I.C.C.

P SYSTEM
FOR
84,000 CBM CLASS LPG CARRIER
HSHI / GEOGAS
S.761

FOR FINAL

Cathelco Limited
Marine House, Dunston Road, Chesterfield S41 8NY, United Kingdom
Tel: (44) 1246 457900 Fax: (44) 1246 467901 Web: www.cathelco.com
 PLAN HISTORY
DRAWN APPROVED
No DATE DESCRIPTION REMAKER
BY BY
 APPROVAL DRAWING
SHIP YARD HSHI
OWNER GEOGAS

HULL No. S.761

SHIP TYPE 84,000 CBM CLASS LPG CARRIER

I.C.C.P SYSTEM
IMPRESSED CURRENT CATHODIC
PROTECTION SYSTEM

IF YOU HAVE ANY QUESTION FOR OUR SYSTEM

PLEASE FEEL FREE TO CONTACT CATHELCO LIMITED. AS FOLLOWS.
Name of
CATHELCO LIMITED CATHELCO KOREA LTD.
manufacturer
Marine House, Dunston Road Office Bldg. 130, Sindeok-gil
Address South Chesterfield, S41 8NY, 2beon-gil, Gangseo-gu, Busan,
United Kingdom 618-803, S.Korea
Tel. (+44) 1246 457900 (+82) 51 972 2540
Fax. (+44) 1246 457901 (+82) 51 972 2545
E-mail [email protected] [email protected]
Homepage www.cathelco.com www.cathelco.co.kr
 INDEX PART 1
ICCP SYSTEM FOR HULL PART

DWG Page
No. DESCRIPTION
No. No.

1 DESIGN AND CALCULATION SCOPE OF SUPPLY 3~5

2 ICCP FWD & AFT SYSTEM LAYOUT C2010 6

3 FWD POWER SUPPLY UNIT DETAILS C2130 7

4 FWD & AFT INPUT CABLE TERMINAL DETAILS C2082 8

5 FWD & AFT SYSTEM WIRING & TERMINAL DETAILS C2201 9

6 FWD C-MAX CIRCULAR ANODE ASSEMBLY C3048 10

7 FWD INSTALLATION OF C-MAX DISC ANODE 100741M 11

8 FWD DI-ELECTRIC SHIELD AREA FOR CIRCULAR ANODE C2022 12

9 FWD DETAIL OF ZINC REFERENCE CELL C3045 13

FWD EXPLODED DIAGRAM OF TYPICAL REFERENCE CELL

10 C3045/A 14
INSTALLATION

11 DESK MOUNTED REMOTE MONITOR M1238/A 15

12 AFT POWER SUPPLY UNIT DETAILS C2132 16

13 AFT DI-ELECTIRIC SHIELD OF C-MAX LINEAR ANODE 102980M 17

14 AFT TYPICAL INSTALLATION SECTION FOR C-MAX ANODE 103214M-1 18

15 AFT EXPLODED DIAGRAM C-MAX ANODE 103214M-2 19

16 AFT DETAIL OF ZINC REFERENCE CELL C3045 20

17 AFT REFERENCE CELL INSTALLATION C3045/A 21

18 GROUND ARRANGEMENT FOR RUDDER STOCK C1165 22

19 ELECTRICAL SPARE PARTS LIST C1288 23

3
 SCOPE OF SUPPLY
SHIPYARD & OWNER HSHI / GEOGAS
HULL No. S.761
OUR REF CA

DESIGN AND CALCULATION FOR REQUIRED CURRENT

WETTED SURFACE HULL 11,660 m2
AREA PROPELLER 43 m2
DESIGN CRITERIA
CURRENT HULL 35 mA/m2
DENSITY PROPELLER 600 mA/m2

REQUIRED HULL 408.1 Amp

CALCULATION
CURRENT PROPELLER 25.8Amp

433.9 Amp
TOTAL 450Amp (FWD:150Amp, AFT:300Amp)

4
FWD SYSTEM
Description Weight
150AMP ”Thyristor” Computerised Control panel IP 44 200Kg x 1ea
INPUT : AC440V / 60hz / 3ph
OUTPUT : 150Amp / 24V DC
ITEM 1
PAINTED : RAL 7032
NEGATIVE EARTH CABLE : 2EA 90SQmm x 3M
CUBICLE EARTH CABLE : 1EA 16SQmm x 1M
Sub total : 200Kg
12Kg x 2ea
75AMP MMO/TI C-MAX CIRCULAR ANODE 60Kg x 2ea
ITEM 2
ANODE DOUBLER PLATE WITH COFFERDAM
Sub total : 144Kg

9Kg x 2ea
ZINC REFERENCE CELL
ITEM 3
ZINC REFERENCE CELL COFFERDAM
Sub total : 18Kg

Total Weight 362Kg

AFT SYSTEM
Description Weight
300AMP ”Thyristor” Computerised Control panel IP 44 325Kg x 1ea
INPUT : AC440V / 60hz / 3ph
OUTPUT : 300Amp / 24V DC
ITEM 1
PAINTED : RAL 7032
NEGATIVE EARTH CABLE : 2EA 120SQmm x 3M
CUBICLE EARTH CABLE : 1EA 16SQmm x 1M
Sub total : 325Kg

14Kg x 2ea
150AMP MMO/TI C-MAX LINEAR ANODE
28.5Kg x 2ea
ANODE COFFERDAM
ITEM 2 70Kg x 2ea
DI-ELECTRIC RIGID SHIELD PLATE 1500 x 1200
1.5Kg x 2ea
HULL BOSS
Sub total : 228Kg
9Kg x 2ea
ZINC REFERENCE CELL
ITEM 3
ZINC REFERENCE CELL COFFERDAM Sub total : 18Kg
2Kg x 1ea
ITEM 4 REMOTE MONITOR
Sub total : 2Kg
ITEM 5 RUDDER STOCK BONDING CABLE 70SQmm x 5M WITH CABLE LUG
ITEM 6 SPARE PART

Total Weight 935Kg

5
 CATHELCO: C-SHIELD ICCP
MARINE IMPRESSED CURRENT CATHODIC PROTECTION

SYSTEM INSTALLATION & INSTRUCTION MANUAL

MARINE HOUSE, DUNSTON ROAD, CHESTERFIELD,S41 8NY, UK

TEL: +44(0)1246 457900, FAX: +44(0)1246 457901, E-MAIL: [email protected]

 C-SHIELD
MARINE IMPRESSED CURRENT
CATHODIC PROTECTION SYSTEM

NOTES:

a) Do not attempt to service or readjust the system operating levels without first reading
and understanding this manual.

b) The system operates at low d.c. voltage levels and may be severely damaged by high
voltage test equipment such as 500V Megger. Read the relevant section in this manual before
carrying out any tests.

c) Should any information be required which is not covered by this manual, please contact
Cathelco immediately. (Address on cover)

- QUOTE –
The system operates at low D.C. voltage levels and may be severely damaged by high voltage test
equipment such as 500V Megger.

The above is because a reference cell or anode is only ever to carry 2 volts or 24 VDC. Cable
meggers give 500V which the equipment is not built for or rated to.

The reference cell only needs to be electrically isolated from ground. To test this only ever use a
Digital Volt Multimeter. Regarding the results the changes in resistance are because too much
current is being applied at too high of a voltage and thus causes conduction which does not ever
happen in reality.

- UNQUOTE -
C-SHIELD MANUAL INDEX:

1.0 Introduction.

2.0 General Descriptions.

3.0 Installation of Equipment.

4.0 Power Supply Operating Instructions.

5.0 Routine Operating Procedure.

6.0 Service & Fault Finding

7.0 C-Shield Commissioning Check List.

8.0 World Wide Agency.

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 sea water. This is termed the
galvanic series of which the following table is an abridged form.

Active or Anodic

Magnesium
Zinc
Mild Steel
Wrought Iron
Cast Iron
Ni-Resist
18.8.3 % Molybdenum SS, Type 316 (Active)
Lead
Tin
Manganese Bronze
Naval Brass
Aluminium Bronze
Copper
70 Copper 30 Nickel
Nickel (Passive)
Monel, 70% Nickel - 30 % Copper
18.8.3 % Molybdenum SS, Type 316 (Passive)

Noble or Cathodic

Note Some metals and alloys have two positions in the series, marked Active
and Passive; the active position is equivalent to the position if corrosion is
occurring and approaches the electro-chemical series position for the material.
The passive position relates to a non-corroding situation where the material is
protected by a self forming surface film. For example, type 316 stainless steel in
sea water is more likely to be passive than type 304 and is therefore generally
preferred for immersed marine applications.
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 rain drops on uncoated steel. Alternatively, they may be close but
discrete cells found when accelerated corrosion occurs at uncoated Anodic areas
on a generally coated cathodic structure. In addition there are long line type
cells that occur on pipelines that pass through aggressive low resistivity soils.
These sections form Anodic areas and corrode in preference to cathodic areas in
less aggressive higher resistivity soils.

Large currents can occur at small Anodic areas and lead to rapid corrosion of
marine structures such as ship's internal tanks, external hull plates, sheet steel
piling in harbours and tubular structures common in jetties and petrochemical
drilling and production platforms.

Cathodic Protection is a system 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 steel under normal non anaerobic conditions it can be shown
theoretically, and is accepted practically, that a steel/electrolyte potential more
negative than -0.85 volts measured against a standard copper/copper sulphate
electrode indicates that cathodic protection is achieved. This is equivalent to -
0.80 volts measured against silver / silver chloride electrode and + 0.24 volts
against a zinc electrode as indicated in figure 1.3.

SACRIFICIAL ANODE CATHODIC PROTECTION:

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

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

2.1.1 IMPRESSED CURRENT CATHODIC PROTECTION:

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

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

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

termed 'IMPRESSED CURRENT CATHODIC PROTECTION'.

Figure 1.2 - Cathodic Protection Applied to a Simple Corrosion Cell

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

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

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

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

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

2.2.0 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 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 3.4.
 The potential of the hull steel to the sea water is unaffected by this increase in
driving voltage, as the resistive effects are local to the anode and the hull/sea
potential is a function of the current flow, the sea water and the coating
condition, not the driving voltage.

The electrical connections to the active surface are made at the back of the
anode and are fully encapsulated and protected by the hull penetration.
Recessed anodes of essentially similar construction are provided for bow
section applications.

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

2.2.2 Impressed Current Reference Electrodes.

The high purity, high stability, zinc reference electrodes are designed to give a
stable reference against which the hull/sea potentials can be measured and a
small current flow that is used in the closed loop circuit to maintain the pre-set
levels of protection.

The construction and the quantity of zinc employed within the electrodes are
such that a minimum life of fifteen years is available without maintenance or
replacement.

The minimum number of reference electrodes per power supply is one although
normally two will be fitted. Ideally, these should be located a minimum of 7.5
metres distant from the anodes. In the case of a stern only installation with the
anodes more than 150 metres from the bows, one reference electrode may be
located in the bows.

A novel feature of the C-Shield closed circuit is that additional reference cells
may be placed at areas that may be susceptible to over-protection such as
adjacent to the anode dielectric shields. These additional reference cells provide
a permanent check, thus preventing any coating damage due to over-protection
if conditions of operation change from those anticipated. This feature is offered
as an optional extra to the standard schemes.

All hull penetrations are provided with substantial cofferdams. The penetrations
themselves are made watertight with heavy duty packing glands. The
cofferdams are fully sealed and provided with watertight cable glands all
conforming to the requirements of the Classification Societies.
2.2.3 Power Supply Unit:

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

thyristor system housed in a range of different sized cabinets, illustrated
on drawings C2130, C2131, C2132 and C2314. The system comprises of a
control PCB, a Thyristor PCB and a Thyristor unit (consisting of a
transformer, a choke and a thyristor bridge) ranging in size from 100
Amperes upto 800 Amperes. The supply requirements are 415 Vac +/-10%,
three phase, 50/60 Hz.

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

line 16 character backlit LCD display which is located in the top centre of
the cabinet door. The display is used to monitor and allow control of the
system. Below the LCD are four push buttons, which are the controls for
changing the system parameters. To the right of the LCD is a power on
indicator, which also acts as an alarm indicator. On the reverse side are a
rotary switch and a potentiometer. The switch toggles between manual
override and normal operation. This allows the operator, in the event of a
fault, to disable the micro-processor control system, and to control the
output current with the potentiometer.

DISPLAY:

This allows the operator to control and monitor the running and set
parameters of the system. It comprises of a 2 line 16 character backlit LCD
display, 4 push button switches and an Alarm LED. This is mounted on
the door of the cabinet.

MAIN CONTROL PCB

This board controls the operation of the system. It provides

control signals to the thyristor driver PCB, which allow control over the
output current and voltage of the system. This is mounted on the back of
the cabinet door.

THYRISTOR PCB

This board monitors and conditions the signals supplied to the thyristor
unit.
2.2.4 Bonding

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

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

To allow protection of the bare propeller and any exposed shafting and to
prevent electrical arcing between shaft and bearings the propeller shaft is
fitted with a slipring assembly. A set of brushes provide the completion of a
low resistance path to allow current to flow to the propeller blades along
the shaft and back to the hull. The slipring is formed from a copper strip
clamped around the shaft with high copper content heavy current capacity
brushes held in geared brush holders. The C-Shield slipring track is silver
plated as standard and in addition silver graphite brushes are used to
minimise contact resistance.
3.0 INSTALLATION OF EQUIPMENT:

3.0.01 Description:

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

for installation through the hull using penetration and cofferdam
arrangements, a power supply unit for location internally and bonding
arrangements for appendages such as propeller and rudder. The system uses
identical cofferdams for both surface mount linear and recessed anodes. The
cofferdams for the reference electrodes are longer than those for the anodes
so that there is a necessity to differentiate between cofferdams before
starting assembly.

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

3.0.03 It is very important that the installation instructions given are followed. The
biggest cause of future problems found with the running of impressed
current systems is incorrect installation. Should any problems occur during
installation of this system or should any instruction appear unclear please
contact Cathelco for advice.
3.2 SURFACE MOUNTED LINEAR LOOP ANODES.

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

1) 250 Amp to 300 Amp output units to Drg no. M1074 with stud fixing
and di-electric shield areas shown on Drg. No. M1065.

2) 150 Amp to 200 Amp output units to Drg no. M1073 with stud fixing
and di-electric shield areas shown on Drg. No. M1071.

3) 50 Amp to 100 Amp output units to Drg no. M1072 with stud fixing and
di-electric shield areas shown on Drg. No. M1070.

3.2.1 For single anode cable type cut a 40mm diameter hole in the hull at each
anode location or for the double type cut a 100mm diameter hole to receive
either the single hull boss (Drg. C1177) or the double hull boss (Drg.
C1178).

3.2.2 Grind off any surplus metal to ensure that the hull boss will locate flat to the
internal shell plating at the inboard side of the hole and radius the external
edge of the hole.

3.2.3 Locate the hull boss centrally in the hole, inside the hull, in the case of the
double boss ensure that the centre line of the two threaded holes are
Vertical and weld it in place using continuous fillet welds both inside and
outside. Take care when welding externally to prevent weld spatter
damaging the thread.

3.2.4 Locate the cofferdam (single type Drg. C1191 or double type C1192)
centrally over the hull boss and position it such that the cable entry pipe(s)
is orientated to suit the installation. Secure it in place by a continuous fillet
weld internally and a full penetration weld externally to give a weld section
at least equal to the plating thickness.

3.2.5 Externally in way of the area to be covered by the anode clean off any weld
spatter from the surface, and grind flat all welds.

3.2.6 Using the stud fixing and the rigid di-electric shield area drawing as noted
in 3.2.0 above. Weld a series of M10 x 1.5p x 37mm long studs directly to
the hull plate. Protect the stud threads with tape or rubber sleeves.
3.2.7 Before proceeding further, ensure that ALL other welding work, either
inboard or outboard has been completed in the area of the rigid di-electric
shield. Any welding carried out after application of the di-electric shield
will damage the shield material even if the welding is not associated with
the cathodic protection system.

3.2.8 The dimensions of the rigid di-electric shield are shown on the drawing as
noted in instruction 3.2.0

3.2.9 Inspect the area to be covered and grind off all weld spatter and surplus
weld material to a smooth profile.

3.2.10 Remove all oil and grease from the areas using clean, dry, oil free rags
soaked in a hydrocarbon solvent such as Xylol, Toluene or white spirit, do
not use petrol or paraffin. Change the rags frequently to avoid merely
spreading contamination.

3.2.11 Ensure that the mounting stud protecting sleeves are still in position and
plug the gland hole in the hull boss to protect the thread. Abrasive blast
clean the entire area to a standard that the paint manufactures recomend

3.2.12 Remove residual dust with a clean dry brush.

3.2.13 Apply the paint coating as recommended by the paint provider.

3.2.14 Remove the mounting stud protective sleeves and degrease the studs.

3.2.15 Apply thread tape to one anode cable gland. Fit the gland to the inside of
the hull boss within the cofferdam recess and fully tighten the main body of
the gland, but fully slacken the compression ring. Two glands will be
required for the double hull boss.

3.2.16 The rigid dielectric shield must now be lifted into place and positioned over
the studs. Once in place weld the rigid dielectric frame in place. This is
what retains the shield in position. Details can be seen on the drawings as
noted in 3.2.0.

3.2.17 The anode must now be fitted onto the studs.

3.2.18 Fit the M 10 threaded eye bolts into the two sockets provided on the outer
surface of the anode carrier, ensuring that they are inserted at least 15 mm.

3.2.19 Using the eye bolts hoist the anode to a position just in front of or above the
stud positions

3.2.20 Ensure that the cable sheath is not damaged at the back of the anode and
that the neoprene compression ring and slip washer are in the cable gland
previously fitted to the cofferdam assembly.

3.2.21 Pass the anode cable through the gland .

3.2.22 Fit the anode into position on the studs taking care to pass the free cable in
the cofferdam recess without it becoming trapped.

3.2.23 Inside the ship tighten the gland fully onto the cable.

3.2.24 Caulk around the mounting studs with the a sealing compound so that the
recesses in the anode are filled up to the bearing surface for the washers and
nuts.

3.2.25 Fit the washers and nuts supplied and tighten the anode fixings evenly from
the centre. Tighten fixings to 4.8kg/metres (35ft lbs).

3.2.26 On completion of tightening the fixings, further caulk around the mounting
studs and the nuts and washers with the sealing compound, ensuring flow of
the compound into the compound previously applied below the nuts and
washers and entirely filling the recess in the anode carrier to present a
smooth, uniform surface.

3.2.28 Inside the ship, remove the blank flange from the cofferdam and check the
cable for damage.

3.2.29 Pass the cable through the side entry hole in the cofferdam and apply thread
tape or sealing compound to the second anode cable gland, and pass the
gland over the anode cable to fit it into position outside the cofferdam in the
side entry hole. Note that two glands will be required for the double hull
exit cofferdam.

3.2.30 Tighten the main body fully into position, then tighten on to the cable
leaving 400mm of slack cable between inner and outer glands.

3.2.31 Fit a yard supply junction box at some convenient point adjacent to the
cofferdam and connect the anode cable to the power supply unit via
shipyard supplied cable (see power supply unit instructions).

3.2.32 Check the insulation of the anode connection circuit to the hull using a
500V earth insulation test meter. Note, if the anode is submerged then this
test will show a short circuit.

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

3.2.33 Refit the cover on the junction box.

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

Do not paint over the anode surface.

3.4 REFERENCE ELECTRODE - EXTENDED EXIT BOSS

Description

See the Reference Cell Arrangement Drawing No: 100006M (Zinc

Reference Electrode) or Drawing No: 100019M (Silver / Silver Chloride
Reference Electrode). Both types of reference electrodes consist of a
cylindrical plate with an integral 12 mm bolt for fastening and electric
contact. The reference electrode is mounted in a rubber holder with
integrated sealings for water tight fitting.

a) Reference Electrode, with contact and fastening bolt mounted in a rubber

holder. The rubber holder includes a sealing ring and conical seal.

b) Cofferdam Body, with a machined recess to fit the reference electrode flush to
the hull plate.

c) In the center of the cofferdam is a carefully machined conical hole for the
conical rubber seal part of the reference electrode.

d) The cable enters the cofferdam through a side pipe. A cable gland provides a
water tight seal for the cable. The cofferdam cover plate and fibre gasket is to be
fastened to the cofferdam with six M8 x 30 bolts to make a water tight seal for the
cofferdam.

e) Because the rubber of the reference electrode represents a very good water
tight seal, do not use mastic, resin or filler. For fastening and electric insulation of
the electrode, use the plastic washer for insulation and the steel washer and an M12
nut for fastening the electrode.

Cofferdam assembly with extended side pipe

Drawing no: 100448M shows an exploded view of the reference electrode cofferdam with side
pipe assembly. Drawing no: 100377M (1 of 2) shows an exploded view of the complete
assembly and hull mounting details

The "General Arrangement of ICCP System" drawing shows where the reference electrodes are to be
situated on the hull.

3.4.01 Cut a 127mm diameter hole in the hull at each reference electrode location
to permit the cofferdam to be inserted. Prepare the hole for welding by
bevelling the outside edge of the hole.

3.4.02 Secure the cofferdam in the position by a continuous fillet weld both
internally and externally to give a weld section at least equal to the plating
thickness. Weld the cofferdam in place so that the outside face is flush to
the outside of the hull. Grind the protruding weld around the cofferdam
flush with the hull before painting the base plate with two coats of primer of
the same quality as the underwater hull.

3.4.03 If the reference electrodes are to be placed in the ballast tanks area, the electrode
cable has to run through a water tight pipe (supplied by yard). The pipe wall
 thickness on tanker vessels is to be according to the requirements of the
classification society. The pipe is to be welded to the straight boss on the coffer-
dam.

3.4.04 Ensure that the back of the reference electrode assembly and the inside of
the base plate recess into which the electrode will fit is clean and dry.

3.4.05 Remove 6 x M8 x 30 lg Hex Head Bolts, M8 washers and cofferdam lid gasket and
cofferdam lid

3.4.06 Insert the reference electrode and assemble the inside parts according to the
assembly drawing in the following order.
Nylon washer, M12 washer wide, M12 nut, M12 washer, Cable shoe with
cable attached, M12 washer and M12 Nyloc Nut.

3.4.07 Tighten all M12 nuts to 1.5 kpm (15 N m) using a torque wrench.

Cabling. The cable size is 6mm2 x 5M long. Enter the cable from the rectifier through the cable gland
and sealing washer. The cable gland is to be fitted on the outside of the cofferdam where
the cables are run in an open area. Where the cable is run through a pipe the cable gland
and sealing washer is to be fitted inside of the cofferdam.

This cable must be shielded. The shield must be terminated in the cabinet of the rectifier at
the earthing point, see terminal drawing in this manual for full details. Under special noisy
conditions it may be favourable to earth the cable also in the cofferdam. An earthing
connection must then be constructed in the cofferdam.

3.4.08 Please ensure that if the vessel is going to be stood in water for a long period
of time during the outfitting period, the reference cells are NOT to be
connected to panel until the ICCP system is commissioned.

3.4.09 After the electric installation is finished the cofferdam can be filled with
yellow Vaseline, however this is down to the yards discretion and is not
essential. The Vaseline must also be supplied by the yard.

3.4.10 Fit the cofferdam gasket and fasten the cover plate with six M8 x 30 mm
long bolts

Vertical cable pipes on the fore ship shall be filled with dry sand.

No welding on or adjacent to the cable pipes shall be performed after cable pull in.
3.5 POWER SUPPLY UNIT:

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

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

maintained all around the equipment for all units.

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

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

Table of cable lengths for different anode size to maintain 3-volt drop

50A 75A 100A 150A 175A 200A CONDUCTOR

SIZE SINGLE
CORE CABLE

45M 16MM2

70M 47M 25MM2

100M 67M 50M 35MM2

125M 83M 62M 41M 50MM2

180M 120M 90M 60M 51M 45M 70MM2

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

3.5.5 Provide and install a cable between the Hull negative terminal on the
equipment and the main ship structure on a stud of minimum M12 welded
to a plate on not less than 100 X 100 X 20mm. It is recommended that these
cables be able to carry the full rated output capacity of the Power Supply
Unit. Cathelco can suggest a suitable cable size to use upon request.

3.5.6 Provide and terminate single core screened cables with a sectional 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 on the terminal plate within
the power unit. Do not connect the screen at the junction box end.
3.5.7 The reference electrode connection block is earthed internally in the Power
Supply Unit.

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

3.5.9 PLEASE ENSURE THAT WHEN WELDING WORK IS BEING

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

3.7.1 The rudder stock must be grounded using the flexible cable
provided

3.7.2 Securely fix one end to the hull or overhead frame work .

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

3.7.4 Please refer to drawings C1165 .

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 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
 In addition there is 1 functional mode1 :-

ACCESS CODE :3991

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

NOTES:

1. Pressing the CTRL button to enter the SELECT MODE menu does not exit
the mode until a new mode has been selected.

2. Configuration mode is only accessible when a valid pass number has been
entered. See PASS NUMBER mode below.
4.0.3 MODE DESCRIPTIONS :

STANDBY MODE:

In this mode all output current from the equipment is shut down to zero.
The display indicates the output voltage and automatically steps through
indicating electrode values and alarms (if any) thus:-

STAND-BY V????V

EL1 ????mV

stepping to:-

STAND-BY V????V

EL2 ????mV

stepping to:-

STAND-BY V????V

EL3 ????mV

stepping to:-

STAND-BY V????V

EL4 ????mV

stepping to:-

STAND-BY V????V

ALARMS (see 4.0.6)

stepping back to the start.

Where ???? is the measured value. Note that in the case of the Anode
voltage the display will be the back emf of the anode system
4.0.4 MANUAL MODE

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

MANUAL I £££%

EL1 ????mV

stepping to:-

MANUAL I £££%

EL2 ????mV

stepping to:-

MANUAL I £££%

EL3 ????mV

stepping to:-

MANUAL I £££%

EL4 ????mV

stepping to:-

MANUAL I £££%

V ???V

stepping to:-

MANUAL I £££%

I ???A

stepping to:-

MANUAL I £££%

“ALARMS” (see 4.0.6)

stepping back to the start.

 Where ??? is the measured value and the £££ is the value that has been
set. The set value is altered by pressing the  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.

4.0.5 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 ££££%

EL1 ????mV

stepping to:-

AUTOMATIC ££££%

EL2 ????mV

stepping to:-

AUTOMATIC ££££%

EL3 ????mV

stepping to:-

AUTOMATIC ££££%

EL4 ????mV

stepping to:-

AUTOMATIC ££££%

V ???V

stepping to:-

AUTOMATIC ££££%

I ????A
 stepping to:-

AUTOMATIC ££££%

“ALARMS” (see 4.0.6)

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

4.0.6 ALARM STATUS:

This mode is embedded in the above 3 operational modes and displays the
status of any alarm, thus:-

SYSTEM FAILURE

MODULE FAILURE

ELECTRODE FAILURE

UNDER-PRO FAIL

OVER-PRO FAIL

4.0.7 ACCESS CODE

This mode provides access to the service functions provided in the

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

ACCESS CODE

3991

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:

4.1.1 Upon entering this mode will access a configuration menu, which will allow
access to the setting of the system parameters. The display will read :-

CONFIGURATION

ZZZZZZZZZZZZZ

where ZZZZZZZZZZZZZ is one of the following:-

SYSTEM SIZE

ELECTRODE TYPE

ELECTRODE NUMBER

ELECTRODE SET mV

OVER PROTECT

UNDER PROTECT

CURRENT LIMIT

QUIT CONFIG

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

4.1.2 SYSTEM SIZE

This parameter will allow the user to define the size in steps of 50Amps.
The display will be as follows, during which time using the  buttons
will vary the setting.

SYSTEM SIZE xxx A

where xxx is the set value in the range 50A to 800A. To store the set
value, the ENT button is pressed.

Pressing the CTRL button will return to the configuration menu.

4.1.3 ELECTRODE TYPE

This parameter will allow the user to define the electrode type. The
display will be as follows, during which time using the  buttons will
vary the setting.

ELECTRODE TYPE

ZINC ELECTRODE

or

ELECTRODE TYPE

SILVER ELECTRODE

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

Pressing the CTRL button will return to the configuration menu.

4.1.4 ELECTRODE NUMBER

This parameter is used to define the number of electrodes. The display

will be ad follows, during which time using the  buttons will vary the
setting.

ELECTRODE NUMBER

where x is the set value in the range of 1 to 4. To store the set value, the
ENT button is pressed.

Pressing the CTRL button will return to the configuration menu.

4.1.5 ELECTRODE SET mV

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

ELECTRODE SET mV

xxx mV

where xxx is the set potential range of -100 to +400 mV in the case of
Zinc Electrode and –1,170 to –670 mV in the case of Silver Electrode. To
store the set value, the ENT button is pressed.

Pressing the CTRL button will return to the configuration menu.

4.1.6 OVER PROTECT

This parameter will allow the user to define the set point at which the
OVER PROTECTION alarm triggers. The display will be as follows,
during which time using the  buttons will vary the setting.

OVER PROTECT, xxx mV

where xxx is the set value in the range OFF, -995 to 0 mV in the case of
Zinc Electrode and OFF, -2,065 to -1,070 in the case of Silver Electrode. To
store the set value, the ENT button is pressed.

Pressing the CTRL button will return to the configuration menu.

4.1.7 UNDER PROTECT

This parameter will allow the user to define the set point at which the
UNDER PROTECTION alarm triggers. The display will be as follows,
during which time using the  buttons will vary the setting.

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.

Pressing the CTRL button will return to the configuration menu.

4.1.8 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.

4.1.9 QUIT CONFIG

This mode will allow the user to exit from the configuration menu. The
display will read :-

QUIT CONFIG, ENT TO CONFIRM

Pressing the ENT button will then exit from the configuration mode,
resetting the whole system. If the CTRL button is pressed, then it will
cancel the quit request and return to the configuration menu.
4.2 SELF CHECKING:

4.2.1 Every 8 hours & upon entry to manual & automatic modes, timed from the
last power up, the system automatically enters a self test mode. This mode
checks the correct function of anodes and electrodes and lasts
approximately 10 seconds. During this time the display reads:-

SELFTEST

PLEASEWAIT

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

Signals from electrodes that have not passed the test are suspended from the
control function for the next 8 hour period and an alarm generated to
indicate an electrode fault. The test is repeated automatically on all
electrodes (including those that have previously been suspended) after an 8
hour interval.

4.2.2 ERROR CHECKING

The equipment is provided with a number of built in self checking

functions. These functions ensure the correct running of the equipment.
5.0 ROUTINE OPERATING PROCEDURE

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

5.0.1 EVERY DAY:

Check that the LCD of the Power Supply unit display is illuminated, and
that the ON/ALARM LED is lit. If either of these are incorrect then refer to
the fault finding section.

Record the O/P Current & Voltage and the 4 electrode voltages on the C-
Shield log sheets provided. Refer to figure 5.1 for an example of how to
complete the log sheet.

NOTES:

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

2. Pressing either the up or down buttons will toggle the display to read
either electrodes 1 & 2 or electrodes 3 & 4.

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

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

5.0.2 EVERY WEEK:

Once weekly the slipring should be checked for cleanliness, for wear on the
brushes and to confirm that the brushes both move freely in their holders
and are held firmly onto the slipring by the brush holder spring. Check the
rudder stock bonding cable for any fraying of the conductor at the
connection points.

5.0.3 EVERY MONTH:

Each log sheet has space for a complete month after which the copies
should be returned to Cathelco, Chesterfield for scrutiny and comment.
5.0.4 EVERY 3 MONTHS:

Every 3 months switch off the equipment isolate the power externally to the
unit remove the covers and inspect the power supply unit internally for
signs of loose wires or other visual defects. The power supply unit is, under
normal operation, fan cooled, and depends on free circulation of cooling air
through the vents to maintain safe working temperature of components.
Check that the ventilation grilles in the sides and top are not obstructed in
anyway. Clean any dust and dirt from the unit paying particular attention
to the cooling fan.

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

5.0.5 30 DAYS PRIOR TO DRY-DOCKING:

One month before the dry docking ensure that daily log sheets have been
maintained and forwarded to Cathelco for assessment with information that
dry docking is expected. This will ensure that any necessary spares can be
despatched in good time. Continue to log the system readings up to the
time the vessel enters the dry dock. It is advised that an Engineer from
Cathelco (Chesterfield) be in attendance during drydocking to check and
service the C-Shield System.

5.0.6 FRESH WATER OPERATION:

At times when the vessel enters a river estuary where the water may be
fresh or brackish the effect will be to limit the spread of current from the
anodes because of the much higher electrical resistivity of water. Normally
this will cause the automatic control to increase the transformer rectifier
output voltage to the maximum but this will be accompanied by a very low
level current and the reference electrode potentials may indicate under
protection. However, this has been taken care of by our computer and is
explained in a separate paragraph in 6.1 The system will return the hull to
the optimum protective level as soon as the vessel returns to the sea water.
 Cathelco Limited
Marine House
18 Hipper Street South
Chesterfield S40 1SS
United Kingdom
Telephone (01246) 207702
Fax (01246) 206519

_________________________________________________________________________________
Daily log for C-Shield impressed current cathodic protection system.
Vessel SHIP NAME Aft system capacity 400 amps 24 volts
Voyage number 23A Forward system capacity 100 amps 24 volts
Date from 01/05/97 To 31/05/97
Complete in triplicate and distribute as follows: 1st copy to owner’s file, 2nd copy to Cathelco, 3rd copy to ship’s file.
Slip ring/brush gear operation and condition to be checked weekly. Ring to be clean, brushes in contact.

Slipring check Wk1  Wk2 Wk3 Wk4

Month Area of operation Sea Aft output Sensing For’d output Sensing Notes
temp. electrode (mV) electrode (mV)
o
2 C
Amp Volt S1 S2 Amp Volt S3 S4
1 Pacific 26 15 2.8 210 220 5 2.8 221 215 light draft
2 Coral Sea 29 15 2.8 212 220 5 2.7 220 215 light draft
3 " " 29 15 2.7 212 220 4 2.7 221 214 light draft
4 Torra St 28 14 2.7 210 220 4 2.7 220 214 light draft
5 Arufura Sea 28 14 2.7 211 220 5 2.8 220 214 light draft
6 Serum Sea 27 15 2.8 212 220 5 2.8 221 215 light draft
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Figure 5.1
Typical Log Sheet with Entries
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 +0.20 volt for optimum protection. This
example gives levels with respect to zinc electrodes.

6.0.4 The d.c. output voltage is the driving potential that produces the protective
current. The standard Cathelco C-Shield Marine Impressed Current System
has a maximum voltage output of 24VDC but this is automatically
regulated according to the current requirement and with a newly painted
vessel at low current output the DC voltage will normally be around + 3.5
volts.

6.0.5 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 (Chesterfield).
 6.0.9 If the Power Supply Unit On/Alarm LED is not lit, then:

a) Press 'CTRL' button. This allows the operator to select a different

mode.

b) Press the up or down buttons until the display reads SELECT MODE,
ALARM STATUS

c) Press the 'ENT' button. This selects the alarm status mode.

The display should now read 'ALARM' in the top left. In the top right the
mode of operation will be displayed, i.e. MANUAL, AUTO or STAND-
BY. Make a note of the mode, and any alarm messages displayed on the
bottom line.

If there is more than on alarm condition, then they will automatically scroll
round.

d) Press the 'CTRL' button to re-enter the 'SELECT MODE' menu.

e) Press the up or down buttons until the mode noted is 'AUTOMATIC

MODE'.

f) Press the 'ENT' button to re-enter mode.

6.0.10 When any of the alarm conditions are found to be displayed contact
Cathelco (Chesterfield) giving full details of the alarm.

6.1 VESSEL IN FRESH WATER

ICCP systems have experienced problems in the past when the vessel has to enter a
harbour or estuary where the water is either fresh or brackish. The C-Shield
computer controller has been programmed to identify this situation by analysing the
voltage reading, the amperage reading and the reference electrode inputs. In fresh
water the amperage goes to zero and the voltage tends to go to maximum to
compensate, the reference electrode readings go high. With the systems self
analytical test the computer will identify this situation and IMMEDIATELY go into
a "standby mode" whereby the amps and volts go to minimum until such time as the
readings indicate that the vessel has moved back into good salt water. The system
will then start to function normally. This will happen at the next "Self Test" that the
computer carries out every eight hour period.
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
carried out.

7.0.2 Follow the attached check list entering readings as requested.

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

Cathelco for analysis. Keep the original copy with the ships manual.
 C - Shield Commissioning Check List

Vessel : ________________________

Shipyard : ________________________

Newbuilding No. : ________________________

System Size : ________________________

Owner : ________________________

1. Check shipyard cable connections to panel fuse terminals. ______

2. Check shipyard cables to reference electrode inputs. ______

3. Check ground connection at terminal in panel. ______

4. Check shipyard mains input cables are connected. ______

5. Check any auxiliary circuit input cables if applicable. ______

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

7. Locate shipyard mains input voltage supply point. ______

8. Make a physical check of the unit for any possible transit damage. ______
 C - Shield Commissioning Check List Cont'd

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

A - B A - C B - C

______ ______ ______

A - Ground B - Ground C - Ground

_______ ______ ______

Disconnect Shipyard anode input cables from fuse terminals in panel.

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

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

Re-connect anode cables to panel terminals / fuses.

Disconnect shipyard reference electrode wires from panel input terminal.

Measure reference cell potentials.

1. ________
2. ________
3. ________
4. ________
These reading will vary in accordance with the state of the hull paint coating adjacent to the
reference cell location.

Re- connect reference electrode cable inputs to terminal block.

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

 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
to 1 & 2).

Manual Mode.

Press "CTRL" button once and unit will go into Select mode. Press "Up arrow"
to choose Manual Mode. When this appears Press "ENT".
The unit will show the following statement. SELF TEST
PLEASE WAIT.

The unit then does a self analysis of all its circuits and modules checking reference
electrodes and all relevant electrical data. On completion of the self test the unit
goes into Manual Mode.

The following will appear on the display panel: MANUAL I %

EL 1 *** 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.

 C - Shield 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 recommendthat this
test is carried out to a maximum of " I 25% ".

Log the data as follows: I = 5%

EL 1 _______mV
EL 2_______mV
EL 3_______mV
EL 4_______mV
Voltage _____V
Current_____A

I = 10% I = 15%

EL 1 ______mV EL 1_______mV
EL 2_______mV EL 2_______mV
EL 3_______mV EL 3_______mV
EL 4_______mV EL 4_______mV
Voltage _____V Voltage_____V
Current_____A Current_____A

I = 20% I = 25%

EL 1 _______mV EL 1______mV
EL 2_______mV EL 2______mV
EL 3_______mV EL 3______mV
EL 4_______mV EL 4______mV
Voltage _____V Voltage____V
Current_____A Current____A

This establishes the correct operation of the manual mode. Reduce I % back to
zero by continuously pressing the "down arrow". When the I % is zero press
"CNTL" this takes it back to STANDBY then press "ENT"
 C - Shield Commissioning Check List Cont'd

Automatic Mode.

The unit is now ready for automatic operation.

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

The unit will show the following statement. SELF TEST

PLEASE WAIT

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

EL 2 ***mV V *V

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

Record readings immediately. EL 1 _______ mV

EL 2 _______ mV
Amps_______ A
Volts _______ V

After 30 minutes record readings again.

EL 1 _____ mV
EL 2 _____ mV
Amps ____ A
Volts ____ V

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

EL 1 _____ mV EL 1 _____ mV
EL 2 _____ mV EL 2 _____ mV
Amps ____ A Amps ____ A
Volts ____ V Volts ____ V
 C - Shield Commissioning Check List Cont'd

The system can now be left permanently in "AUTOMATIC MODE" and the
readings should be taken daily. These should be filled in on the C - Shield log sheet
which has been provided and then returned to Cathelco head office monthly for
analysis.

Please 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.

C - Shield Systems
Cathelco Limited
Marine House
Dunston Road
Chesterfield
S41 8NY U.K.

Telephone : +44(0) 1246 457900

Fax: +44(0) 1246 457901

E-mail: technical@cathelco co.uk

8.0 WORLD WIDE AGENCY

8.0.1 Cathelco Ltd are world leaders in the supply of corrosion suppression and
control systems to the marine industry. Backed with over 35 years of
experience the C-Shield marine impressed current cathodic protection
system is second to none.

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

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.

8.0.3 Our worldwide network of sales and service centres can provide immediate
advice and assistance on the complete range of Cathelco products. Agents`
contacts details are available on our web site : www.cathelco.com