CATHELCO: C-SHIELD ICCP
MARINE IMPRESSED CURRENT CATHODIC PROTECTION
SYSTEM INSTALLATION & INSTRUCTION MANUAL
CLIENT: SCANEL INTERNATIONAL A/S
VESSEL: OLYMPIC PRINCE:
CATHELCO REFERENCE: Ca 4932
Jesu By: AW
Date: 19-Oct-10
MARINE HOUSE, DUNSTON ROAD, CHESTERFIELD, DERBYS. S41 8NY, UK
TEL: +44 (0)1246 457900. FAX: +44 (0) 1246 457901. E-MAIL: technieal@eatheleo.com
‘Section 0 Rev 0
Page 1 of 3 C-SHIELD MANUAL INDEX:
0.0
10
2.0
30
40
5.0
6.0
70
8.0
9.0
List of drawings,
Introduction,
General Descriptions.
Installation of Equipment.
Power Supply Operating Instructions.
Routine Operating Procedure,
Service & Fault Finding
C-Shield Commissioning Check Li
World Wide Agencies.
Diver Change Instructions
Section 0 Rev 0
Page 3 0f3 1.0 INTRODUCTION:
1.0.1
PRINCIPLES OF CORROSION AND CATHODIC PROTECTION:
e i termed activity or
potential. These potentials can be tabulated and form the electrochemical
‘A more practical approach is the determination of the tendency of certain metals
to corrode in a particular electrolyte, such as sea water. Thie i termed the
Balvanic series of which the following table is an abridged fon
Active or Anodic
Magnesium
Zine
Mild Stee!
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 8S, 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 stee! in
sea water is more likely to be passive than type 304 and is therefore generally
preferred for immersed marine applications.
Section 1 Rev 0
Page | of 3 crt will pass through the clay fom tte
ti 1, The least active met
entree sal onto the least active metal THe X
sore ete is tered the cade. The more metal, the anodes
into solution and the flow of electrical current increases. This isa
aretvon transfer process i.e it rTodes
‘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
Teetaet 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
aes cells found when accelerated corrosion occurs at uncoated Anodic areas
Gna generally coated cathodic structure. In addition there are long line type
ors that oecur 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.
Cathodie Protection is a system of i i
‘ preventing corrosion by forcing all
ofa structure to be cathodes by providing external ee aaa
Section 1 Rev 0
Page 2 of 3 Snsure a galvanic cell is not created,
Typical examples of galvanic cells are:
4) Steel or cast iron Jeter boxes in contact with non ferrous (often copper
based) tube plates in condenser water boxes in ships or generating
Plant. Rapid corrosion ofthe ferrous water bog Occurs close to the tube
Plate,
>) Brass or bronze valves fitted to immersed steel buoyancy tanks or
Rooding chambers on marine petrochemical structures. Accelerated
corrosion of the steel occurs near the valve
© The connection oF ‘steel pipes into an otherwise cast iron system.
Accelerated corrosion ofthe 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
Guthodie. For steel under normal non anaerobic conditions it cay te 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 eguivalers 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
i nium, zine and magnesium,
commonly used Anodic metals are alloys of aluminium, zi
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 | Rev 0
Page 3 of 3 2.0 GENERAL DESCRIPTIONS:
211
IMPRESSED CURRENT CATHODIC PROTECTION:
A metal also can be made cathodic by clectrcally connecting it to another
ietallic component in the same electrolyte through a source of direct seers
urrent and directing the current flow to occur off the surface of added menllic
component (anode), into the electrolyte and onto the metal (cathode) This cay
easily be visualised by reference to the simple cell and assuming yet another
electrode with a power source is introduced and that the current flew om thas
electrode is sufficient to overcome the natural corrosion current,
Because an external current source is employ i ion i
e ed, this type of protect
termed UMPRESSED CURRENT CATHODIC PROTECTION, erent
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-clectrodes, 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 Rev 0
Page | of 6 sacrificial’ anodes
feasible,
sophisticated j
Figure 1.3 - Comparison of Reference Electrodes & Interpretation
2.2.0 MARINE IMPRESSED CURRENT SYSTEM:
The C-Shield Marine Impressed Current System comprises 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 carrer.
Section 2 Rev 0
Page 2 of 6 222
The use of a 24 volt system reduces the number and length of the anodes from
that required with @ 12 volt system. The increased anode/sea water resistance
ne 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 hliace
Potential is @ 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 bons
section applications.
All Tull 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.
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 stern only installation with the
anodes more than 150 metres from the bows, one reference electrode may be
located in the bows.
A novel feature of the C-Shield closed circuit is that additional reference cells
may be placed at areas that may be susceptible to over-protection such as
adjacent to the anode dielectric shields. These additional reference cells provide
a permanent check, thus preventing any coating damage due to over-protection
if conditions of operation change from those anticipated. This feature is offered
as an optional extra to the standard schemes.
Al 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 Rev 0
Page 3 of 6 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
snanual. The system comprises of a control PCB, a Thyristor PCB and.
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 +/-10%, three phase, 50/60 He.
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 arc a
Totary 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
i a ic the output current and
to the thyristor driver PCB, which allow control over the outpy
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 Rev 0
Page 5 of 6 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,
Section 2 Rev 0
Page 6 of 6 30
3.0.01
3.0.02
3.0.03
3.0.04
INSTALLATION OF EQUIPMENT:
Description:
It is very important that the installation instructions
biggest cause of future problems found with the ru
Section 3 Rev 0
Page | of | 35
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
S50A | 75 | 100A | 150A | 175A | 200A | 300A | CONDUCTOR
SIZE SINGLE
CORE CABLE
45M 16MM*
70M | 47M 25MM
100M | 67M | SOM 35MM?
125M | 83M | 62M | 41M 50MM?
180M | 120M | 90M | 60M | SIM | 45M 70MM?
250M | 167M | 125M | 83M | 71M | 62M | 41M 95MM?
315M | 210M | 158M | 105M | 90M | 79M | 53M 120MM?
Section 3.5 Rev 0
Page | of 2 3.5.6
3.8.7
3.5.8
3.5.9
and terminate single core screened cables with a
area of minimum 1.0mm 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
ine ferminal plate within the power unit De ‘not connect
the screen at the junction box end.
Provide
sectional
The reference electrode connec
internally inthe Power Supply Unit.
ion block is earthed
Provide and install « connection to the ship's earthing
Coe riom the cubicle earth stud, typically 1 X 16mm
Core Cable,
PLEASE ENSURE THAT WHEN WELDING WORK
IS BEING CARRIED OUT ON THE VESSEL THAT
THE PANEL _IS_ SWITCHED OFF ANDTHE
SYSTEM \GATIVE CABLE I
DISCONNECTED,
Section 3.5 Rev O
Page 2 of 2 40
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, ft, U.
At power up, achieved by operating the MCB switch
mounted on the side or front of the cabinet, the system
displays
" CATHELCO C - SHIELD 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 Rev 0
Page 1 of 11 In addition there is 1 functional modet :.
ACCESS CODE
NOTES:
4.0.3
Pressing the CTRL button to enter the SELECT MODE
menu does not exit the mode until a new mode has been
selected,
Configuration mode is only accessible when a valid pass
number has been entered. See PASS NUMBER mode
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?
ELI 22??mV
nv
stepping to:~
STAND-BY V?272V
EL2 222?mV
stepping to:-
STAND-BY V?222V
EL3 277?mV
stepping to:-
Section 4 Rev 0
Page 2 of 11 4.0.4
STAND-BY v2?77y
EL42222mV
stepping to:-
STAND-BY V??72V
ALARMS (see 4.0.6)
stepping back to the start
Where 222? is the measured value. Note that in the case of
the Anode voltage the display will be the back emf of the
anode system
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 168%
ELI 227?mv
stepping to:-
MANUAL 1 £££%
EL2 2272_mV
stepping to:-
MANUAL I £££%
EL3 7772mV
stepping to:-
MANUAL I£££%
EL4 2222mV
stepping to:-
Section 4 Rev 0
Page 3 of 11 4.0.5
MANUAL rese%
Vv
stepping to:-
MANUAL Teee%
1227
stepping to:-
MANUAL I£28%
“ALARMS” (see 4.0.6)
stepping back to the start,
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 ££££%
ELI
mV
stepping to:-
AUTOMATIC ££8£%
EL2
stepping to:~
Section 4 Rev 0
Page 4 of 11 4.0.6
AUTOMATIC sese,
EL3 2272mVy
stepping to:-
AUTOMATIC seeey
EL4 2222my
stepping to:-
AUTOMATIC se¢¢%
Vv 220V
stepping to:-
AUTOMATIC £¢¢2%
122724
stepping
AUTOMATIC ss¢8%
“ALARMS” (see 4.0.6)
stepping back to the start. Where 22? is the measured value
and the £££ is the set value
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 Rev 0
Page 5 of 11 4.0.7
ACCESS CODE
pais mode a valid pass number needs 16 f° entered,
Initially the display shows the following
ACCESS CODE
0000
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,
Section 4 Rev 0
Page 6 of 11 41 CHANGING CONTROLLER SET POINTS:
ALL
‘hich will allow access to the setting of t 1
ti the sys
Parameters. The display will read :- oe
CONFIGURATION
ZLLLLLLLIILIL
where 2222222277722 is one ofthe following:-
SYSTEM SIZE
ELECTRODE TYPE
ELECTRODE NUMBER
ELECTRODE SET mv
OVER PROTECT
UNDER PROTECT
CURRENT LIMIT
QUIT CONFIG
‘The 10 buttons allow scrolling through the menu items,
and pressing the ENT button will enter the displayed
configuration mode, as follow:-
SYSTEM SIZE
This parameter will allow the user to define the size in
steps of 50Amps. The display will be as follows, during
which time using the 1!) buttons will vary the setting.
SYSTEM SIZE wx A
where xxx is the set value in the range SOA to 800A. To
store the set value, the ENT button is pressed.
Pressing the CTRL button will return to the configuration
‘menu.
Section 4 Rev 0
Page 7 of 11 413
4d
ELECTRODE TYPE
one "The dty wa © ne a tin
‘sing the TU buttons will vary the setting, ets
ELECTRODE Typp
ZINC ELECTRODE
or
ELECTRODE Type
SILVER ELECTRODE
To store the set type, the ENT button is pressed.
Pressing the CTRL bution will return to the configuration
menu,
ELECTRODE NUMBER
This parameter is used to define the number of electrodes.
The display will be ad follows, during which time using the
1M. buttons will vary the setting
ELECTRODE NUMBER
a
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 Rev 0
Page 8 of 11 41s
4.16
417
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 MU buttons will vary
the setting
ELECTRODE SET my
xxx mV
Where xx is the set potential range of -100 to +400 mV in
the case of Zine 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 bution will return to the configuration
menu,
OVER PROTECT
This parameter will allow the user to define the set point at
Which the OVER PROTECTION alarm trigger. The
display will be as follows, during which time using the fil
buttons will vary the setting,
OVER PROTECT, xxx mV
Where xox is the set value in the range OFF, -995 to 0 mV
in the case of Zine 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.
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 ft
buttons will vary the setting.
Section 4 Rev 0
Page 9 of 11 418
419
UNDER PROTECT, xxx mV
‘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.
peel
menu.
the CTRL button will return to the configuration
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 f1U. buttons will vary
the setting.
SYSTEM CURRENT, xxx %
Where xxx js 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,
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 Rev 0
Page 10 of 11 42
SELF CHECKING:
42.1
422
Every § hours & upon entry to manual & automatic modes,
timed from the last power up, the system automatically
enters @ self test mode, This mode checks the correct
finetion of anodes and electrodes and lasts approximately
10 seconds. During this time the display reads:-
SELFTEST
PLEASEWAIT
Zhe Power output is shut down to zero and the potential
From each of the system electrodes is measured. Output
second period. At the start (0A) 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 30% 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 retums 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,
ERROR CHECKING
is provided wi f built in self
The equipment is provided with a number 0
checking funetions. These functions ensure the conn
running of the equipment,
Section 4 Rev 0
Page 11 of 11 The Cathelco Marine impressed Current System is completely automatic with
litle maintenance required ang Will normally require no adjustments during
routine operation of the vessel However, careful attention on a roming basis
should be given to the following Points, by the ships staff to ensure thee 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/AL,
‘ARM LED is lit. If either of these are incorrect
then refer to the faut finding section.
the C-Shield log sheets provided. Refer te figure 5.1 for an example
of how to complete the log sheet,
NOTES;
|. Ifthe O/P Current is set to display % then ress the 'ENT" button
to toggle to Amperes,
2. Pressing either the up or down buttons will toggle the display to
read cither electrodes | & 2 of electrodes 3 & 4,
5.0.2 EVERY WEEK:
pri for cleanliness, for wear
Once weekly the slipring should be checked 2
on the brushes and "0 coafien that the brushes both move Seely in
their holders and are held firmly onto the sliprng by the brush older
spring. Check the rudder stock bonding cable for any fraying of the
conductor at the connection points.
5.0.3 EVERY MONTH:
hich the copies
has space for a complete month after which the
should ‘be eum to Cathelco, Chesterfield for scrutiny and
comment.
Section 5 Revo
Page | of 3 5.0.4
5.0.5
5.0.6
5.0.7
EVERY 3 MONTHS:
Fvety 3 months switch off the equi ent i
povver em? 2" signs of toose wires or other ian defects. The
depends Ply unit is, under normal operation cooled, and
depends on free circulation of cooling air through the vents ts
ventana working temperature of componene’ Check that the
Creation grilles in the sides and top are nee obstructed in anyway,
Clean any dust and dirt from the Unit paying particular attention ty
Replace all covers provide power and operate the mains switch to t
(On position and shut the front door sae
30 DAYS PRIOR To. DRY-DOCKING:
ne month before the dry docking ensure that daily log sheets have
been maintained and forwarded to: Catheln for assessment with
information that dry docking is expected. ‘This Crk ensure that any
the spate putes can be despatched in good time. Continue ss log
System,
FRESH WATER OPERATION;
At times when the vessel enters a river estuary where the water may
be ftesh or brackish the effect will be to limit the spread of cane
ftom 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 curent 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,
PREVENTATIVE MAINTENANCE,
It is recommended practice that routine service by Catheleo should
be carried out as recommended by the classification body for the
vessel which in some instances is 2 yearly.
Section 5 RevO
Page 2 of 3 6.0
61
SERVICE AND FAULT FINDING:
6.0.1
6.0.2
6.0.3
6.0.4
6.0.7
6.0.8
RECOGNITION OF 4 PROBLEM:
The a. ; a
2 re 1 Tabu Voltage is the driving potential that Produces the protective
gaze ng andar Cathelo Shield Marine Impressed Current Ssere
s ding #8e Output OF 24VDC but this is i
regulated sccording to the current requirement and with fey ae
vessel at low current output the DC Voltage will normally be around) 13
{est equipment is used. To check insulation of ‘any cables outside the Power
Supply Unit disconnect them at both ends.
Ifthe LCD display is not illuminated then first check the mains supply to
the cabinet and that the system is switched on, If ne fault can be found then
1port conditions to Cathelco (Chesterfield),
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 Cathelos
(Chesterfield) giving full details of the alarm,
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 controler 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 Rev 0
Page 1 of | 7.0
C-SHIELD 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
7-02 Follow the attached check list entering readings as requested,
7.03 Itis recommended that completed check lists be copied and submitted to
Cathelco for analysis. Keep the original copy with the ships manus,
Section 7Rev0
Page C- Shield Commissioning Cheek 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 Rev
Page? of C- Shield Commissioning Check Li it Con
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)
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,
Re-connect anode cables to panel terminals / fuses,
Disconnect shipyard reference electrode wires from panel input terminal
Measure reference cell potentials, L
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
200 mV - 300 mY. For a hull in bad painted condition the readings will be higher ie. 300 mV +.
Re- connect reference electrode cable inputs to terminal block.
Measure -v terminal to ground. ohms (Should be zero)
Sexton 7 Rev
Page 30f7 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 CSHIELD
* * * A SYSTEM
The unit will then automatically go into the standby mode indicating as follows:
STANDBY VOLTS
1 ***mv 2 *** mv
(To obtain reference cells 3 & 4 if applicable press "up" arrow. Press "up" arrow to return
to1 & 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 1 %
ELI ** mv
The bottom half of the display is a continuous read out of Ref 1 &2&3& 4
followed by the voltage followed by the current.
At start up the I % should be "zero".
The unit is now ready for testing,
Seaton 7 Revo
Page 4of7 C- Shield Commissioning Check List Cont'
Manual Mode Cont'
By pressing the "UP arrow" you will be able to increase the I %. This will result in
the reference cell readings reducing and the voltage and current increasing. To
avoid applying too much current to the hull at this stage we recommendthat this
test is carried out toa maximumof "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 Vv Voltage. v
Current A Current___A
I = 20% I = 25%
ELI mV EL1___smV
EL2. mV EL2____mV
EL3 nV EL3__mvV
EL4 mV EL4, mV
Voltage Vv 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 Rev
Page oT C- Shield Commissioning Check List Cont'
Automatic Mod
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: ELI“ my ~ #4
EL2 ***my y *¥
BY pressing the "Up arrow" you can read EL3 & EL 4 if applicable.
Record readings immediately, EL1 mv
EL27 amv
Amps A
Volts
After 30 minutes record readings again.
EL1 mV
EL2 mV
Amps ___ A
Volts v
After One (1) Hour record readings. _After Two (2) Hours record readings.
ELI mv
ee a
— Amps
Amps ___ + Volts v
Volts
Sect 7 eyo
Page Gof7 After six (6) Hours record readings, After (wenty four (24) Hours record readings,
ELI mV EL1
mv
EL2 mV EL2 mv
Amps ___ A Amps___ A
Volts v Volts Soy
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 Catheleo head office monthly for
analysis,
Please review the instruction manual for “Alarm Conditions"
Ifthere are any problems relating to these instructions or else the computer
control unit does not funetion as it should then please immediately contact
Cathelco head office for further instructions.
C- Shield Systems
Cathelco Limited
Marine House
Dunston Road
Chesterfield
S41 8NY U.K.
Telephone: (01246) 457900
Fast (01246) 457901
E-mail: technical@cathelco.com
Section 7Rev 0
‘Page 7087 8.0
WORLD WIDE AGENCIES
8.0.1
8.0.2
8.0.3
Cathelco Ltd are world leaders in the supply of corrosion suppression and
Control systems to the marine industry. Backed with over 33 years of
experience the C-Shield marine impressed current cathodic protection
In order to meet customers requirements world-wide, Cathelco have an
extensive agency network of Catheleo trained Engineers. These Engineer are
available to assist with installation and commissioning as well ws providing
on site instruction for operating staff,
Please contact Cathelco UK in the first instance for details of ‘your nearest
agent world-wide,
CATHELCO LTD
MARINE HOUSE
DUNSTON ROAD
CHESTERFIELD
DERBYS
‘S41 8NY
UK
Tel: 00 44 (0)1246 457900
Fax: 0044 (0)1246 457901
E-Mail: technical@cathelco.com
Section 8 Rev 0
Page 1 of | ICCP Full System Check Cathelco=
Half Cell Plot
Connect the cable tail of the Half Cell into the Common Socket of the multimeter and
allow the Half Cell to dangle in Telatively still water. This test should not be carried out
whilst the vessel is in motion. Plug the red probe into the ‘Positive Socket of the
multimeter and hold the probe against a suitable section of the vessel (paint removal to
bare metal is required to ensure a good connection).
Set the multimeter to the 2000mV DC setting and record the vaules at various points
around the hull on the following sheet
It should be noted that if the plot is done whilst the vessel is in dock the results received
can be affected by other vessels as well as the dock itself
Half call plot layout diagram Sectional plots
‘round the vessel
Tm Pm PMWM MMPI
mv] ate Fed > 2am
rm Tem | PPM
Ideal Value for
protection
Halfcell atleast 1m
CS bslow sea level
: |
O+-
Half cell
vy
-—to! ICCP Full System Check Cathelco=
Automatic Mode Checks
Change the panel to Automatic Mode as described in the operators manual.
Depending on the system type the unit may now run a self test before going into
Automatic Mode.
Does the panel show a fault? If so which one? wo
Record the panel readings immediately Voltage = 2(V Vv
(Forcanicopant wee Up Arow oad EL BELA wh aplestle) Current OA A
Blt = -65 mv
EL2 Oe mV
Eig = mv
El4 = mv
Record the panel readings after 30 minutes Voltage = LOY vy
Current = Of A
Ell = “6 mv
El2 = =20 mv
E30 = mV
El4 = mv
Record the panel readings after 1 hour Voltage = U2 v
Current 04 A
Eu ~16 mv
EL2 -25 mv
EL3 mv
EL4 mv
Record the panel readings after 2 hours Voltage = 1, z Vv
Current = ¢ A
EL AS mV
EL2 ~20 mv
EL3 mV
EL4 mv ICCP Full System Check Cathelco=
=
Additional Comments
Please include any information that may help us with your query.
EL-CHETER: FLOKE ZZ Iv MOLTV4STER
WE ARE CETlME "OUEK FRO” cUcY Kkiten Stides
1O0-1¢ KV0B, WE ANE Sarclaé Filci~ APPERDEE an
Fo Mutes woRrrhe Fe A PCat oRex,
‘ 5 MACS
AcE cece wftor wer Powe 4 YE Pow? Ca
THe recs REAop RUBLE ele
Contact Information
Once this form has been completed it should be emailed back to the person who
Tequested it, or to technical@cathelco.com with details of why the test was carried out.
Ifyou require any spare parts or would like to request a service engineer's visit, please
Contact us at sales@cathielco.com or alternatively contact your local agent (see
\www.catheloo.com for further information) ICCP Full System Check Cathelco=
Half Cell Plot (continued)
Take readings at various Points around the vessel and record the readings below
Type of half cell
Port/Forward mv Starboard/Forward mv
Port/Fore-Mid mv Starboard/Fore-Mid mv
Port/Midship mv Starboard/Midship mV
Port/Mid-Aft mv Starboard/Mid-Aft mv
PortlAft mv Starboard/Aft mv
Record the panel Teadings when the Half Cell measurements are taken
Forward System Aft System
Error Message Error Message
Voltage Vv Voltage = Vv
Current A Current == A
ELI = mV El1 = mv
El2 = mv El2 = mv
EL3 = mV EL30 = mV
El4 = mV El4 = mV ICCP Full System Check Catheico=
Manual Mode Checks
The system should now be turned on.
Put the panel fo Manual Mode as described in the operators manual. Depending on
the system type the unit may now run a self test and before going into Meriual Mode
Does the panel show a fault? If so which one? NO
The current output from the system should now be increased in steps (starting at 0)
whilst recording the voltage and reference cell Potentials. To avoid applying too much
Current to the hull, this test should be carried out up to 25% of the maximur output of
the system. Depending on the type of system the steps maybe as a percentage of the
maximum output (0%, 8%, 10% ete.) or as defined levels (1, 2, 3 etc),
Please note that the values EL1, EL2 etc. represent the reference cells and that these
may be labelled differently on different systems,
Stepws.o%tec) = 120% Step = 226%
Voltage av Vv Voltage = wee Vv
Current on A Curent = ? A
Et = -/9 mv Et = “M65 ny
El2 = 25 mv Bi2 = -166 oy
EL3 = mv EL3 = mV
EL4 = mv El4 = mv
Step = 32-16% Step = Y=/S%
Voltage = Og ay Vv Volage = 32 Vv
Curent = [24 A Curent = 228 4
Eli = 728" mv El1 = ~f00 ny
E2 = -2% mV EL2 “355 my
EL3. = mv EL3 mv
El4 = mV El4 = mv
Step = 20% Step 25%
Vottage = 10,fu Vv Voltage "GV oy
Current A Current 384 A
Eu mv Eu pA mv
EL2 mv EL2 620 mv
EL3 mv EL3 mv
EL4 mv EL4 mv
Once complete, reduce 1% back to zero as described in the operator's
manual. ICCP Full System Check Cathelco=
Voltage Checks
Please take care to note the units when entering these readings
Tur the unit off and check the following mains A-B WE /
input voltages
ao unt ony uses single phase supp, pease :
Sr gy NH Pec oeeaee
B-C 43, 2.
A- Ground 2606
B-Ground
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