INSTALLATION, OPERATING

& MAINTENANCE MANUAL

‘ALUTEK’
IMPRESSED CURRENT HULL PROTECTION SYSTEM

10 AMP SYSTEM

Vessel Name: C05

OUR REFERENCE No: CA 63227-1

Cathelco
Marine House
Dunston Road
Chesterfield
S41 8NY
U.K.

: 00 44 1246 457900
Fax: 00 44 1246 457901

E-Mail: sales@cathelco.com
Website: www.cathelco.com
 Table of Contents

1. Introduction

2. General Description

3. Installation of Equipment

4. Power supply unit operating instructions

5. Routing operating procedure

6. Service and fault finding

7. Commissioning check list

8. World Wide agency list

9. Drawing list
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 series.

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

corrode in a particular electrolyte, such as seawater. 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 seawater is more likely to be
passive than type 304 and is therefore generally preferred for immersed marine
applications.

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:

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 raindrops 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 of preventing 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 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
aluminium under normal non-anaerobic conditions it can be shown theoretically, and is
accepted practically, that an aluminium/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 seawater 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.
2.0 GENERAL DESCRIPTIONS:

2.1 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.

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.
 Figure 1.3 - Comparison of Reference Electrodes & Interpretation

2.2 MARINE IMPRESSED CURRENT SYSTEM:

The ‘Alutek’ Marine Impressed Current System comprises the following components.

2.2.1 Impressed Current Anodes

The function of the anode is to conduct the d.c. protective current into the sea water.
Anodes have been designed to perform this function whilst maintaining a low electrical
resistance contact with the seawater. Standard surface mounted anodes are available
in 5 and 10 ampere maximum ratings.

Materials now used by ‘Alutek’ for Anodes have now gone beyond lead alloy with
specialist coated titanium based Anodes now available. All ‘Alutek’ anode designs
utilize a tough, chlorine resistant plastic carrier.

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 3.9.

The potential of the hull Aluminium 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 sealed and protected by the hull penetration.

All hull penetrations are of the one piece cofferdam type. The penetrations themselves
are made watertight with 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 Control Reference Electrode.

The high accuracy, high stability, silver chloride seawater 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 silver employed within the electrodes are such that
a minimum life of ten 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.

2.2.3 Impressed Current Monitoring Reference Electrode.

The high accuracy, high stability, silver chloride seawater reference electrodes are
designed to give a stable reference 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 and ‘alkaline’ damage due to
over-protection if conditions of operation change from those anticipated. This feature is
offered as standard scheme together with the anode shield sensor.

All hull penetrations are provided with substantial cofferdams. The penetrations
themselves are made watertight with packing glands. The cofferdams are fully sealed
and provided with watertight cable glands all conforming to the requirements of the
Classification Societies.

2.2.4 Impressed Current Shield Sensor.

The shield sensor is a fail-safe safety device located behind the anode shield.

The shield sensor is used to monitor any failure or damage of the anode shield which
can cause localized overprotection to the aluminium of the hull which could result in
potential pitting and damage to the hull plate. The sensor shuts down the system if any
failure of the shield occurs. This feature is offered as standard on all Cathelco Alutek
systems.

All hull penetrations are provided with substantial cofferdams. The penetrations
themselves are made watertight with packing glands. The cofferdams are fully sealed
and provided with watertight cable glands all conforming to the requirements of the
Classification Societies.

2.2.5 Power Supply Unit:

The impressed current cathodic protection power supply unit is a system housed in a
standard bulwark mounting cabinet, illustrated on drawing C1994. The system
comprises of a control module and a power unit, with standard output rating of either 10
or 20 amperes. Systems larger than 20 amperes will require more than one cabinet.
The supply requirements are to be specified but the standard is 230Vac +/-10%, 1
phase, 50/60 Hz.

The control module, mounted in the top right corner of the cabinet, is a microprocessor
based system having a 2 line 16 character backlit LCD display. 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.
2.2.6 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 rudderstock 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 Cathelco slip-ring track is
silver plated as standard and in addition silver graphite brushes are used to minimise
contact resistance.
3.0 INSTALLATION OF EQUIPMENT:

3.1 Description:

The ‘Alutek’ Impressed Current System consists of anodes, electrodes and shield
sensors 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 similar cofferdam arrangements for
both types of recessed anodes and reference electrodes.

Locations for components are shown on the drawings supplied for the particular vessel,
but are normally subject to final confirmation between the ‘Alutek’ engineer on site and
the Shipyard.

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.

3.2 ‘Alutek’ Shield Sensor Cofferdam

3.2.1 Cut a 90mm diameter hole in the hull at each anode location. Refer to
Drg. P1106.

3.2.2 Grind off any surplus metal to ensure a smooth surface around the hole inside and out,
so that the shield sensor housing body will locate centrally inside the hole in the shell
plating at the inboard side of the hole. Profile the inner and outer edges for welding.

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 anode.
3.3 ‘Alutek’ Anode Cofferdam

3.3.1 Cut a 127mm diameter hole in the hull at each anode location. Refer to Drg.
2200114-1 and 2200114-2

3.3.2 Grind off any surplus metal to ensure a smooth surface around the hole inside and out,
so that the anode housing body will locate centrally inside the hole in the shell plating
at the inboard side of the hole. Profile the inner and outer edges for welding.

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 anode.
3.4 ‘Alutek’ Silver / Silver Chloride REFERENCE ELECTRODE Cofferdam

3.4.1 Cut a 90mm diameter hole in the hull at each anode location. Refer to Drg. P1163.

3.4.2 Grind off any surplus metal to ensure a smooth surface around the hole inside and out,
so that the reference electrode housing body will locate centrally inside the hole in the
shell plating at the inboard side of the hole. Profile the inner and outer edges for
welding.

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.
3.5.0 ‘Alutek’ Shield Sensor

3.5.1 Ensure that the neoprene sealing ‘O’ ring is on the back of the shield sensor assembly
and that the inside of the cofferdam recess into which the shield sensor will fit is clean
and dry.

3.5.2 Apply the two-part epoxy mastic, in a one part to one part mix, and screw the shield
sensor firmly into place in the cofferdam using a socket wrench ensuring that the
locator pin is correctly positioned. DO NOT OVER TIGHTEN AND ONLY USE THE
EPOXY MASTIC SUPPLIED BY CATHELCO. THE TWO PART EPOXY MASTIC
WILL ONLY CURE CORRECTLY IN A MINIMUM AIR TEMPERATURE OF 10
DEGREES CELSIUS. USE AIR HEATERS IF REQUIRED BUT DO NOT APPLY
DIRECT HEAT TO THE MASTIC.

3.5.3 Inside the ship, remove the screw cap from the Cofferdam and using a socket wrench
tighten the sensor into position. DO NOT OVER TIGHTEN. Feed the cable through
the cable gland and secure.

3.5.4 On completion of the inspection caulk the gap between the shield sensor and the
cofferdam with two-part mastic, to leave a smooth uniform surface.

3.5.5 Fit the locking nut on the shield mounting screw and tighten.

3.5.6 Pass the cable through the front entry hole in the cofferdam.

3.5.7 Apply thread tape to the shield sensor cable gland, and pass the gland over the shield
sensor 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.

3.5.8 Fit a junction box (if fitted) at some convenient point adjacent to the cofferdam and
connect the shield sensor cable to the power supply unit via shipyard supplied cable,
see power supply unit instructions.

3.5.9 Check installation of the sensor connection circuit to the hull using 500 Volt earth
insulation meter only if the sensor is not submerged. The result should give an open
circuit.
3.5.10 Refit the cover on the junction box, (if fitted).

3.5.11 Make a final visual check of all connections and finally fit the cable gland to seal the
cofferdam.

3.6 Di-Electric Shield

3.6.1 The preformed GRP di-electric shield is installed as per Drg 2200114-1.

3.6.2 For the G.R.P. shielding, the recess and surrounding 1000 by 600mm of the hull area
should be short/grit blasted to minimum S.A. 2.5 to provide a clean keying surface.
The shield sensor should be suitably masked while any grit-blasting takes place. Any
grit blasting is to be carried out immediately before applying the shield mastic and
fitting the shield.

3.6.3 A thin layer of holding epoxy paint primer can be applied around the prepared area of
the recess - this is to hold the cleanliness of the surface and allow for any delay in
anode installation and also provides the essential improved bonding between the
mastic sealant and the aluminium hull plate.

NOTE: The layer of primer is only required if the di-electric shield is not being
applied directly after completion of the grit blasting.

3.6.4 On completion of the surface preparation a sufficient quantity of the two part epoxy
mastic should be mixed and spread over the entire back of the di-electric shield to
a 3-4mm thickness. The shield is then fitted into position and supported to ensure
the shield follows the contours of the hull and provides good seal and adhesion. The
shield should be held in situ using wooden wedges. Remember to remove any
masking from the face of the shield sensor prior to installing the GRP di-electric
shield.

NOTE: When the GRP shield is installed the shield sensor will be coated in a
layer of two part epoxy mastic and buried behind the GRP shield. This is
correct, the shield sensor should not be exposed.
3.6.5 Allow the resin to cure before welding the edging strips and horseshoes to hold the
shield firmly in place. The edging strips and horseshoes should be cut to length to
match the edge of the shield as per Drg. 2300007-1. A fillet weld is required around
the outside edge of each edging strip section and each horseshoe. Avoid
overheating the GRP shield. It is recommended that a heat retardant cloth is put
over the face of the shield to protect it from scorching. On completion caulk the gap
between the edge of the edging strips or horseshoes with the surface of the GRP
shield using the two-part epoxy mastic.

NOTE: As an alternative, Sikaflex can also be used for this to provide more
flexibility.
3.7 Alutek Anode

3.7.1 Ensure that the neoprene sealing gasket is on the back of the anode assembly and that
the inside of the cofferdam recess into which the anode will fit is clean and dry.

3.7.2 Apply the two part epoxy mastic to the recess and push the anode firmly into place in
the recess in the anode backing shield.

3.7.2 Inside the ship, remove the lid from the Cofferdam. Fit the Dowty Seal (item 9 on Drg
2200114-2) over the shank on the back of the anode then screw the locking nut (item 5
on Drg. 2200114-2) down the shank and using a socket wrench tighten the anode into
position. DO NOT OVER TIGHTEN. Screw down the larger gland nut on top of the
locking nut and tighten into position. Feed the cable grommet (item 7 on drawing
2200114-2) down the cable and push into the recess in the gland nut. Feed the nylon
washer (item 8 on drawing 2200114-2) down the cable and push into the recess in the
gland nut. Feed the Gland boss (item 6 on drawing 2200114-2) down the cable and
screw into the inner thread of the gland nut to create a watertight seal on the cable.

3.7.3 Feed the anode cable tail through the cofferdam side arm then feed the cable grommet
(item 7 on drawing 2200114-2) down the cable and push into the recess in the side
arm. Feed the nylon washer (item 8 on drawing 2200114-2) down the cable and push
into the recess in the side arm. Feed the Gland boss (item 6 on drawing 2200114-2)
down the cable and screw into the inner thread of the side arm to create a secondary
watertight seal on the cable.

3.7.4 On completion of the inspection caulk the gap between the anode and the
cofferdam with two part epoxy mastic, to leave a smooth uniform surface.

NOTE: As an alternative Sikaflex can also be used for this to provide more
flexibility.

3.7.5 Fit a junction box (if fitted) 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.
3.7.6 Check installation of the anode connection circuit to the hull using 500 Volt earth
insulation meter only if the anode is not submerged. The result should give an open
circuit.

3.7.7 Refit the cover on the junction box, (if fitted).

3.7.8 Make a final visual check of all connections and refit the cofferdam lid.
3.8 ‘Alutek’ Silver / Silver Chloride REFERENCE ELECTRODE

3.8.1 Ensure that the neoprene sealing ‘O’ ring 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.

3.8.2 Apply the two-part epoxy mastic, in a one part to one part mix, and push the
reference electrode firmly into place in the cofferdam ensuring that the locator pin is
correctly positioned. DO NOT OVER TIGHTEN AND ONLY USE THE EPOXY
MASTIC SUPPLIED BY CATHELCO. THE TWO PART EPOXY MASTIC WILL
ONLY CURE CORRECTLY IN A MINIMUM AIR TEMPERATURE OF 10 DEGREES
CELSIUS. USE AIR HEATERS IF REQUIRED BUT DO NOT APPLY DIRECT
HEAT TO THE MASTIC.

3.8.3 Inside the ship, remove the screw cap from the Cofferdam and using a socket wrench
tighten the sensor into position. DO NOT OVER TIGHTEN. Feed the cable through
the cable gland and secure.

3.8.4 On completion of the inspection caulk the gap between the reference electrode and the
cofferdam with two-part mastic, to leave a smooth uniform surface.

3.8.5 Fit the locking nut on the shield mounting screw and tighten.

3.8.6 Pass the cable through the front entry hole in the cofferdam.

3.8.7 Apply thread tape to the shield sensor cable gland, and pass the gland over the shield
sensor 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.

3.8.8 Fit a junction box (if fitted) at some convenient point adjacent to the cofferdam and
connect the reference electrode cable to the power supply unit via shipyard supplied
cable, see power supply unit instructions.
Refer to Drawing Number P1163.

NOTE: Insulation of the silver/silver chloride reference electrode to the hull should
never be measured using a 500 Volt Megger as any high current flow can destroy the
electrode.
3.9.0 POWER SUPPLY UNIT:

3.9.1 The units are designed for bulkhead mounting, typically using the mounting holes
provided.

3.9.2 To ensure adequate ventilation it is recommended that an air gap be maintained all
around the equipment for all units.

3.9.3 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.

3.9.4 Provide and terminate single core cables with a voltage rating in excess of 24V d.c.
from the anode cofferdams to the appropriately labelled connection studs on the
terminal board. Equivalent area multi-core cables may be used with all cores
connected. The cables should be sized according to the following table to ensure that
the maximum voltage drop in each cable is equal and does not exceed 2 volts.

3.9.5 Table of cable lengths for different anode size to maintain 2 volt drop

5A 10A 20A CONDUCTOR

SIZE SINGLE
CORE CABLE
55M 27M 13M 2.5MM²
87M 44M 22M 4MM²
130M 65M 32M 6MM²
220M 110M 55M 10MM²

3.9.6 Provide and install a cable between the Hull negative terminal on the equipment and
the main ship structure on a stud of minimum M12 welded to a plate on not less than
50 X 50 X 4mm. It is recommended that these cables be able to carry the full rated
output capacity of the Power Supply Unit. Cathelco can suggest a suitable cable size to
use upon request. This Cathode Earth must be at least 2M from the Reference Earth.

3.9.6 Provide and terminate single core screened cables with a sectional area of minimum
2.5mm² 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.

3.9.7 The reference electrode connection block is earthed internally in the Power Supply
Unit.

3.9.8 Provide and install a connection to the ship's earthing system from the cubicle earth
stud, typically 1 X 10mm² Core Cable.

NOTE - Reference Earth must not be used for main earth.

3.10.1 Shaft Earthing Assembly

The shaft slipring is supplied as two matched halves complete with stainless steel band
and clamping arrangement and can be readily installed by competent engineering
personnel.

All sliprings are manufactured slightly oversize to allow some degree of

tolerance for final fitting. Using a fine file excess material should be removed by
filing down the joint faces, before securing with the band clamping to form a
tight, close fit around the shaft diameter.

NOTE: To avoid brush ‘bounce’ and ensure maximum utilisation of the silver graphite
brushes, it is essential that both joints form a smooth, flush profile.

The balanced brush holder is supplied ready for fitting to a 16mm diameter rod, which
should lie with its centre parallel to the tangential to the shaft centre. The brush holder
should then be clamped to this rod and aligned centrally over the silver track.

The rod and mounting bracket are to be supplied by the shipyard and can be mounted
from either a suitable frame or bearing pedestal.

It is essential that the complete assembly should provide a good electrical contact
between the shaft and the hull, therefore the brush holder spigot support, should either
be welded to the ships structure. If bolted, a short length of 16 mm2 bonding cable
should be connected between the brush holder and ships structure.

On completion of installation the complete assembly should be checked for trueness

and smooth running of the brushes in accordance with the attached check list.

SLIPRING INSTALLATION CHECKS

1) Confirm slipring and brush gear are installed

as per Drawing No. M1191. YES / NO
2) Is assembly clean and free from oil and grease? YES / NO
3) Is slipring a tight fit to the shaft over its whole length? YES / NO
Ensure no bumps or indentations can be felt over the
whole working surface.
4) Are joints a good fit with no gap? YES / NO
5) Is brush holder secured on its shaft? YES / NO
6) Confirm that brush holder and its mounting are solid
and that it will not be affected by vibration. YES / NO
7) Confirm that brush faces are tangential to slipring. YES / NO
8) Confirm that brush is free to move in its holder. YES / NO
9) Is there electrical continuity between tail shaft and
the hull? YES / NO
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, , .

At power up, achieved by operating the MCB switch mounted on the side of the
cabinet, the system displays

“CATHELCO”
“ALUTEK SYSTEM”

for approximately 3 seconds.

The system then reverts to the last operational mode prior to power down.

4.0.2 OPERATING MODE SELECTION

There are 3 Operating modes :-

1) MANUAL MODE,

2) AUTOMATIC MODE

3) CONFIGURATION MODE

In addition there is 1 functional mode1 :-

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 3 operating modes on the
bottom line. The  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 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 £££%

CONTROL ????mV

stepping to:-

MANUAL £££%

MONITORING ????mV

stepping to:-

MANUAL £££%

VOLTAGE ???V

stepping to:-

MANUAL £££%

CURRENT ???A

stepping to:-

MANUAL £££%

“ALARMS” (see 4.0.5)

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  buttons. The initial value is the one stored as the
system default. A new system default can be stored by setting the current output to the
desired value and then pressing the ENT button.

4.0.4 AUTOMATIC 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 ££££%

CONTROL ????mV

stepping to:-
 AUTOMATIC ££££%

MONITORING ????mV

stepping to:-

AUTOMATIC ££££%

VOLTAGE ???V

stepping to:-

AUTOMATIC ££££%

CURRENT ????A

stepping to:-

AUTOMATIC ££££%

“ALARMS” (see 4.0.5)

stepping back to the start. Where ??? is the measured value and the £££ is the set
value

4.0.5 ALARM STATUS:

This mode is embedded in the above 2 operational modes and displays the status of
any alarm, thus:-

SHIELD FAILURE

UNDER-PRO FAIL

OVER-PRO FAIL

4.0.6 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  button will
increment the flashing digit by one. When the correct number is displayed, pressing the
 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 INVALD will be displayed.
 4.1 CHANGING CONTROLLER SET POINTS:

4.1.0 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:-

CURRENT LIMIT 4.1.1

CONTROL 4.1.2

SET POTENTIAL 4.1.3

OVER PROTECT 4.1.4

UNDER PROTECT 4.1.5

QUIT CONFIG 4.1.6

The  buttons allow scrolling through the menu items, and pressing the ENT button
will enter the displayed configuration mode, as follow:-

4.1.1 SYSTEM CURRENT

This parameter will allow the user to define 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  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.

4.1.2 ELECTRODE CONTROL

This parameter is not adjustable.

4.1.3 ELECTRODE SET mV

This parameter will allow the user to define the set point about which the AUTOMATIC
MODE will maintain a constant potential at the electrodes. The display will be as
follows, during which time using the  buttons will vary the setting.

ELECTRODE SET mV

xxx mV

where xxx is the set potential range of -1200 to -750 mV. To store the set value, the
ENT button is pressed.
Pressing the CTRL button will return to the configuration menu.
4.1.4 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  buttons will vary the setting.

OVER PROTECT, xxx mV

where xxx is the set value in the range of, -1200 to -600 mV. To store the set value,
the ENT button is pressed.

Pressing the CTRL button will return to the configuration menu.

4.1.5 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  buttons will vary the setting.

UNDER PROTECT, xxx mV

where xxx is the set value in the range of, -1200 to -600 mV. To store the set value,
the ENT button is pressed.

Pressing the CTRL button will return to the configuration menu.

4.1.6 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.
5.0 ROUTINE OPERATING PROCEDURE

The Cathelco Alutek 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 O/P Current & Voltage and the 4 electrode voltages on the Alutek log
sheets provided. Refer to figure 5.1 for an example of how to complete the log sheet.

NOTES:

1. If the O/P Current is set to display % then press the 'ENT' button to toggle to
Amperes.

2. 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 for analysis and comment. Email to iccplogsheets@cathelco.com

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 dispatched 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 be in attendance during dry-docking to check
and service the Alutek 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. The system, will return the hull to the optimum protective
level as soon as the vessel returns to the seawater.
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 from a level of –850mV
for optimum protection. This example gives levels with respect to Silver/Silver Chloride
(Ag/Ag Cl) electrodes.

6.0.4 The d.c. output voltage is the driving potential that produces the protective current. The
standard Alutek 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.

6.0.5 Bearing the above points is mind, it is clearly important to maintain the daily log and
return the copies to Cathelco for scrutiny at the end of each month. Thus any
abnormality in the readings will be noted and diagnosed and recommendations can be
forwarded for action to be taken without undue delay.

6.0.6 In reviewing the daily log sheets it is necessary first to check that the reference
electrodes are within the range of protection and then to assess the output current and
volts for variations in the level of protection applied.

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.

6.0.9 If the Power Supply Unit On/Alarm LED is RED, then:

Contact Cathelco giving full details of the alarm.
7.0 ALUTEK 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 ship's manual.
 ALUTEK 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.
______
 ALUTEK Commissioning Check List Cont'd

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

A - B
______

A - Ground B - Ground

_______ ______

Disconnect Shipyard anode input cables from fuse terminals in panel.

Measure anode open circuit potential. ( Anode - ground)

1. ________

2. ________

For a new installation where the anodes have never had power applied to them
readings should be in the range of -0.650V to –0.450 V in respect to Ag/Ag Cl
reference electrode. 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 of the hull paint coating adjacent
to the reference cell location. For a newly painted installation the readings will be in
the range of –850mV to –750mV Ag/Ag Cl. For a hull in bad painted condition the
readings will be higher i.e. –750mV Ag/Ag Cl.

Re- connect reference electrode cable inputs to terminal block.

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

 ALUTEK Commissioning Check List Cont'd

Check supply voltage and compare with power unit rating

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
ALUTEK SYSTEM

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 following will appear on the display panel: MANUAL %

CONTROL *** mV

The bottom half of the display is a continuous read out of CONTROL,

MONITORING followed by the voltage followed by the current.

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

The unit is now ready for testing.

 ALUTEK Commissioning Check List Cont'd

Manual Mode Cont'd.

By pressing the "UP arrow" you will be able to increase the I %. This will
result in the reference cell readings reducing and the voltage and current
increasing. To avoid applying too much current to the hull at this stage we
recommend that this test is carried out to a maximum of " I 25% ".

Log the data as follows: I = 5%

CONTROL _______mV
MONITORING _______mV
Voltage _____V
Current _____A

I = 10% I = 15%

CONTROL _______mV CONTROL _______mV

MONITORING _______mV MONITORING _______mV
Voltage _____V Voltage _____V
Current _____A Current _____A

I = 20% I = 25%

CONTROL _______mV CONTROL _______mV

MONITORING _______mV MONITORING _______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".
 ALUTEK 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 following will appear on the display panel: AUTOMATIC *** %

CONTROL****** mV

The bottom half of the display is a continuous read out of PORT:C,

STRB:C, PORT:M & STRB:M followed by the voltage followed by the
current.

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

Record readings immediately. CONTROL ______ mV

MONITORING___ mV
Amps ________ A
Volts ________ V

After 30 minutes record readings again.

CONTROL ______ mV
MONITORING___ mV
Amps ________ A
Volts ________ V

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

CONTROL ______ mV CONTROL ______ mV

MONITORING___ mV MONITORING___ mV
Amps ________ A Amps ________ A
Volts ________ V Volts ________ V
 ALUTEK Commissioning Check List Cont'd

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

CONTROL ______ mV CONTROL ______ mV

MONITORING___ mV MONITORING___ mV
Amps ________ A Amps ________ A
Volts ________ V Volts ________ V

The protection potential around the ship is confirmed by completing a ‘dip-

cell’ survey around the ship using a portable calibrated Ag/AgCl reference
electrode and digital volt meter (DVM). Should any area of the ship does not
meet the minimum protection criteria then the preset potential should be
changed until full protection is achieved to all the underwater Aluminium
hull surfaces.

The system can now be left permanently in "AUTOMATIC MODE" and the
readings should be taken daily. These should be filled in on the Cathelco log
sheet which a copy has been provided in the manual. A completed copy
should be returned to Cathelco head office monthly for analysis. For this
service the first year of operation of the Alutek system is free.

Please revue 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.

ALUTEK Systems
Cathelco
Marine House
Dunston Road
Chesterfield
S41 8NY U.K.

Telephone : (01246) 457900

Fax: (01246) 457901

E-mail: sales@cathelco.com
 ALUTEK Cathelco
Marine House
Dunston Road
Chesterfield S41 8NY
United Kingdom
Telephone (01246) 457900
Fax (01246) 457901
_______________________________________________________________________
Daily log for ALUTEK impressed current cathodic protection system. (A Format)
Vessel SHIP NAME System capacity 10 amps 24 volts
Date from To
Complete in triplicate and distribute as follows: 1st copy to owner’s file, 2nd copy to
Cathelco, 3rd copy to ship’s file. Slip ring/brush gear operation and condition to be checked
weekly. Ring to be clean, brushes in contact.
Slipring check Wk1  Wk2 Wk3 Wk4
Sea
Month Area of operation temp. Output Controlling Monitoring Notes
o
C electrode (mV) electrode (mV)
August Amp Volt
1 Pacific 26 15 2.8 840 840 light draft
2 Coral Sea 29 15 2.8 832 832 light draft
3 " " 29 15 2.7 839 839 light draft
4 Torra St 28 14 2.7 841 841 light draft
5 Arufura Sea 28 14 2.7 850 850 light draft
6 Serum Sea 27 15 2.8 820 820 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
8.0 WORLD WIDE AGENCY

8.0.1 Cathelco are world leaders in the supply of corrosion suppression and control
systems to the marine industry. Backed with over 45 years of experience, the
Cathelco marine impressed current cathodic protection systems are second to
none.

8.0.2 In order to meet customers requirements world wide, Cathelco have an agency
network of Cathelco trained Engineers. These Engineers are available to assist with
installation and commissioning as well as providing on site instruction for operating
staff.
9 DRAWINGS LIST

DESCRIPTION DRAWING No. ISSUE

Anode, Cofferdam and GRP Shield GA 2200114-1 C

Anode, Cofferdam and GRP Shield GA 2200114-2 C
Shield Sensor Sub Assembly 2200114-3
GRP Di-Electric shield 2300007-1 A
Shield Sensor & Cofferdam P1106 A
Ag/Ag Cl Reference Electrode P1163 B
Straight Edge Strip for Di-Electric Shield 2400179 C
Horseshoe Edging Strip 2300324 B
Shaft Earthing General Arrangement Details M1191
Shaft Earthing Band Clamp Details M1192
Shaft Earthing Brush Holder Details C1181
Typical Shaft Earth Holder Mounting Post C2158
Shaft Earthing Wiring (Switchable) Details C1159
GA for 10A ALUTEK Power Unit C1994 A
Terminal Layout for 10A ALUTEK Power Unit P1176
Interconnection Drawing P1244

In case of difficulties, queries should be addressed to:-

Marine Manager
Cathelco Limited
Marine House
Dunston Road
Chesterfield
Derbyshire
S41 8NY
U.K.

Tel: (01246) 457900

Fax: (01246) 457901

E-Mail: sales@cathelco.com
Website: www.cathelco.com
 REVISIONS
REV. DESCRIPTION DATE APPROVED
3 2 REDRAWN IN 3D CAD USING SOLIDWORKS 02/02/2012 D.T
1 BI-METAL STRIPS ROLLED TO
SUIT REQUIRED DIAMETER OF 4
SHAFT MONITORING INTERMEDIATE SHAFT AREA PROP
BAND CLAMP DETAILS SHAFT
BRUSH SET & mV TIGHTEN BOTH BAND
METER SYSTEM IS CLAMPS TO 10 Nm 1
OPTIONAL SUPPLY:
2
SHAFT EARTHING BRUSH SET:
SHAFT MONITORING
SHAFT EARTHING BRUSH HOLDER
BRUSH HOLDER
BY CATHELCO
BY CATHELCO
SHAFT EARTHING BRUSHES BY
SHAFT MONITORING CATHELCO
BRUSH BY
CATHELCO
MOUNT SLIP-RING CLOSE TO BEARING
BLOCK OR WALKWAY SO THAT
SUPPORT BARS CAN BE WELDED
INTO POSITION. ALTERNATIVELY
YARD MUST PROVIDE SEPARATE
SUITABLE MOUNTING POSTS

+1
2 0

75 ±5
NOTE:
BI METAL STRIPS ARE SUPPLIED SLIGHTLY LARGER THAN
SHAFT TO ALLOW FOR FINAL FITTING OPERATIONS ON
INSTALLATION:-

A) FILE ENDS OF STRIPS UNTIL FLUSH WHEN FITTED TO SHAFT 2 REF. SLIP RING
B) IF NECESSARY INFILL WITH SOFT SOLDER AND POLISH DETAIL

RUNNING SURFACES OF BI-METAL RINGS MUST BE FLUSH AND

REMAIN UNMARKED AFTER COMPLETION OF (A) & (B)

KEY TO DRAWING ITEMS: ROLLED TO SUIT

SHAFT DIA
1) SHAFT EARTH MILLI-VOLT BRUSH SET DETAILS SEE DRG
No. C1157M, 103451M OR 104005M, DEPENDANT ON TYPE
SUPPLIED

DETAIL OF ALTERNATE mV 2) MAIN SHAFT EARTHING BRUSH SET DETAILS SEE DRG
METER BRUSH SET AS PER No. C1181M, 103450M OR C2144M, DEPENDANT ON TYPE
DRG No. 104005M SUPPLIED TEL: +44 (0)1246 457900
FAX: +44 (0)1246 457901
3) BI-METAL STRIPS - ROLLED TO SUIT SHAFT DIAMETER EMAIL: technical@cathelco.com
SCALE: NTS DO NOT SCALE. TITLE:
4) BAND CLAMP DETAILS SEE DRG No. M1192M SHEET SIZE: A4 SHEET: 1 OF 1 SHAFT EARTHING GENERAL
DRN BY: D.T DATE: 02.02.2012 ARRANGEMENT DETAILS
5) SYSTEM WIRING DIAGRAM INC. SHAFT MONITORING
SHOWN ON SEPARATE DRAWING APP' BY: S.C DATE: 08.02.2012
DRG TYPE: MANUAL DRG NO: M1191M REV: 2
 REVISIONS
REV. DESCRIPTION DATE APPROVED
1 REDRAWN IN 3D CAD USING SOLIDWORKS 01/02/2012 D.T

EACH END OF A SUITABLY CUT LENGTH OF

BANDING IS FED INTO EACH OF THE TWO
TENSIONERS WHICH ARE TIGHTENED BY
TURNING THE SCREWS UNTIL THE DESIRED
CLAMP DIA. IS ACHIEVED

8 mm A/F TURN CLOCKWISE

TO TIGHTEN CLAMP (2 OFF)

BAND CLAMP
CONNECTOR

TO SUIT SHAFT DIA

STAINLESS STEEL
BANDING

16 2 x WORM DRIVE BAND

CLAMP TENSIONER

TEL: +44 (0)1246 457900

FAX: +44 (0)1246 457901
EMAIL: technical@cathelco.com
SCALE: NTS DO NOT SCALE. TITLE:
SHEET SIZE: A4 SHEET: 1 OF 1 SHAFT EARTHING BAND
MATERIAL: ALL COMPONENTS ARE IN DRN BY: D.T DATE: 01.02.2012 CLAMP DETAILS
STAINLESS STEEL, GRADE AISI 304 BAND CLAMPS - CXCNM1192 APP' BY: S.C DATE: 02.02.2012
(B.S.970 - 304 S15) BANDING - CXCN004 DRG TYPE: MANUAL DRG NO: M1192M REV: 1
 REVISIONS
REV. DESCRIPTION DATE APPROVED
5 REDRAWN IN 3D CAD USING SOLIDWORKS 01/02/2012 D.T

KEY TO DRAWING ITEMS:

1) MOUNT THE SLIP-RING & BRUSH

14.1
SET ON THE INTERMEDIATE SHAFT
AREA, NEAR TO A BEARING BLOCK
OR WALKWAY. WELD IN POSITION
A SUPPORT BAR OF 16 mm
DIAMETER. USE THIS TO CLAMP
16 x 60 LONG 1 THE BRUSH SET IN POSITION.

2) HIGH DENSITY, LOW

RESISTANCE, SILVER GRAPHITE
BRUSH.
NB: BRUSHES MUST BE MOUNTED PART No. CXBRC1170-01
TANGENTIALLY TO SHAFT
3) BRUSH SET EARTHING CABLE
BOLT TERMINAL. CONNECT TO
3
HULL PLATE USING 35 mm SQ
CABLE OR SIMILAR SEE WIRING
2 DIAGRAM FOR FURTHER DETAILS.

4) BRUSH GEAR ALIGNMENT

BOLTS. TIGHTEN & SECURE WITH
LOCKTAB AFTER SET IS MOUNTED.

5) DISTANCE BETWEEN CENTRE OF

BRUSH GEAR SUPPORT BAR AND

32
5 TOP SURFACE OF ASSEMBLED
SLIP RING.

6) COPPER SLIP-RING ASSEMBLY,

SEE DRG No. M1191M FOR DETAILS
6

4
TEL: +44 (0)1246 457900
FAX: +44 (0)1246 457901
EMAIL: technical@cathelco.com
SCALE: NTS DO NOT SCALE. TITLE:
WEIGHT = 0.3 kg APPROX SHEET SIZE: A4 SHEET: 1 OF 1 BRUSH HOLDER DOUBLE
NOTE: ITEMS 2, 3, 4 & 6 BY CATHELCO DRN BY: D.T DATE: 01.02.2012 CATHELCO
REST PROVIDED & WELDED BY YARD PART No. CXBHC1181 APP' BY: S.C DATE: 02.02.2012
DRG TYPE: MANUAL DRG NO: C1181M REV: 5
CATHELCO LIMITED STANDARD TERMS AND CONDITIONS
1. INTERPRETATION
1.1 The following definitions and rules of interpretation apply in these terms and conditions (“the Conditions”):-
Authorised Person: any director of Cathelco.
Buyer: the person, firm or company who purchases the Goods from Cathelco.
Cathelco: Cathelco Limited, a company registered in England and Wales under registered company number 562740 and whose
registered address is Marine House, Dunston Road, Chesterfield S41 8NY United Kingdom.
Commercial Arbitration: an arbitration process conducted by (and in accordance with the rules of) the London Court of International
Arbitration:-
i) consisting of one arbitrator;
ii) taking place in London;
iii) conducted in the English language; and
iv) seated in England
Contract: any contract between Cathelco and the Buyer for the sale and purchase of the Goods incorporating the Conditions.
Date of Commissioning: the date that the vessel to which the Goods have been fitted is completed and the commissioning report
has been signed. In the case of retrospective fittings on vessels that are already operating, the Date of Commissioning will be the
date upon which either the fitting is completed or (in the event that the vessel is in dry dock during fitting) the vessel is returned to
the water.
Delivery Documents: means the delivery receipt, bill of lading, airway bill or such other document as specified in the Contract as
to be passed to the Buyer on delivery as receipt of delivery.
Delivery Point: such location as is specified in the order confirmation issued by Cathelco or as advised by the Buyer.
Goods: any goods agreed in the Contract to be supplied to the Buyer by Cathelco (including any part or parts of them).
Incoterms: Incoterms 2000 as published by the International Chamber of Commerce.
Intellectual Property Rights: all copyright, database rights, topography rights, design rights, trade marks, patents, domain names
and any other intellectual property rights of a similar nature (whether or not registered) subsisting anywhere in the world in or
associated with the Goods.
1.2 A reference to a particular law is a reference to it as it is in force for the time being taking account of any amendment,
extension, application or re-enactment and includes any subordinate legislation for the time being in force made under it.
1.3 Words in the singular include the plural and in the plural include the singular.
2. APPLICATION OF TERMS
2.1 Subject to any variation under Condition 2.2, the Contract shall be on these Conditions to the exclusion of all other terms and
conditions (including any terms or conditions which the Buyer purports to apply under any purchase order, confirmation of order,
specification or other document) other than those specified by Cathelco in their quotation.
2.2 These Conditions apply to all Cathelco's sales and any variation to these Conditions and any representations about the Goods
shall have no effect unless expressly agreed in writing and signed by an Authorised Person. The Buyer acknowledges that it has
not relied on any statement, promise or representation made or given by or on behalf of Cathelco which is not set out in the
Contract. Nothing in this Condition shall exclude or limit Cathelco's liability for fraudulent misrepresentation.
2.3 Each order or acceptance of a quotation for Goods by the Buyer from Cathelco shall be deemed to be an offer by the Buyer to
buy Goods subject to these Conditions. No order placed by the Buyer shall be deemed to be accepted by Cathelco until a written
acknowledgement of order is issued by Cathelco or (if earlier) Cathelco delivers the Goods to the Buyer.
2.4 Any quotation is given on the basis that no Contract shall come into existence until Cathelco despatches an acknowledgement
of order to the Buyer.
3. DESCRIPTION/PRICE
3.1 Subject to Condition 3.4 below, the quantity, description and price of the Goods shall be as set out in Cathelco's quotation or
acknowledgement of order subject to availability.
3.2 The Buyer shall ensure that the terms of its order and any specifications are complete and accurate. The specification shall
include the waters that the vessel will operate in as well as a full specification of the vessel to which the Goods will be fitted along
with any such other details or information requested by Cathelco.
3.3 Unless the quotation specifies otherwise, all quoted prices for Goods are inclusive of packing, but exclusive of carriage,
insurance, VAT and all other duties, fees and taxes.
3.4 All samples, drawings, descriptive matter, specifications and advertising issued by Cathelco (other than those provided in the
written quotation provided by Cathelco) and any descriptions or illustrations contained in Cathelco's catalogues, brochures or
website are issued or published for the sole purpose of giving an approximate idea of the Goods described in them. They shall not
form part of the Contract.
4. DELIVERY
4.1 Delivery of the Products shall take place at the Delivery Point. Acceptance of any change to the Delivery Point requested by
the Buyer shall be at Cathelco’s sole discretion and the Buyer shall be liable for any additional expenses incurred by Cathelco as a
result of such change. Cathelco shall arrange for suitable transport to the Delivery Point.
4.2 On delivery Cathelco (or its appointed carrier) shall where necessary provide the Buyer with any UK licence required for the
export of the Goods along with Delivery Documents.
4.3 Any dates specified by Cathelco for delivery of the Goods are intended to be an estimate and time for delivery shall not be
made of the essence by notice unless otherwise agreed in writing by Cathelco. If no dates are so specified, delivery shall be within
a reasonable time taking into account all relevant factors (including without limitation the distance and chosen method of delivery).
The Buyer shall take delivery of the Goods on receipt of adequate notice from Cathelco (being not less than 4 days) that the Goods
are ready for delivery.
4.4 Cathelco may deliver the Goods by separate installments unless otherwise stipulated on the Purchase Order. Each separate
instalment shall be invoiced and paid for in accordance with the provisions of the Contract. Each instalment shall be a separate

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Contract and no cancellation or termination of any one Contract relating to an instalment shall entitle the Buyer to repudiate or
cancel any other Contract or instalment.
4.5 If for any reason the Buyer fails to accept delivery of any of the Goods when they are ready for delivery, or Cathelco is unable
to deliver the Goods on time because the Buyer has not provided appropriate instructions, documents, licences or authorisations:
(a) risk in the Goods shall pass to the Buyer (including for loss or damage caused by Cathelco's negligence);
(b) the Goods shall be deemed to have been delivered; and
(c) Cathelco may store the Goods until the Buyer takes possession of the Goods, whereupon the Buyer shall be liable for all
related costs and expenses (including, without limitation, storage and insurance).
4.6 Unless agreed otherwise in the quotation (including by way of reference to a relevant Incoterm) the Buyer shall provide at the
Delivery Point and at its expense adequate and appropriate equipment and manual labour for unloading the Goods.
4.7 The Buyer shall examine the Goods as soon as reasonably practicable after delivery and shall immediately notify Cathelco of
any incomplete or failed delivery or any loss or damage during carriage. Unless the Buyer so notifies Cathelco within 30 days after
the date at which the Buyer became or ought reasonably to have become aware of the incomplete or failed delivery or loss or
damage to the Goods during carriage, the Buyer will be treated as having waived all claims connected with the matter.
4.8 Where the Buyer has entered into more than one Contract with Cathelco failure to deliver the Goods under this Contract will
not affect the Buyer’s obligation to comply with the terms of any other contracts.
5. IMPORT AND EXPORT LICENCES
If appropriate, Cathelco undertakes to obtain any UK licence required for the export of the Goods from the UK by Cathelco. The
Buyer shall comply with any such licence and shall obtain and comply with all other necessary licences, permits and consents. If
required by Cathelco, the Buyer shall make any such licences or consents available to Cathelco prior to delivery.
6. RISK/TITLE
6.1 The Goods are at the risk of the Buyer from the time of delivery. The condition and security of the Goods from the date of
delivery to the Date of Commissioning is the sole responsibility of the Buyer.
6.2 Ownership of the Goods shall not pass to the Buyer until Cathelco has received in full (in cash or cleared funds) all sums due
to it in respect of the Goods and all other sums which are or which become due to Cathelco from the Buyer on any account.
Cathelco shall be entitled to recover payment for the Goods notwithstanding that ownership of any of the Goods has not passed
from Cathelco.
6.3 Until ownership of the Goods has passed to the Buyer, the Buyer shall:
(a) hold the Goods on a fiduciary basis as Cathelco's bailee;
(b) store the Goods (at no cost to Cathelco) separately from all other goods of the Buyer or any third party in such a way that they
remain readily identifiable as Cathelco's property;
(c) not destroy, deface or obscure any identifying mark or packaging on or relating to the Goods; and
(d) maintain the Goods in satisfactory condition and keep them in a safe and secure manner.
6.4 The Contract and the Buyer's right to possession of the Goods shall terminate immediately if:
(a) the Buyer commits a breach of any term of any Contract and (if the breach is capable of remedy) fails to remedy it within 30 days
after receipt of notice in writing requiring it to do so; or
(b) the Buyer makes any voluntary arrangement with its creditors or (being an individual or firm) becomes bankrupt or (being a
company) becomes subject to an administration order or goes into liquidation (otherwise than for the purpose of amalgamation or
reconstruction) or an encumbrancer takes possession or a receiver is appointed of any of the property or assets of the Buyer, or the
Buyer ceases, or threatens to cease, to carry on business; or
(c) any event analogous to those described in condition 6.4(b) which occurs in relation to the Buyer in any jurisdiction in which the
Buyer is incorporated, resident or carries on business.
6.5 The Buyer grants Cathelco, its agents and employees an irrevocable licence to enter any of its premises or vessels where the
Goods are or may be stored in order to recover Goods when the Buyer’s right to possession of the Goods has terminated.
6.6 On termination of the Contract, howsoever caused, Cathelco’s rights contained in this Condition 6 shall remain in effect.
7. PAYMENT
7.1 Subject to Conditions 7.2 and 7.5 and unless otherwise agreed in writing in accordance with Condition 2.2, invoices shall be
settled within 30 days of the date of the invoice and time for payment shall be of the essence.
7.2 Should Cathelco stipulate a requirement for security for payment before dispatch of the Goods, Cathelco shall have the right to
withhold delivery of the Goods until such security has been received.
7.3 No payment shall be deemed to have been received until Cathelco has received cleared funds in the currency stated on the
invoice. In the event of any failure to pay Cathelco any sum due pursuant to the Contract and without prejudice to any other
remedies available to Cathelco under the Conditions, the Buyer shall be liable to pay interest to Cathelco at 6% above HSBC Bank
Plc base rate for the time being per annum accruing on a daily basis until payment is made, whether before or after judgement.
7.4 All payments payable to Cathelco under the Contract shall become due immediately on its termination despite any other
provision.
7.5 All payments under the Contract are due in full without deduction by way of set-off, counterclaim, discount, or otherwise unless
the Buyer has a valid court order requiring an amount equal to such deduction to be paid by Cathelco to the Buyer.
7.6 Where the Buyer has entered into more than one contract with Cathelco, failure to pay Cathelco any sum due pursuant to the
Contract will entitle Cathelco to terminate all other contracts with and/or suspend any deliveries to the same Buyer and seek
payment of all outstanding sums.
7.7 The Buyer shall indemnify Cathelco against all costs, charges and expenses (including legal costs) incurred by Cathelco in
recovering sums owing by the Buyer (including but not limited to seizure of vessels).
8. QUALITY
8.1 Cathelco warrants that (subject to the other provisions of the Conditions) the Goods will conform in all material respects to the
specification provided by the Buyer in accordance with Condition 3.2. Cathelco further provides a one year warranty applying to all
Cathelco systems but excluding all consumable items. The warranty period starts from the delivery date. Consumable items are
not included in the warranty unless they fail before their recommended operating period. The condition and security of the
equipment from the date of receipt to the date of commissioning is the sole responsibility of the purchaser. All other warranties or
conditions (whether express or implied) as to quality, condition, description, compliance with sample or fitness for purpose (whether

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statutory or otherwise) other than those expressly set out in this agreement are excluded from this agreement to the fullest extent
permitted by law.
8.2 Cathelco shall not be liable for a breach of the warranty in Condition 8.1 unless the Buyer gives written notice of the defect to
Cathelco within 30 days of the date of which the Buyer became or ought reasonably to have become aware of the breach and
Cathelco is given a reasonable opportunity after receiving the notice to examine such Goods. The Buyer shall as far as possible
preserve the Goods for inspection by Cathelco.
8.3 Cathelco shall not be liable for a breach of the warranty in Condition 8.1 if:
(a) the Buyer makes any further use of such Goods after giving such notice; or
(b) the Buyer alters or repairs such Goods without the written consent of Cathelco; or
(c) the defect was caused in any way by the Buyer’s failure to provide a full and accurate specification of the vessel that the
Goods would be applied to and/or the waters that the Goods would be used in (as required by Condition 3.2); or
(d) the defect was caused in any way by the Buyer’s failure to follow good trade practice or the Cathelco’s oral or written
instructions as to storage, installation, use or maintenance of the Goods.
8.4 Subject to Conditions 8.2 and 8.3, if any of the Goods do not conform with the warranty in Condition 8.1, Cathelco shall at its
option repair or replace such Goods (or the defective part) or refund the price of such Goods at the pro rata Contract rate provided
that, if requested, the Buyer shall return the Goods to Cathelco.
8.5 If Cathelco complies with Condition 8.4 (or if Cathelco’s reasonable attempts to comply with its preferred remedy under
Condition 8.4 are obstructed by the Buyer), Cathelco shall have no further liability for a breach of the warranty in Condition 8.1 in
respect of such Goods.
8.6 Where Goods are returned to Cathelco, Cathelco will accept no responsibility for the condition of the Goods received from the
Buyer. It is the responsibility of the Buyer to ensure that the packing is sufficient to protect the Goods during transit. The Buyer will
be required to pay for the replacement of Goods received which are damaged beyond economical repair or for repairs where such
damage is caused by transit.
9. INSTALLATION AND TESTING
9.1 It is the sole responsibility of the Buyer to ensure that the Goods are installed correctly and in compliance with Cathelco’s
instructions. Cathelco can accept no responsibility for any damage or loss to Goods or otherwise arising as a result of incorrect
installation. The conditions of warranty may be extended if the installation is supervised by a Cathelco approved engineer but any
such extensions of warranty must be agreed in writing and signed by an Authorised Person. The supervision will not apply to the
structural applications involving preparation, cutting or welding of the vessel for the purposes of mounting and securing the installed
equipment.
9.2 Cathelco accepts no responsibility for testing and commissioning unless it is carried out by a Cathelco-approved engineer. In
such cases, Cathelco warrants that the engineer will exercise reasonable care and skill within the meaning of the Supply of Goods
and Services Act 1982. This warranty will run for one year from the Date of Commissioning where the Cathelco-approved engineer
has signed the commissioning report and it has also been countersigned by a recognised representative of the shipyard.
10. LIMITATION OF LIABILITY – THE BUYER’S ATTENTION IS PARTICULARLY DRAWN TO THE CONTENTS OF THIS
CONDITION
10.1 All warranties, conditions and other terms implied by statute or common law (save for the conditions implied by section 12 of
the Sale of Goods Act 1979) are, to the fullest extent permitted by law, excluded from the Contract.
10.2 Nothing in the Conditions excludes or limits the liability of Cathelco:
(a) for death or personal injury caused by Cathelco's negligence; or
(b) under section 2(3) or any other applicable section under the Consumer Protection Act 1987; or
(c) for any matter which it would be illegal for Cathelco to exclude or attempt to exclude its liability; or
(d ) for fraud or fraudulent misrepresentation.
10.3 The Buyer will not be entitled to claim any damages in contract, tort (including negligence or breach of statutory duty),
misrepresentation, restitution or otherwise, arising from the performance or contemplated performance of the Contract unless they
have first given notice of the claim to Cathelco in compliance with Condition 8.2.
10.4 Subject to Conditions 10.1 and 10.2:-
(a) Cathelco's total liability in contract, tort (including negligence or breach of statutory duty), misrepresentation, restitution or
otherwise, arising in connection with the performance or contemplated performance of the Contract shall be limited to the total cost
of the Goods; and
(b) Cathelco shall not be liable to the Buyer for:-
i) any indirect, special or consequential loss or damage; or
ii) loss of data or other equipment or property; or
iii) economic loss or damage; or
iv) incurring of liability for loss or damage of any nature whatsoever suffered by third parties (including in each case incidental
and punitive damages); or
v) any loss of actual or anticipated profit, interest, revenue, anticipated savings or business or damage to goodwill even if
Cathelco is advised in advance of the possibility of any such losses or damages.
The Buyer acknowledges and agrees that the price of the Goods reflects the limitations of liability contained in the Contract.
11. INTELLECTUAL PROPERTY
11.1 The Buyer acknowledges that:
(a) the Intellectual Property Rights are Cathelco's (or its licensor's) property;
(b) nothing in this Contract shall be construed as conferring any licence or granting any rights in favour of the Buyer in relation to
the Intellectual Property Rights; and
(c) any reputation in any trade marks affixed or applied to the Goods shall accrue to the sole benefit of Cathelco or any other
owner of the trade marks from time to time.
11.2 The Buyer shall not remove any copyright notices, confidential or proprietary legends or identification from the Goods save for
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11.3 The Buyer shall not use or seek to register any trade mark or trade name (including any company name) which is identical to,
confusingly similar to or incorporates any trade mark or trade name which Cathelco or any of its associated companies own or
claim rights to anywhere in the world.
11.4 The Buyer shall promptly and fully notify Cathelco of:
(a) any actual, threatened or suspected infringement of any Intellectual Property Rights which comes to the Buyer's notice; and
(b) any claim by any third party that comes to the Buyer's notice that the sale or advertisement of the Goods infringes the rights
of any person.
11.5 The Buyer agrees (at Cathelco's request and expense) to do all such things as may be reasonably required to assist Cathelco
in taking or resisting any proceedings in relation to any infringement or claim referred to in Condition 11.4.
11.6 On termination of the Contract howsoever caused Cathelco’s rights contained in this Condition 11 shall remain in effect.
12. FORCE MAJEURE
Cathelco shall not be liable for any delay in performing or failure to perform any of its obligations under this Contract if such delay or
failure results from events or circumstances outside its reasonable control which shall include (without limitation): natural disasters; war;
terrorism; accidents; explosions; incidents; breakdown of equipment or machinery; sabotage; strikes or other labour disturbances
(regardless of the reasonableness of the demands of labour); acts or omissions of government; port congestions; and shortage of
supplies or labour. Such delay or failure shall not constitute a breach of this Contract and the time for performance shall be extended by
a period equivalent to that during which performance is so prevented or a period of 21 days, whichever is the shorter, after the expiry of
which the Buyer shall be entitled to give notice in writing to Cathelco to terminate the Contract with respect to any Goods undelivered at
that time.
13. SEVERANCE
13.1 If any Condition (or part of a Condition) of the Contract is found by any court or administrative body of competent jurisdiction to
be invalid, unenforceable or illegal, the other Conditions will remain in force.
13.2 If any invalid, unenforceable or illegal Condition would be valid, enforceable or legal if some part of it were deleted, that
Condition will apply with whatever modification is necessary to make it valid, enforceable and legal.
1.1.1.1 13.3 The parties agree, in the circumstances referred to in Condition 13.1 to substitute for any invalid, unenforceable
or illegal Condition a valid, enforceable and legal Condition which achieves to the greatest extent possible the same
effect as would have been achieved by the invalid or unenforceable Condition.
1.1.1.2 14. WAIVER
Failure or delay by Cathelco in enforcing or partially enforcing any term of the Contract shall not be construed as a waiver of any of
its rights under the Contract. Any waiver by Cathelco of any breach of, or any default under, any term of the Contract by the Buyer
shall not be deemed a waiver of any subsequent breach or default and shall in no way affect the other terms of the Contract.
15. THIRD PARTIES
15.1 The parties to the Contract do not intend that any term of the Contract shall be enforceable by virtue of the Contracts (Rights
of Third Parties) Act 1999 by any person that is not a party to it. This Condition 15.1 does not affect any right or remedy of any
person that exists or is available otherwise than pursuant to that Act.
15.2 Each party shall promptly notify the other of any claims brought or contemplated by third parties in relation to the Contract or
the particular Goods sold hereunder and shall comply with the other’s reasonable requirements to minimise and/or avoid any
further liability and shall allow the other conduct of any action and/or settlement on reasonable terms.
16. ASSIGNMENT
Cathelco may assign the Contract or any part of it without the prior written consent of the Buyer. The Buyer shall not assign this
Contract or any rights hereunder in whole or in part to any third party without the prior written consent of an Authorised Person.
17. LAW, JURISDICTION AND DISPUTES
17.1 The formation, existence, construction, performance, validity and all aspects of the Contract shall be governed by English law.
The parties submit to a final resolution of any dispute by Commercial Arbitration rather than through the English Courts. For the
avoidance of doubt, the United Nations Convention on the International Sale of Goods shall not apply to this Agreement.
17.2 Nothing in this Condition 17 shall limit the right of Cathelco to take proceedings against the Buyer in any other court of
competent jurisdiction, nor shall the taking of proceedings in any one or more jurisdiction preclude the taking of proceedings in any
other jurisdiction, whether concurrently or not, to the extent permitted by the law of such other jurisdiction
17.3 Incoterms shall apply to the Contract but where they conflict with the Contract, the Contract shall prevail.
17.4 Subject to Condition 17.1, any disputes that cannot be resolved between the parties must be referred to Commercial
Arbitration within one year of either (i) the date of this Contract, or (ii) the end of the warranty period as defined in Condition 8.3,
whichever is the later.
18. COMMUNICATIONS
18.1 All communications between the parties about the Contract shall be in writing and delivered by hand or sent by pre-paid first
class post (or airmail if sent from outside the UK) or sent by fax or e-mail:
(a) (in case of communications to Cathelco) to the Sales Team at Cathelco’s registered office; or
(b) (in the case of the communications to the Buyer) to any address of the Buyer as shall be notified to Cathelco by the Buyer.
18.2 Communications shall be deemed to have been received:-
(a) if delivered by hand, at the time of delivery;
(b) if posted first-class within the United Kingdom, 48 hours after posting;
(c) if posted by airmail, five days after the date of posting; and
(d) if sent by fax or e-mail on a working day prior to 4.00 pm, at the time of transmission and otherwise on the next working day.

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