Impressed Current System (ICCP)

Instruction Manual

Ship:
Yard: Hellesy Verft
Yard No.: 150

CathwellAS,POBox68,Clarksgate5,NO3970Langesund,Norway
Tel.+4735967850,fax.+4735967860,contact@cathwell.com
www.cathwell.comwww.cathwell.no
Instruction Manual
ICCP System, BN 150, Hellesy Verft

TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................................................ 3
1.1 GENERAL ..................................................................................................................................................... 3
1.2 CORROSION AND CATHODIC PROTECTION ................................................................................................... 3
1.3 IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM .............................................................................. 3
2. PROPELLER SHAFT...................................................................................................................................... 4
3. RUDDER BONDING ....................................................................................................................................... 4
4. SYSTEM OPERATION ................................................................................................................................... 4
5. CONTROL UNIT OPERATION .................................................................................................................... 5
5.1 CONSTRUCTION ........................................................................................................................................... 5
5.2 INTERFACE PANEL ....................................................................................................................................... 5
5.3 OPERATION.................................................................................................................................................. 5
5.3.1 Main picture ....................................................................................................................................... 5
5.3.2 Alarm limits ........................................................................................................................................ 6
5.3.3 Regulation Mode ................................................................................................................................ 6
5.3.4 Set Point ............................................................................................................................................. 6
5.3.5 Manual Current.................................................................................................................................. 7
5.3.6 Miscellaneous..................................................................................................................................... 7
6. TROUBLE SHOOTING .................................................................................................................................. 8
6.1 DISPLAY READING ....................................................................................................................................... 8
6.2 FAULT FINDINGS .......................................................................................................................................... 8
7. RECOMMENDATIONS.................................................................................................................................. 9
7.1 GENERAL ..................................................................................................................................................... 9
7.2 LOG READINGS ............................................................................................................................................ 9
7.3 DRY-DOCKING ............................................................................................................................................. 9
8. APPENDICES ................................................................................................................................................. 10

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

1. INTRODUCTION
1.1 General

The purpose of the installed impressed current cathodic protection (ICCP) system is to prevent
corrosion on the external surfaces of the ships underwater hull. The system will have no, or
only limited effect on shielded areas as water inlets, sea chests, thruster tunnels, rope guard, etc.

1.2 Corrosion and Cathodic Protection

On metal surfaces submerged in seawater different local electrical voltages (anode-cathode cell)
will exist. This involves a current flow resulting corrosion on the areas where the current
dissipates (anodic area) and protection of the areas where the current enters the metal surface
(cathodic area).

The principle of cathodic protection is to make the area to be protected a cathode. The anodic
reaction takes place at the anodes.

Current is supplied from a control unit via the anodes, through the seawater and into the hull
surface. The current is flowing in the less resistance path, hence, it will flow to the surfaces with
paint damages. The current is distributed to hull surface areas requiring protection.

Measuring the hull potential by a reference electrode will indicate the effectiveness of the
cathodic protection.

1.3 Impressed Current Cathodic Protection System

The impressed current cathodic protection (ICCP) system consists of the following main
components, positioned as shown on the ICCP system arrangement drawing:

1. Control unit, type 24/100-CCEL IP44

2. 2 nos. inert anodes, type ADS-1
3. 2 nos. reference electrodes, type RSH
4. Cabling (yard supply)

The control unit supplies current to the anodes. Based on the reference electrode potential
measurement the control unit regulates the current supply to the anodes to maintain reference
potentials at protected level.

The ICCP system design depends on the size of the hull to be protected, the hull geometry and
operation of the ship.

Both anodes and reference electrodes are recessed into the hull for reduced drag.

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

2. PROPELLER SHAFT

Due to a potential difference between the propeller and the hull special shaft bonding equipment
is recommended to be installed to avoid spark corrosion in bearings. An installed shaft slipring
arrangement will reduce the potential difference between the shaft and the hull and the current
will flow through the brushes rather than through the bearings. It is recommended that the
potential difference between the shaft and the hull is kept lower than 75 mV.

3. RUDDER BONDING

In order to include the rudder in the protection by the impressed current system a bonding cable
should be connected between the rudder stock and the hull. This bonding will also reduce the
risk of current flowing through the bearings creating spark corrosion.

Rudder flaps shall always be equipped with sacrificial anodes.

4. SYSTEM OPERATION

When a good and dense paint system is applied (for new building or after dry-docking) the
current requirement will be low. The current requirement will increase with deterioration of the
underwater hull paint system. Hence, the current is an indication of the underwater hull paint
system condition.

Whilst moored the current may increase abnormally, due to contact with unprotected bare steel
surfaces. Special care should be taken when welding operation are carried out onboard, using
power supply from land side. If insufficient return connection, the welding current may be
flowing through the ship and result severe corrosion attack may occur at certain areas.
Conversely, if the polarity is reversed the paint system may be damaged due to considerable
over protection.

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

5. CONTROL UNIT OPERATION

5.1 Construction

The CCEL control units are in principle built up by the following main components:

1. Transformer
2. Rectifier bridge
3. Control circuit board with display

The input and output terminal blocks are situated in the top of the cabinet and marked with
terminal numbers and declarative text.

5.2 Interface Panel

The control unit controller module is equipped with push-buttons for navigating the menu tree:
ENT (ENTER), , and ESC. The arrow keys are used to move up and down in the menu
listing, adjust limits and select options. The ENTER-key is used to go one level into the menu
system and to confirm changes made to limits and settings. The ESC-key takes you one level up
in the menu listing. It is also used to cancel any changes made to limits or settings. To get back
to the main picture, press the ESC-key a couple of times.

5.3 Operation

The following describes the main functions and menu possibilities required for onboard
operation of the ICCP system.

Correct settings of the system will be made during system commissioning and adjustment
should only be done in accordance with recommendation from Cathwell.

5.3.1 Main picture

The main picture contains three pages, showing the output effect, reference potentials and
alarm status.

Page 1 shows time and date together with the output voltage and output current for
each of the two connected outputs

Page 2 shows the potentials measured by the connected reference electrodes (up to 4,
normally 2)

Page 3 shows the active alarms together with the input voltage Hz.

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

5.3.2 Alarm limits

The system is equipped with alarm for underprotection (HI limit) and overprotection (LO limit).
The values should normally be set to:

HI Limit: 350 mV

LO limit -150 mV

It is also possible to connect up to four shaft potential measurements to the control unit. High
and low alarms for these potentials together with an upper temperature alarm is possible to set in
this menu.

5.3.3 Regulation Mode

The system is normally set up for automatic regulation according to the highest of the reference
potential readings from the installed reference electrodes.

However, if the reference electrodes fail the system can be set to manual regulation mode, and a
desired current output entered.

These settings are available in the operation mode under the mode settings menu.

5.3.4 Set Point

In automatic regulation mode the system adjust the current output in order to keep the selected
reference potential close to the adjusted set point.

The set point value can be changed under the Mode settings menu.

During commissioning of the system the recommended system set point is chosen. No change of
set point should be made without recommendations by Cathwell.

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

5.3.5 Manual Current

If manual regulation mode is selected the current output will be according to setting made for
manual current under the menu Mode settings. This is only recommended if both reference
electrodes for any reason are not functioning.

5.3.6 Miscellaneous

In the above we have only described the menus normally required for the operation of the
system. Other settings can be made, however, these are mainly for service personnel.

Attachment A shows all menus and how to navigate make adjustments.

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

6. TROUBLE SHOOTING
6.1 Display reading

Minor fluctuation in the control unit display reading may occur at low current requirement.
However, this will not have any negative effect on the cathodic protection system performance.

Possible fluctuation may be caused by the following:

Low current requirement.
Contamination on the shaft slip ring contact surface.
Electrical noise created by other systems being picked up by the reference electrodes
and/or cabling.

6.2 Fault findings

Important safety
Even with the front door isolator in Off position there are live terminals inside the cabinet.

Whenever the front door is open the front door isolator should be left in Off position and the
supply to the control unit isolated elsewhere.

Never touch the input terminals of the front door isolator without ensuring that the mains input
supply is isolated.

Symptom Check Remedial action

No display Mains power to unit
No display Front door isolator is Off
Internal main circuit breaker
No display
is Off
Alarm screen value Set-up correct
Zero output current Set-up correct
Alarm screen mains frequency
Zero output current
mis-match
Zero output current External output circuits
System operating in brackish
High voltage, low current
or fresh water
High voltage, low current External output circuit
Disconnect reference
Reference potentials out of
electrode and check voltage
alarm limits
with digital volt meter
Provide mains power
Switch On
Reset to On
Reset or clear fault
Review all set parameters
Confirm AC power to control
unit
Operate test mode to verify
external circuits
Await return to seawater with
higher salinity
Check circuits and anodes
Replace reference electrode if
faulty

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

7. RECOMMENDATIONS
7.1 General

In order to secure continuous proper operation it is recommended that the ICCP system is being
serviced by an Cathwell service engineer at dry-dockings.

7.2 Log Readings

In order to ensure continuous proper operation of the ICCP system a log sheet has been prepared
for system operation data completion. Completed log sheets are recommended dispatched to
Cathwell for evaluation and comments.

7.3 Dry-docking

It is recommended to switch off the ICCP system approximately 1 week prior to dry-docking in
order to dissolve the build up salt deposit.

All anodes and reference electrodes must be covered prior to any paint application.

The anode surface must under no circumstances be painted or scraped.

If paint has been applied on the zinc reference electrode surface a steel brush may be used to
remove paint.

The cover on anodes and reference electrodes must be removed prior to un-docking.

In order to prevent stress to the new hull paint system it is important not to impress any current
to the hull before the paint is fully cured. Hence, do not switch on the ICCP system before
three weeks after un-docking.

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

8. APPENDICES

1. Display screens
a. Main display screen
b. Setting display screens
2. Drawings
a. 1905-MIA, ICCP System Arrangement, NB 150, Hellesy Verft
b. 1045-MIA, Disc anode type ADS-1, Arrangement drawing
c. 1044-MIA, Zinc reference electrode type RSH, Arrangement drawing
d. 1979-MID-01, ICCP control unit cabinet type 24/100-CCEL IP44
e. 1979-MID-02, ICCP control unit interface diagram type 24/100-CCEL IP44
3. Control Unit Data Sheet
4. Standard log sheet

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Instruction Manual
ICCP System, BN 150, Hellesy Verft

APPENDIX 1
Instruction Manual
ICCP System, BN 150, Hellesy Verft

Main Display Screens

Display 1 (-key to next) Display 2 (-key to next) Display 3 (-key to next)

Time Date Ref cell 1: ### mV Alarms V#.##

Output Vdc ##.# V Ref cell 2: ### mV
Current shunt ### A Ref cell 3: ### mV
Ref cell 4: ### mV
CS1: ## A CS2: ## A Shafts
CS3: ## A CS4: ## A S1: ### mV S2: ### mV CW ## Hz ## Hz
CS5: ## A CS6: ## A S1: ### mV S2: ### mV
T1: ## C T2: ## C Note CW could display as CCW counter
clockwise phase rotation
Instruction Manual
ICCP System, BN 150, Hellesy Verft

Setting Display Screens

Esc
Alarm limits (-key to next) Overcurrent (-key to next) Mode Settings (-key to next) System Settings (-key to next) Fitted Options (-key to next)
Enter Enter Enter Enter Enter
>R1 Upper mV 350 >Shunt Max A 1000 >Operating mode >Set time/date >Ref 1 Enabled Y
Enter Highlighted to desired Enter Highlighted to desired Enter Enter Enter Enabled N
value value Slave >Hours hr Enter Enabled Y
Enter Enter Current Enter Highlighted to desired
Ref. Cell * value Ref 2 Enabled Y
R1 Upper mV 350 C.S.1 Max A 1000 Test Mode Enter Ref 3 Enabled N
R1 Lower mV -100 C.S.2 Max A 1000 Esc Minutes min Ref 4 Enabled N
R2 Upper mV 350 C.S.3 Max A 1000 Date dd Shaft 1 Enabled N
R2 Lower mV -100 C.S.4 Max A 1000 Manual current A ## Month mm Shaft 2 Enabled N
R3 Upper mV 350 C.S.5 Max A 1000 Set potential mV 140 Year yy Shaft 3 Enabled N
R3 Lower mV -100 C.S.6 Max A 1000 Fan start temp C 60 Esc Shaft 4 Enabled N
R4 Upper mV 350 Alarm alert slow N C.S. 1 Enabled Y
R4 Lower mV -100 Esc FW trip current A 500 3 Phase System Y/N C.S. 2 Enabled Y
Shaft 1 Upper mV 75 Esc FW voltage V 23 Hourly logging N C.S. 3 Enabled N
Shaft 1 Lower mV -5 FW Timer h 24 Shunt rating A 300 C.S. 4 Enabled N
Shaft 2 Upper mV 75 FW enabled N C.S.1 rating A 150 C.S. 5 Enabled N
Shaft 2 Lower mV -5 C.S.2 rating A 150 C.S. 6 Enabled N
Shaft 3 Upper mV 75 Esc C.S.3 rating A 150 Therm 1 Enabled Y
Shaft 3 Lower mV -5 Esc C.S.4 rating A 150 Therm 2 Enabled Y
Y C.S.5 rating A 150
Shaft 4 Lower mV -5 C.S.6 rating A 150 Esc
Temp. Upper C 100 Voltage Max % 100 Esc
Shunt voltage
Esc Enter
Esc 75 mV Shunt
60 mV Shunt *
Esc

Shunt/sensor select
Enter
Shunt
Current sensor *
Esc
Write SD settings Enter
Read SD settings Enter
Write SD offsets Enter
Read SD offsets Enter
Instruction Manual
ICCP System, BN 150, Hellesy Verft

APPENDIX 2
Instruction Manual
ICCP System, BN 150, Hellesy Verft
Instruction Manual
ICCP System, BN 150, Hellesy Verft
Instruction Manual
ICCP System, BN 150, Hellesy Verft
Instruction Manual
ICCP System, BN 150, Hellesy Verft
Instruction Manual
ICCP System, BN 150, Hellesy Verft
Instruction Manual
ICCP System, BN 150, Hellesy Verft

APPENDIX 3
Instruction Manual
ICCP System, BN 150, Hellesy Verft
Instruction Manual
ICCP System, BN 150, Hellesy Verft

APPENDIX 4
Instruction Manual
ICCP System, BN 150, Hellesy Verft