL031-PO
! 6" ST[[L BLANK FLANG[S TO BS4504,
1
CLASS 150, PN 16, CODE 105, OF
-----1---- 4 SIZE 285¢ x 22 THICK WITH 8
I
X 22¢ HOLES ON A 240 PCD.
COFFERDAM
TUBE

PRODUCTION NOTES:
WELDING
FLANGE
0/ BLANK
FLANGE
o M20 BOLTING
DRILL & TAP C[NTRE OF FLANG[ TO
SUIT M20 x 1.5P TO ACC[PT IT[M 5

5 I M20 x I.SP BRASS FLANGE PLUG

CXGSOl2
1) MATERIALS: ALL STEEL ITEMS TO BS4360 GR43A OR EQUIVALENT. TUBE TO BE API 5L TESTED 6 NEOPRENE FLANGE SEALING GASKET
I
OF SIZE 210 % x 170 I/o x 3 THICK
2) WELDS: ALL CONTINUOUS FILLET TYPE OF MIN SIZE 6MM X 45" AND TO CONFORM TO BS4870
CXBTO 12, CXBUO 13, CXWA034
3) FINISH: DEGREASE THE SURFACE AND APPLY ONE COAT OF GREY WELDABLE PRIMER 7 I M20 BOLTS X 80 LONG GRADE I 8 EA
WEIGHT 28.5KG I 8.8 BIP - WITH NUTS AND FLAT WASHERS
C JA 07.03.07 TITLE: DATE: SCALE:

I
STK REF NO.S ADDED. M20 BOU WAS 75LG
CATEIELCO LIMITED B 16.02.05 ITEM 2 DRG NO, WEIGHT ADDED 6" NOMINAL BOR[ COFFfRDAM WITH 18:JAN:95 NOT TO SCALE
MARIN[ HOUSE, 18 HIPPER STR[U SOUTH,
CH[ST[RFI[LD, D[RBYSHIRE, S40 ISS, UK. I A 18:01:95 RE-DRAWN U10 TUDfAO'[D f'ADI[ [Vir O[TA"S DRAWN: DRG
C-SHIElD (ICCP) !REV: BY: DATE: MODIFICATION: NIL ImlUl [I vAOL [iii IfliL JRH NO: Cl191/M20
 1 --1 26 -6

1 'ISl.
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MATERIAL: USE STEELS TO BS4360 GRADE 43A OR EQUIVALENT

NOTE: EACH BOSS WILL BE PROVIDED WITH
FINISH: DEGREASE AND APPLY ONE COAT OF GREY WELDABLE PRIMER A SUITABLE CABLE GLAND BY CATHELCO

~ CATHELCD LIMITED
TITLE' PA NO: SCALE:

~ ~~~ CII 77Ie1M20

c-sHino HUll BOSS FOR SINGlE TYPE 17:JAN:95 NOT TO SCALE
MARINE HOUS£, 18 IIiPPER STREIT SOUTH, C 17:0195 R£ -DRAWN liNEAR ANODE WITH V20 CIAND THREAD DR::
TANK BLAST[R CHESTERFIELD, DERBYSHIRE, 540 !55, UK. REV: DATE: MODIFICATION:
 NOTES: ITEM No. DESCRIPTION
I. BEFORE ATTEMPTING ANY ANODE INSTALLATION 50A TO 200A TYPE MMOjTi OR Pt/Ti
ALWAYS CONSULT THE CATHELCO (C-SHIELD) LINEAR LOOP ANODE (SEE NOTES).
INSTRUCTION MANUAL PROVIDED. CjW 5M FLEXIBLE CORE CABLE
2. FOR DETAILS OF LINEAR LOOP ANODES REFER TO: ANODE MOUNTING:
c9'~ 50-100A ANODE TO DRG.NO. Ml072 A) STUDS WELDED DIRECTL Y TO HULL
125-200A ANODE TO DRG.NO. MI07J PLATE. BY YARD
2 B) DI-ELECTRIC SHIELD
C) NUTS & WASHERS FOR ANODE
INSTALLATION SUPPLIED BY CATHELCO
J I HULL PLATE WITH RECESS FOR INSERTION
c9~ ~ Ii OF HULL BOSS
4 I SINGLE ENTRY HULL BOSS Cjw SUITABLE
SIZED BRASS CABLE GLAND
I CABLE GLAND MOUNTING SLEEVE CjW
5 BRASS CABLE GLAND
6 M20 BOLTING ASSY X 8# FOR COFFERDAM
4) / i 6)
7 6" NjB COFFERDAM HOUSING
7
NEOPRENE SEALING GASKET FOR
-((o)- 8 COFFERDAM ASSY

~7
'" 6" BLANK FLANGE TO FORM TOP COVER
9
FOR COFFERDAM ASSY
2 ) II I I BRASS PLUG FOR COFFERDAM INSPECTION
10
OR FILLING

O/~
J
~6
5

C'fiATluELCO LIMITED
~
C 18/04/06 CABLE SIZES REMOVED TlTL£: I PA NO:
C MARINE 11.
HOUS[ 18 HIPPER STREU SOUTH,
B
A
04/02/04
19/04/01
MOUNTING PLATE REMOVED
RE-DRAWN IN AUTOCAD
EXPLODED DIAGRAM OF 50A TO ~~-,-;:-~I:c-:--~~--L--~----.--=-=---i
200A LINEAR LOOP ANODE I DRAWN: I I
n .. r n u nnn

C-SHIElO ~CCP) CHESTERFIELD, DERBYSHIR[ S40 ISS, UK. REV DAT£: MODIFICATION: ASSEMBLY JRH
 JUNCTION BOX DETAILS
1---------200--------1 100 ENCLOSURE TYPE: K6
MATERIAL: HIGH QAULITY ALUMINIUM ALLOY (ALS; 12)
1-------180 CRS-------I 65 34 FlNSIH: SMOOTH NATURAL FINISH
LID FIXING: 4xM6 STAINLESS STEEL SLOTTED CAPTIVE
4 xCLEARANCE SCREWS
MOUNTING HOLES
GASKET: BLACK NEOPRENE
FOR M6 PAN
PROTECTION: RATED IP66 TO IEC 144
HEAD SET SCREW.
IMPACT TEST: 7NM
r BOX MOUNTING: 4xM6 HOLES (CLEARANCE)
I I I I
KEY TO DRAWING ITEMS:
1 YARD SUPPLY ANODE POWER CABLE
2 CABLE GLAND REF: A2EX??
3 CATHELCO SUPPLY ANODE CABLE TAIL
5
4 CABLE GLAND REF: A2EX??
5 CABLE CONNECTOR TERMINAL X 3
o o 6 CABLES TO BE SUPPLIED BY YARD

o o 6

o o

BOXES REQUIRED PER SHIP:

I I I I
I I JUNCTION BOX LOCATION:
4
VESSEL:

CATHELCO LIMITED ~ ~RJ-P ~".,..----.-::7Ed-:CH-;-;-;~T.T3:"'T"n0~~;:;;;-.~6------L--1:_2

TfTL£: PA NO: DATE: SCALE:
I-B--+---22:-01:-I05 t-KEY-DEA-=-TAlL:-::-S=MOD=--------j lAYOUT OF CABLE CONNECnoNS &- GlAND ---j
MARINE HOUSE, 18 HIPPER STREET SOUTH, A 19:10:95 MDA RE-DRAWN DETAILS FOR K6 JUNCTION BOX DRAJt~ NO: M1259
CHESTERFIELD, DERBYSHIRE, S40 ISS, UK. REV: DATE: SIG: MODIRCAnON:
 I~ 188 - 0.51 _I 160
-I RESIN BODY TO HAVE 2 x lMMo x
2SMM DEEP HOLES FOR LOCKING
PIN SPANNER

)Dr ( ; \ KEEP METAL FACE

~ CLEAN AT ALL

L_
TIMES

-r CXl

a
'&
I

I
~///II/I
.---------- b;d-J1Q IH~ '-J
1-1-
C)
3;

4S'
\"0 ~ J
•
0) ELECTRODE ZINC BLOCK TO DRG.NO.Cll03 o NEOPRENE SEALING RING TO DRG.NO.Cll08
o STEEL MOUNTING SLEEVE TO DRG.NO.CnOl

o RESIN BLOCK AS FORMED BY MOULD TOOL o NEOPRENE WASHER TO DRG.NO.Cl 109

o BRASS M20 x 1.SP FULL NUT

o CABLE CONNECTOR TO DRG.NO.Cl IDS o STEEL DISHED WASHER TO DRG.NO.Cl 110

o FLEXIBLE CABLE SEE ORDER JOBCARD
16MM SO 10.lMM 0/0

CATHELeD LIMITED TITLE: I PA NO.' DATf' ISCALE:

I
E 23:08:01 ELEMENT AMENDED
C D 27.02:97 DIMENSION AMENDED J 14:MARCH:95 3/4 FULL SIZE
MARIN[ HOUSE, 18 HIPP[R STR[U SOUTH, C 14:03:95 RE-DRAWN I ZINC TYPE REFERENCE CElL INSERT I DRAWN: CHECK: I DRG C 1102/[
C-SHIElD ~CCP) CH[ST[RFI[LD, D[RBYSHIRE, S40 ISS, UK. REV DATf' MODIFICATION: I JRH DP NO.
 CUT HOLE IN HULL PLA TE AS SHOWN CABLE GLAND DURING ASSEMBLY FILL THE VOID BETWEEN
AND WELD IN COFFERDAM HOLDER. I I I / PROVIDED BY THE REFERENCE CELL INSERT AND THE
USE FULL PENETRA TlON WELD WITH COFFERDAM HOLDER WALL WITH EPOXY
BACK SEALING RUN OPTIONAL SPLICE KIT ,II 11,1/ CATHELCO FILLER MASTIC. CA THELCO TO SUPPL Y.

~
\, ,I
REFERENCE CELL
TO DRG.CII02
]@ \
/
/
/

-~- 1
I
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~ ----i------- C)
~ i
"
'G. PJ
\ r-

--~

/\
@) """\
\
~

'''-'''-,,,-,
"-,
~/ ,

HULL ~ I I COFFERDAM HOLDER ~. ~ ----------

PLATE ~ TO DRG.CI190 ;'

INSTALLATION ORDER I.. 350 APPROX .. I I- 2850 --

I) CUT HULL PLATE
2) WELD COFFERDAM INTO POSITION 5) SCREW REFERENCE CELL IN THROUGH COFFERDAM
3) PLACE REFERENCE CELL CABLE THROUGH COFFERDAM 6) FIT WASHER AND RETAINING NUT INSIDE COFFERDAM
4)COVER BACK OF REFERENCE CELL IN EPOXY 7) SMOOTH EPOXY TO SURFACE OF COFFERDAM AND REFERENCE CELL
TITLE. PA NO: SCALE.
~ CATHELeD LIMITED DETAILS OF ZINC REFERENCE CEa 14:MAR:95 I NOT TO SCALE

~ MARINE HOUSE, 18 HIPPER STREET SOUTH, 8 14:03:95 RE-DRAWN MOUNTED INTO COFFERDAM HOLDER DRAWN:
DP
DRG
NO: C1162
C-SHI[LD ~CCP) CHESTERFIELD. DERBYSHIRE 540 155, UK REY DATE. MODIFICATION: JRH
 f-I·I------- 350 APPROX LENGTH ----I 1----- 285 APPROX DIAMETER KEY TO COFFERDAM DRAWING ITEMS:
REF CELL MOUNTING ITEM: DESCRIPTION: REQD:
PLATE HELD BY FULL EXIT I
PENETRATION WELDS PIPE -,-I_ _ ~~ CXSW007
AS SHOWN. '. 6" NOMINAL BORE SCH 80 TUBE

0-~
NEOPRENE
or SIZE 168.3 % x 10.97 WALL
8 C)
GASKET x 300 LG WITH 40.5 HOLE CUT
<:
G)
TO ALLOW ENTRY or BOSS ITEM 2
CXSWC 1947 -03
400 EXIT PIPE DRILLED THROUGH &
TAPPED EACH END M20 x 1.5 PITCH
2 x 20 DEEP. PIPE IS 90 LONG
I
TO DRG C1947 ITEM J
i
I CXFL032
i
6" STEEL PLATE F'LANGE F'OR WELDING
--------~------- TO BS4504, CLASS 150, PN 16,
CODE 101, or SIZE 285 % x
3 170.5 I/O X 22 THICK WITH 8 X
220 HOLES ON A 240 peD. NOTE
rLANGE HAS 2120 x 3 RAISED rACE
CXFL031-PD
6" STEEL BLANK rLANGES TO 854504,
i CLASS 150, PN 16, CODE 105, or
1-1---- 240 I 4 SIZE 2850 x 22 THICK WITH 8
----1---- X 220 HOLES ON A 240 PCD.
ENSURE CHAMFER FLANGE i DRILL & TAP CENTRE or rLANGE TO
COFFERDAM PLUG
ON ITEM 8 IS SUIT M20 x I.SP TO ACCEPT ITEM 5
TUBE
WELDED FACING
ON SIDE SHOWN WELDING
FLANGE
0 BLANK
FLANGE
0 M20 BOL TlNG
5 M20 x I.SP BRASS FLANGE PLUG
CXGS012
6 NEOPRENE rLANGE SEALING GASKET
PRODUCTION NOTES: OF' SIZE 210 % x 170 I/O x J THICK
CXBTO 12, CXWA034 & CXNUO 13
I) MATERIALS: ALL STEEL ITEMS TO BS4360 GR43A OR EQUIVALENT. TUBE TO BE API 5L TESTED
7 M20 BOL TS x 80 LONG GRADE 8 EA
2) WELDS: CONTINUOUS FILLET TYPE OF MIN SIZE 6MM X 45' UNLESS STATED OTHERWISE AND CONFORM TO BS4870 B.B BZP - WITH NUTS AND F'LAT WASHERS
3) FINISH: DEGREASE THE SURFACE AND APPLY ONE COAT OF GREY WELDABLE PRIMER CXSWCI430
8 MOUNTING PLA TE TO DRG C1430
----~--- -------~----------.-.-.--- -~-_,_~=__--.__:_:--,-::----L-__t

~ C11 THELC0 LIMITED C JA 07/03/07 SfKiloS AIJIJmMJO BOcr WAS 75 LC 6~,ENOMINAI BOR[ COFFERDAM FOR ~;s~ 1190 OA:~JAN 95 NOT TO SCAlE
~ MARINE HOUSE, 18 HIPPER STREET SOUTH,i-B- -t---+---2S-'---:oS-'--.9S-+---TU-BE-L[-NG-TH-CO-RR[-CfI-
W- i R'LLLR'LNC[ LI CCTROD[ CLiL I-D-RA~-N:-~c-c--rDN=-=-ROG.:---C1--'--1-90----.---::RC=c-EV:--t
C-SHIElD (ICCP) CHESTERFIELD, DERBYSHIRE, 540 ISS, UK. REV: BY.' DATE. MODIFICATION: LI LI LI LLLI II LL JRH
 NOTES: ITEM No. DESCRIPTION
FOR FURTHER DUAILS OF A TYPICAL FOR CORRECT INSTILLATION INSTRUCTIONS FOR THIS REFERENCE ELECTRODE HOUSING WITH
REFERENCE ELECTRODE ASSEMBLY ANODE TYPE ALWAYS CONSULT THE CATHELCO ELECTRODE ELEMENT
C- SHIELD MANUAL _____ _
SEE DRG. NO. C1162 ~trtHtNCE ELECTRODE NEOPRENE
2
SEALING RING
REFERENCE ELECTRODE STEEL
3 MOUNTING SPINDLE / SLEEVE
HULL PLATE SHOWING RECESS FOR
4
INS TIL LA TlON OF COFFERDAM
REFERENCE ELECTRODE FLANGED
5 COFFERDAM ASSEMBLY, 6" NIB
6 REFERENCE ELECTRODE THREADED
MOUNTING PLATE
M20 NUTS, BOLTS & WASHERS FOR
7 COFFERDAM ASSEMBL Y. NOTE 8X SUS
7 REQUIRED PER COFFERDAM
5 REFERENCE ELECTRODE INSTILLATION KIT
8 COMPRISING: NEOPRENE WASHER, DISHED
WASHER & M20 TIGHTENING NUT
9 COFFERDAM ASSY TOP COVER 6" FLANGE
16mm CORE CABLE X3m EXTENSION TO
10 B.S. 638 PART4
BRASS CABLE GLAND AS SUPPLIED WITH
11 COFFERDAM MOUNTING SLEEVE
12 ICOFFERDAM CABLE GLAND MOUNTING SLEEVE
~ 13 NEOPRENE SEALING GASKU FOR
4 ~ COFFERDAM ASSEMBLY
9 14 COFFERDAM FILLING I INSPECTION
BRASS PLUG
][E: PA NO·. SCALE:
V~~ CATHELCD LIMITED [XPLODED DIAGRAM 01 TYPICAL
~
OIlAWN
MARINE HOUSE, 18 HIPPER SIRW SOUTH, A 20.04.01 RE-ORAWN IN AUTOCNJ R[FER[NC[ [[[CTROD[ INSTILlATION JRH
C-SHIEID ~CCP) CHESTERFIELD, DERBYSHIRE, 540 ISS, UK REV: DATE: MODIFICATION:
 1- 82--- I" 72 ---<

68 CRS---
JUNCTION BOX DETAILS
50 ---1-22- ENCLOSURE TYPE: K4
MATERIAL: HIGH QUALITY ALUMINIUM ALLOY (ALSi 12)
FlNSIH: SMOOTH NATURAL FINISH
LID FIXING: 4xM4 STAINLESS STEEL SLOTTED CAPTIVE
SCREWS
2 GASKU· BLACK NEOPRENE
PROTECTION: RATED IP66 TO IEC 144
IMPACT TEST: 4NM
4 X CLEARANCE BOX MOUNTING: 4xM5 HOLES (CLEARANCE)
MOUNTING HOLES
FOR M5 PAN
HEAD SET SCREW KEY TO DRAWING ITEMS:
1 YARD SUPPLY ANODE POWER CABLE
2 CABLE GLAND REF : A2EX??
3 CATHELCO SUPPLY ANODE CABLE TAIL
4 CABLE GLAND REF ." A2EX20S
5 CABLE CONNECTOR.

a
tQ
u
"" '-0

BOXES REQUIRED PER SHIP:

JUNCTION BOX LOCATION.

4

K4 JUNCTION BOX VESSEL.

CATHELCD LIMITED ~ C~8L[ CONNEGnONS &:

PA NO: I DATE" SCALE"
TITLE 1"2
B 220105 RJP KEY DFTAILS MOD lAYOUT OF DRAWN .
MARINE HOUSE, 18 HIPPER STREET SOUTH, A 19:10:95 MDA RE-DRAWN GLAND DETAILS IN K4 JUNCTION BOX MDA
CHESTERFIElD, DERBYSHIRE, S40 1SS, UK. REV: DATE SIC: MODIFICATION: Ml046/B
 o
SHAFT MONITORING
BRUSH SET & mV
1

i
BI-METAL STRIPS ROLLED TO
SUIT REQUIRfO DIAMETER
OF INTERMEDIATE SHAFT AREA
PROP. SHAFT

MUER SYSTEM IS
i
i
i
1
BAND CLAMP DETAILS
TIGHTEN BOTH BAND
0
i CLAMPS TO 10Nm ±1 Nm
i
------------~-----------

1
MOUNT SLIP-RING CLOSE TO BEARING
! BLOCK OR WALKWAY SO THAT SUPPORT
1

BARS CAN BE WELDED INTO POSITION

i
1 ALTERNATIVELY YARD MUST PROVIDE
i SEPARATE SUITABLE MOUNTING POSTS.
i

2 +1
-0

i
i
NOTE
BI-METAL STRIPS ARE SUPPLIED
2R:J\
1
2 SLiGHTL Y LARGER THAN SHAFT ¢ TO DETAIL Z
i ALLOW FOR FINAL FITTING OPERATlONS:-
! ON INSTALLATION:
- - - - _ _ _ _ _ _1_ _ _ _ _ _ - - - - - -
A) FILE ENDS OF STRIPS UNTIL FLUSH WHEN FITTED TO SHAFT
B) IF NECESSARY INFILL WITH SOFT SOLDER AND POLISH
z
RUNNING SURFACES OF BI-METAL RINGS MUST BE FLUSH AND
REMAIN UNMARKED AFTER COMPLETION OF (A) AND (B) ABOVE
DRAWING NOTES: 3) BI-METAL STRIPS - ROLLED TO SUIT REQUIRED ¢ ~
I) SHAFT EARTH MILL/-VOLT BRUSH SET DUAILS SEE DRG.N0.c1157 4) BAND CLAMP DETAILS SEE DRG. NO. MI192
2) MAIN SHAFT EARTHING BRUSH SU DUAILS SEE DRG.N0.c1181 5) SYSTEM WIRING DIAGRAM INC. SHAFT MONITORING SEE DRG.NO.CI159
TITLE: PA NO: OAT£' SCAL£:
~ CATHELeD LIMITED f---+----t---~~--il C-SHIELD ICCP PROPElLER SHAFT ~-r;;-;~~-----'-~----t
~ MARINE HOUSE, 18 HIPPER STREU SOUTH, A 19/09/03 DETAILS CORRECTED
C-SHIELD VCCP) CHESTERFIELD, DERBYSHIRE, 540 ISS, UK. EARTHING GENERAL ARRANGEMENT DR:::.
REV: OAT£: MODIFICATION:
 BAND CLAMP CONNECTOR
EACH END OF A SUITABLY CUT LENGTH OF
BANDING IS FED INTO EACH OF THE TWO
TENSIONERS WHICH ARE TIGHTENED BY HEX. HEAD, 8mm AIF
TURNING THE SCREWS UNTIL THE TURN CLOCKWISE TO
DESIRED CLAMP DIA. IS ACHIEVED TIGHTEN CLAMP (2 PLACES)

!
I
~ i
::::::::::: i ~<~
i ~\;;V
~
---- i~~Y
--- ~&"-~---
---- ~! -

---- f'\S
\'0
I
iI

----
B~NO
STAINLESS I ~6m~ I
STEEL BANDING
\ 2 - WORM ORIVF
CLAMP TENSIONERS
MATERIAL.' ALL COMPONENTS ARE IN
STAINLESS STEEL, GRADE AISI 304
(B,S.970 - 304 S15)

~ CATfIELCO LIMITED
TlTL£' PA NO: SCAL£'
BAND CLAMP DETAILS FOR
~ MARIN[ HOUSe 18 IiIPP[R SlRm SOUTI( SIiAFT [ARlHING ASSEMBLY D~:;
C-SHIElO ~CCP) CHESTERFIELD, DERBYSHIRE, S40 ISS, UK REV: OAT£' MODIFICATION
 KEY TO DRAWING ITEMS:
t t MOUNT THE SLIP-RING & BRUSH

Co
Cl
c.o
CD SET ON THE INTERMEDIATE SHAFT
AREA, NEAR TO A BEARING BLOCK
OR WALKWAY. WELD IN POSITION A
SUPPORT BAR OF 16MM DIAMETER.

o l-- 016 x 60 LONG SUPPORT BAR

USE THIS TO CLAMP THE BRUSH
SET IN POSITION. REFER TO
DRG.NO.MI191 FOR MORE DETAILS

)2! O HIGH DENSITY, LOW RESISTANCE,

SILVER GRAPHITE BRUSH.

BRUSH SET EARTHING CABLE BOLT

5 O 3 TERMINAL. CONNECT TO HULL PLATE

USING 35MM SQ CABLE OR SIMILAR
SEE DRG.NO. 1159 FOR FURTHER
WIRING DETAILS.
Ul
1'0
(;\4
BRUSH GEAR ALIGNMENT BOLTS.
~ TIGHTEN & SECURE WITH LOCKTAB
AFTER SET IS MOUNTED.

o
( ; \ DISTANCE BETWEEN CENTRE OF

~
BRUSH GEAR SUPPORT BAR AND
TOP SURFACE OF ASSEMBLED SLIP
RING.

I.. 150 --I

f6\
COPPER SLIP-RING ASSEMBLY, SEE
NOTE: ITEMS 2, 3, 4 & 6 BY CA THELCO, NB: BRUSHES MUST BE MOUNTED ~ DRG. NO. M1191 FOR DETAILS.
REST PROVIDED AND WELDED BY YARD TANGENTIALL Y TO SHAFT
'1;1D
CA THELCO LIMIT
PA NO' OAT£' SCAL£'
r«re
~
£;
MARINE HOUSE, 18 HIPPLR SfREFT SOUTH,
0
C
B
01.MAR:06
15.APR05
OlNDV94
60MM WAS 125MM
OfTNLS CORRECTED
REDRAWN ANO DPIJA/ED
TlTL£'
C-SHI[ID ICCP PROrEll[R SHAFT
[ARTHING' MAIN BRUSH SET DUAII
DRAWN
JRH
. OlN0V'94
. ORC
NO
NOT TO SCALE

C1181
REV
D
C-SHIElD (ICCP) CHESTERFIELD, DERBYSHIRE, 540 15S, UK. RBI' OAT£' MODIFICATION:
 KEY TO DRAWING ITEMS:

t 0) MOUNT THE SLIP-RING & BRUSH

I:~I:~=~I ~i
• SU ON THE INTERMEDIATE SHAFT

0; ffi LLbJ~ I
Q
c.o AREA, NEAR TO A BEARING BLOCK
OR WALKWAY. WELD IN POSITION AN
INSULA TED SUPPORT BAR OF 16MM
FINISHED DIAMUER (SEE NOTE ON
016 x 60 LONG
INSULATED SUPPORT BAR
-I I-- IMPORTANT NOTE:
END OF SUPPORT BAR MUST
BE SLEEVED WITH INSULA TlNG
DRAWING). USE THIS TO CLAMP THE
BRUSH SU IN POSITION. REFER TO
DRG.NO.MI191 FOR MORE DUAILS

!7
PLASTIC OR SIMILAR WHEN

I .
BEING USED TO MOUNT THE
mV MUER SHAFT MONITORING
BRUSH SU
O HIGH DENSITY, LOW RESISTANCE,
SILVER GRAPHITE BRUSH.

I BRUSH SU EARTHING CABLE BOLT

4 O 3 TERMINAL. CONNECT TO HULL PLATE
THROUGH MILLIVOLT MUER PROVIDED
USING 1.5MM SQ CABLE OR SIMILAR
SEE DRG.NO. 1159 FOR FURTHER
WIRING DUAILS.
~
r.:\ BRUSH GEAR ALIGNMENT BOL T.
~ TIGHTEN & SECURE WITH LOCKTAB
AFTER SU IS MOUNTED.

DISTANCE BUWEEN CENTRE OF

O
5 BRUSH GEAR SUPPORT BAR AND
TOP SURFACE OF ASSEMBLED SLIP
RING.
6
97
r(;\
COPPER SLIP-RING ASSEMBL Y, SEE
NB: BRUSH MUST BE MOUNTED NOTE: ITEMS 2, 3, 4 & 6 BY CATHELCO, ~ DRG.No.MI191 FOR DUAILS.
TANGENTIALL Y TO SHAFT REST PROVIDED AND WELDED BY YARD

r?r1f CfI T'UELCO LIMIT'DD PA NO: DATE: I SCALE:

I A E 01:MAR:06 60MM WAS 125MM TITLE: OlN0V'94 NOT TO SCALE
C-SHI[ID ICCP PROP[lI[R SHArf
~
11. 1'; U 15 APR. 05 OUAII S CORRfCTm DRAWN . DRG
MARINE HOUS£, 18 HIPPtR SIRW SOUTH, C 0lNOV94 R[DRAWN AND OPDATED [ARlHING mV METER BRUSH SET D[Wl JRII NO C1157
C-SHlfLO (ICCP) CHESTERFlELD, DERBYSHIRE, S40 !SS, UK. REV DATE: MODIFICATION:
 DRILL 2-HOLES TO SUIT STEEL SHAFT MILD STEEL CHANNEL SECTION
AND VELD INTO CHANNEL SECTION 102X51MM NOMINAL
AS SHOVN

bO
A) lbMM DIA STEEL ROD
FOR DOUBLE EARTH BRUSH HOLDER
(REFER TO DRG C1181>

B) lbMM DIA INSULATED STEEL ROD

FOR SINGLE MV METER BRUSH HOLDER
(REFER TO DRG C1157>

NB: THIS DIMENSION SHOUL.D lDEALL Y BE

THE SAME HEIGHT AS THE CENTRE-LINE OF
THE SHAFT,

~ VELD TO DECK

NB: THIS ITEM IS YARD SUPPLY,

DRG IS FOR GUIDANCE ONLY

, £~r~!,L~ ~ppk{M{Tsfu£ 1}~03}~061- R,: - :;P+- N-B TlTL~YPICAL SHAFT EARTHING

PA NO: DA TE: SCALE:
3/3/05 NTS
I--A-t--:-O -NOr,-[A-DD£-O- - - - I DRAWN: TECH MAN: DRC C2 158 REV
C-90£W(KXP) CHESTERFIELD, DERBYSHIRE, S40 ISS, UK. R£Il DATE' SIC: MODIFICATION: HOLDER MOUNTING POST SRE RJP No. A
 KEY TO C- SHIELD MV METER CABLE TERMINALS:
~------------200-------------·1 01 EARTH CABLE FROM BRUSH GEAR
EARTH CABLES
1--------- 160 CRS - - - - - - - - - · 1 02 EARTH CABLE TO HULL PLA TE

FOR DETAILS OF TYPICAL CABLES TO

~~

I ___ DUAL SCALED USE REFER TO DRAWING C1159

~ v--- MV METER
~~ _ _L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~~~

,-------------, ~ 110ll'SC4I[-HlalSOU[1 V
SELECTOR
SWITCH
-
/

~o mV 250
q5);/ TERMINALS

m
~ ___ DOOR LOCK

~~
§§
CATHELCO LTD: C-SHIELD MILL/-VOLT METER
PROPEUER SHAFT TO HULL PLATE GROUNDING INDICATOR OPERATION:

A) MIJIJI READING !lJJV£ 150mV INDICATES BAD COlliACT: CWII mE SUP-RING AND BRUSHES
8) MIJIJI READING OF ZERO '!/HEN SHAFT IS TURNING INDICATES FAULlY GROUNDING OR MIJIJI INSTRUCTION
PLATE
WHElCO /JIfTfD, w.R1N[ HOOSE, HIPPfR STRm srom, acsmfllJ, 0CRfI'tSINlf. sw ISS, tNfm KiNGfXJI
ff1IPHON[ (0124$) 201102 (1( 2;5916, fAX5'MlE: (OIZ~) 206519, !U£X: 54l5J4 Will G
.--+--
o o
-

PART VIEW WITH DOOR REMOVED:

WIRING IMFORMATlON:
ENCLOSURE DETAILS:

1) MATERIAL: 1.5MM COLD ROLLED STEEL, FOLDED AND

NICKEL PLATED CABLE GLANDS PLATED STEEL MOUNTING LUGS DOOR SWINGS 180' WELDED TO FORM A RIGID STRUCTURE
TO SUIT 5MM TO 10MM0 CABLE APPROX JMM THICK WITH 09MM UNIT IS SEALED TO
2) FINISH: EPOXY POLYESTER PRIMED FOLLOWED BY TOP
HOLES ON CENTRES SHOWN IP55 RATING
COAT OF ACRYLIC PRIMER ro GREY RAL 7035
GENERAL ARRANGEMENT: I
o
~ CATHELeD LIMITED
22/05/06 246 WAS 250 TInE: PA NO: DATE: SCALE:
C-SHiElD SHAFT fARTHING METER ~-::-:----~~09_:MAr;c;Y:9=-4-----L_N_OT_TO_S--.--CAL~E_:_t
~ MARINE HOUSE, 18 HIPPER STREET SOUT~
!.-C--+----'-2J.----'08.0-5-+-120-w-as- 8 0 - - - - - 1

B 19.05.05 80 was 150 WITH SaEC~BLE TWlN SCALED DISPLAY DR~:~: CHEg~: ~~G M11 00 I/ZV
C-SHIELD VCCP) CHESTERFIELD, DERBYSHIRE, S40 ISS, UK. REV: DATE: MODIFICATION:
 # EARTH CONNECTION TO SHIPS MAIN HULL # CABLE CONNECTION TO SHAFT MONITOR EARTH CONNECTION TO SHIPS MAIN HULL
STRUCTURE USE l.5MM SO CORE SHIPS- BRUSH SET. USE l.5MM SO CORE SHIPS- STRUCTURE USE 35MM SO CORE SHIPS-
WIRING CABLE OR SIMILAR, UNLESS WIRING CABLE OR SIMILAR, UNLESS WIRING CABLE OR SIMILAR, UNLESS
PROVIDED BY CA THELCO PROVIDED BY CATHELCO PROVIDED BY CATHELCO

# SHAFT MONITORING # SHAFT MONITORING SHAFT EARTHING BRUSH

METER BY CATHELCO
BRUSH SET BY SET BY CATHELCO
~r-1i CATHELCO
mV

!
,----------11 1 I ,

NOTES: PROPELLER
1) ITEMS MARKED BY #ARE OPTIONAL SUPPLY ACCORDING ~ SHAFT
TO CONTRACT DETAILS
~ COPPER SLIP RING
2) FOR FULL ASSEMBLY INSTRUCTIONS ALWAYS REFER TO ASSY BY CATHELCO
THE CATHELCO C- SHIELD MANUAL

I«C
TITLE PA NO: SCALE
CATIlELCO LIMITED C 280897 CABLE SilLS AMENDED WIRING DIAGRAM FOR C-SHltID DRAWN IOMA~:; Nor 10 SCALE
~ MARIN[ HOUSE, 18 HIPPER STR[ET sour~ B 10.0594 RE-DRAWN PROPEllER SHAFT EARTHING ASSY JRH ND C1159
C-SHIELD rccp) CHESTERFIELD, DERBYSHIRE, 540 ISS, UK. REV DATE MODIFICATION:
 J

2
DECKHEAD PLA TED COPPER LUG 70mm CABLE

,'. L~
~I
CABLF L U C /
2
3m OF 70mm CORE III
FLEXIBLE CABLE TO
B.S. 638 Pt 4
17.2MM DID HOLE TO SUIT M10 WELD OR
BOLT LUG IN POSITION. ......
BY YARD CABLE CRIMPED
CABLE LUG~ INTO LUG
rl----rr-r77/

~
E
E
~

RUDDER~
STOCK
I~ SOmm LUG LENGTH.

RUDDER STOCK BONDING ARRANGEMENT CABLE LUG ARRANGEMENT

(DO NOT SCALE) (SCALE: FULL SIZE)

~ CATHELeD LIMITED
TITLE" PA NO: DATE" SCALE"

~
B 15.03.04 CABLE LENGTH WAS 7MTR
GROUND ARRANGEMENT
FOR RUDDER STOCK It---::-=DRA=-::-:-WN:-rl~~
.. ~~=--
.. ~I-:::=-::~_~--'--------f
I

MARINE HOUSE, 18 HIPPER STREU SOUTH, A 1.4.99 PUT ON AUTOCAD

C-SHIFlO vccp) CHESTERFIELD, DERBYSHIRE, S40 ISS, UK. REV DATE" MODIFICATION: JRH
 THYRISTOR STACK CONTROL TRANSFORMER

1------------ 760 - - - - - - - - - - - -

~2'
LIFTING LUGS
1-----------700------------1
1---------- 600 - - - - - - - - - 5-

FAN
o
o
II
C=:~:;;:::::J
NAMEPLATE

PRINTED CIRCUIT
~
MAINS FUSES

~ () ~ ____-++-____~PO~WE~R~BR~~~KE~R COMPUTER CONTROLLER

o 0

TERMINALS

CHOKE
TRANSFORMER

VENT

HOLES IN BOrrOM TO
ENABLE PLINTH MOUNTING

Jl Jl
1---------540 --------~ 1------370---1

NOTE:
A) : INTERNAL TERMINAL WIRING DETAILS ARE SHOWN ON A SEPARATE DRAWING.
S) . ENCLOSURE PAINT FINISH IN TEXTURED STOVE ENAMEL TO RAL 7035 OR AS REQD.
C) : POWER CONSUMPTION OF UNITS : 100A=3. 15DA=4.5. 2DDA=6. 25DA=B. 30DA= lOKW.
D) : NET WEIGHT OF UNITS: lODA=19D. 15DA=21D. 2DOA=23D. 25DA=255. 3DOA=325KG.
E) : SYSTEM COMPUTER KEYPAD AND R~DING DISPLAY UNIT TO DRAWING C1623

~ CATHELCD LIMITED TlTL£- PA NO: OAT£- SCAL£-

~ MARlN[ HOUSE, 18 HIPPER STRffT SOUT~ A 09.02.05 NUT WflCHTS ADDED

!OOA TO JOOA olp JPHASE THYRISTOR
TYP[ POWER jUPPLY UNIT DETAILS
DRAWN:
21/07/04
CHECK: DRC
NOT TO SCALE

C-SHIELD VCCP) CHESTERFIELD, DERBYSHIRE S40 ISS, UK REV: OAT£- MODIFICATION: RJP PL NO: C 2130
 MOO
- - - - - - - - - - - PANEL BASE

BACK
--------- --------------------

CDAMING CUTOUT

~
C\.

~
'o;;:t

~
I
I
I
I
I
I
I
I
I
--------- -------------1--------
FRONT
177 ~ ?4~ 177.~
±3MM
TOLERANCE

,
C-SJUElO (KXfJ)
GATHELeD LIMITED
MARINE HOUSE, 18 HIPPER STREET SOUTH
CHESTERFIELD, DERBYSHIRE, S40 ISS, UK. REV: DATE: SIG: MODIRCATlON:
TITLE:
100 TO JOOA THYRISTOR PANEL
PLAN VIEW OF CABLE COAMING
PA NO:

DRAWN:
CH
DATE:
06/02/08
TECH MAN: DRG
AIR No. C2291
SCALE:
NTS
 •

KEY TO CABLE TERMINATIONS:

CABLE
SUPPLY ~
01 ENCLOSURE EARTH
02 LlVE1-MINS IN (U)
CATHELCO

8 8 8 8
OJ OJ OJ
03 LlVE1-MINS IN (V) YARD 22 23 24
04 LlVE1-MINS IN (W)
~ ~ @ ~
05 NORMALLY CLOSED RELAY
06 COMMMON RELAY YARD
8 8 8 8 oJ oJ OJ
07 NORMALLY OPEN RELAY
VIEW AT TERMINAL PLATE IN FRONT OF PSU WITH DOOR OPEN
08 18V AC POWER RETURN
09 18V AC POWER OUT -FUSED(F7) YARD r---

Q
10 DATA CORE 1
11 DATA CORE 2 YARD
12 DATA EARTH-SCREEN
y y y y Q Q
<:d <:d <:d <:d <:d <:d <:d <:d <:d <:d <:d I
13 PORT ELECTRODE CELL
~ ~
®

;1 ®
14 STBD ELECTRODE CELL YARD @J @ @ @ @ @ @ @ @ @ @ @ @ @
15 ELECTRODE CELL EARTH -SCREEN y y y y <:d <:d <:d <:d <:d <:d <:d <:d <:d <:d <:d
~ '----'

16 MAIN HULL EARTH RETURN CATHELCO I I I I I I I I I Q Q Q

17 PORT ANODE
18 STBD ANODE YARD
U W
/ \
\ T
\
19 TRANSFORMER CONTROL FUSE(F4)
20 TRANSFORMER CONTROL FUSE(F5)
21 FAN CONTROL FUSE(F6)
CATHELCO
I CUBICLE EARTH I
/
I RELAY ALARM SIGNAL I REMOTE READINGS UNIT I
POWER SUPPLY NEGATIVE
EARTH RETURN CONNECTION
YARD SHOULD LUG ANY
STUD CABLE TERMINATIONS DATA CABLE TERMINALS CABLE USED ACCORDINGLY
22 MAINS FUSE -LlVE1 (F1)
ANODE CONNECTIONS
23 MAINS FUSE -LlVE2(F2) CATHELCO REMOTE READINGS UNIT REFERENCE ELECTRODE VIA BOLTS. YARD SHOULD
I MAINS INPUT I
24 MAINS FUSE -LlVE3(F3) TERMINATIONS VAC SUPPLY TERMINALS CELL TERMINATIONS LUG CABLES ACCORDINGLY

PA NO: DATE- SCALE-

CATHELeD LIMITED TITLE-

I
C-SHIElO ~CCP)
MARINE HOUSE, 18 HIPPER STREET SOUTH,
CHESTERFIELD, DERBYSHIRE, S40 1SS, UK
A
B

REV-
20.09.04
16.06.04
DATE-
FUSE CABLES CATHELCO SUPPLY
18V CORRECTED
MOD/FICA TlON:
INPUT CABLE TERMINAL DETAilS FOR
3 PHASE POWER SUPPLY UNIT
DRAWN:
CAN PL
01/08/0J
CHECK:
:c C 2082
NOT TO SCALE
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1- 280MM ~

ELI: 240mV V: 03V

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EL2: 225mV A: 15A
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CATHODIC PROTECTION
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COMPANY LIQUID CRYSTAL DISPLA Y MULTI-FUNCTION LIGHT EMITTING DIODE STATUS
DETAILS SYSTEM READINGS UNIT KEYPAD INDICATOR:
GREEN - NORMAL RUNNING
RED - ALARM STA TUS

~ CATHELCD LIMITED TITLE: PA NO: SCALE:

~ MARIN[ HOUS£ 18 HIPP[R STR[ET SOUT~ COMPUTER KEYPAD AND DISPLAY UNIT ~.----------r~-----,;;-;=---~-~
C-SHIEID (ICCP) CH[ST[RFI[LD, D[RBYSHIR£ S40 ISS, UK REV.' DATE: MODIFICATION: FOR THYRISTOR POWER SUPPLY (MK5) DR::;:
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THYRISTOR DRIVER
(PR0491 ISSUE2)
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18V OV OV IOV 15V OV 15V 7 8 9 10 II 12 13 14 15 13 14 15 16
6VA 18VA 12VA 12VA
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220V OV OV 18V OV 380V 415V 440V

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TITLE: PA NO: DATE: SCALE:

CATHELeD LIMITED
I
C-SHIElO vecP)
MARIN[ HOUSE, !8 HIPP[R STR[ET SOUTH,
CH[ST[RFIELD, D[RBYSHIRE, S40 !SS, UK
1----+----+---------1

REV. DATE: MODIFICATION:

SCHEMATIC CIRCUIT BLOCK D~CRAM fOR ~-,---------~;__01/___,_08/=03--'--NO-TTO_S--,--;:CAL=-:-E- I
J PHASE THYRISTOR POWER SUPPLY UNIT D~:Z: CHE~2 ~~G C 2083 REV:
 CArRELCO C~SRJEL~ JCCP SYSTEfil SPARE PARTS &TOOLS LJST

DRG No. C1273

REMARK
No. NAME. SKETCH / W£lGHT MAn DRG No. REMARK
WORKG. SPARE
..
C)

~
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HARD- C)

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1 SPARES STORAGE BOX WEARING 1 C1267 ~

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PLASTIC 0)
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(0.361 KG)
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ELECTRODE FOR ~
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C)
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(SEE CATHELCO
C-SHIELD MANUAL
IS.?
.------ PLASTIC G."
0)
f'--.)
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& DRD. No.CI606) (0.735 KG)

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C)

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C)

EARTHING ASSY. SILVER C)

3 3 - C1267 ~
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(0.144 KG) \\)

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PIN SPANNER TOOL:
r-<::::> C1332
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4 FOR INSTALLATION OF STEEL 1 1 ~
G."
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(0.325 KG) -I».
f'--.)

CLAW FOOT SPANNER CUT OUT FOR ~~

TOOL: FOR INTL. !vI20 NUT ~ STEEL
5
INS TAL LA nON OF
REFERENCE CELL (0.225 KG) 70mm0

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C-SHIELD ~CCP) CHESTERFIELD, DERBYSHIRE, 540 ISS, UK DATE REV MOD/FICA nON J RH 0 P
 CATRELCO C~SH/£LP,' ELECTRICAL SPARE PARTS LIST

DRG No. C1288/CH

• I------------------~------------------------~----~--~----~
SUPPL Y POSN. STOCK
ITEM / DESCRIPTION SKETCH / WEIGHT No. No. No.

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MAIN POWER SUPPL Y FUSES ~ ~
<:
C)
V)
X::
RATED TO PANEL OUTPUT. SEE ~
SPECIFICA nON FOR DETAILS. 2 V)
a
FUSES L0CATfD IN BACK SECTION PER
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C)
:::::I
<:
2
a V)
OF POWER SUPPL Y UNIT. REFER <:
TO TERMINAL LAYOUT DRAWING. PSU '"
0
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c:: C)
0

ANODE FUSES RATED TO ANODE ~ ::D.

<:
OUTPUT. SEE SPECIFICA TlON FOR C)
X::
a
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DETAILS. FUSE HOLDERS LOCATED IN 2 V)
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BACK SECTION OF POWER SUPPLY PER '"
C)
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V)
UNIT. REFER TO TERMINAL LA YOUT a
PSU <: '"
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FUSE TYPE- BARREL FUS[ DETAILS ON ruSE

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FAN SUPPLY FUSES LOCATED IN BACK 2 V) ~
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SECTION OF POWER SUPPL Y UNIT.
PER '":::::Ia
C)
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REFER TO TERMINAL LAYOUT DRAWING <: V)

PSU '"
FUSE TYPE : 2A 0
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, CATHELCO LTD
MARINE HOUSE, 18 HIPPER STREET SOUTH,
C-SHIELD (ICCP) CH[ST[RFI[LD, D[RBYSHIRE, S40 ISS, UK
DATE

NKG
SCALE
NTS
CHECK
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L2 ICCP CONTROL PANEL TO DRAWING C21JO
L1 440V / JPH / 60HZ BkW
TERMINAL DRAWING C20B2

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PA NO:
~ CATHELCD liMITED C~SHIElD SYSTEMWIRING DMGfIMI, /JPA~5BIMCllECK
TTTLE'
B 05.05.06 POlIfI/ CONSIIIIP1IOII NJI)f/}
~ MNlfNE HOUSE, 18 HIPPER STREff SOIlTII, A 1MB.04 SCRfEN TEl/l/INIL ctJIIR[ClED FOR ' NB 938 IV!' AR REV
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C-$1ElO pCCP) CHESTERFIELD, DERBYSHIRE, S40 ISS, UK. REV: DATE: MODIRCAT/ON:
 KEY TO DRAWING ITEMS:

o 125A LINEAR LOOP ANODES

POSITION FRAME 15 + 550mm (P&S)
AT A HEIGHT IN CIL WITH PROPELLOR

® REFERENCE ELECTRODE ASSEMBLY

POSITION FRAME 44.5 (P&S)
AT A HEIGHT IN CIL WITH PROPELLOR

ENGINE ROOM

FRAME 44.5

TffLE: PA NO: DATE: SCALE:

~ CATHELCO LIMITED I-----t---;------j C-SHIElD ICCP AFT SYSTEM lAYOUT JJ758/M 14/04/08 NOT TO SCALE
~ MAlIfNE /lOUSE, 18 HIPPER STREET SOIJTII, FOR ' NB 938' DJ:,WN: CHECK: DRG
C-SHI£lO ~CCP) CHESTERAELD, DERBYSHIRE, S40 ISS, UK. REV: DATE: MODIACATlON: AR NO: C 2103