ICCP Installation Manual 38658AE 'S1163' REV1

CATHELCO: C-SHIELD ICCP MARINE IMPRESSED CURRENT CATHODIC PROTECTION

SYSTEM INSTALLATION & INSTRUCTION MANUAL

CLIENT:

SHANGHAI SHIPYARD CO LTD VESSEL:

S1163

CATHELCO REFERENCE:

CA 38658/AE

Rev: 1 Issued By: CH Date: 28/7/11

MARINE HOUSE, HOUSE, DUNSTON ROAD, ROAD, CHESTERFIELD, CHESTERFIELD, DERBYS. S41 8NY, UK TEL: +44 (0)1246 457900 . FAX: +44 (0) 1246 457901 . E-MAIL: technical@c E-MAIL: [email protected] athelco.com

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)

C-SHIELD MANUAL INDEX: 0.0

List of drawings.

1.0

Introduction.

2.0

General Descriptions.

3.0

Installation of Equipment.

4.0

Power Supply Operating Instructions.

5.0

Routine Operating Procedure.

6.0

Service & Fault Finding

7.0

C-Shield Commissioning Check List.

8.0

World Wide Agencies.

9.0

Diver Change Instructions.

LIST OF DRAWINGS: ANODE DETAILS: ELLIPTICAL

50-125A RECESSED ELLIPTICAL ANODE DETAILS 125-175A RECESSED ELLIPTICAL ANODE DETAILS 125-175A RECESSED ELLIPTICAL ANODE ASSY (PLAIN OUTLET) 50-125A RECESSED ELLIPTICAL ANODE ASSY (FLANGE OUTLET) 6” COFFERDAM DETAILS M25 GLAND 6” COFFERDAM DETAILS M25 GLAND (FLANGE OUTLET) 50-125A DIELECTRIC SHIELD AREA DETAILS 125-175A DIELECTRIC SHIELD AREA DETAILS 50-125A DIAGRAM RECESSED ELLIPTICAL ANODE ASSY. 125-175A DIAGRAM RECESSED ELLIPTICAL ANODE ASSY. K6 JUNCTION BOX TYPICAL SPLICE KIT CONNECTOR DETAILS

DRG NO. C1202 DRG NO. C2008 DRG NO. C2025 DRG NO. C2126 DRG NO. C1191/M25 DRG NO. C1468/M25 DRG NO. C1196 DRG NO. C2022 DRG NO. M1000 DRG NO. M1236 DRG NO. M1047 DRG NO. M1043

REFERENCE CELL DETAILS

ZINC REFERENCE CELL INSERT REFERENCE CELL ASSEMBLY DETAILS (PLAIN OUTLET) REFERENCE CELL ASSEMBLY DETAILS (FLANGED OUTLET) REFERENCE CELL COFFERDAM DETAILS (PLAIN OUTLET) REFERENCE CELL COFFERDAM DETAILS (FLANGED OUTLET) EXPLODED DIAGRAM OF REFERENCE CELL ASSY K4 JUNCTION BOX TYPICAL SPLICE KIT CONNECTOR DETAILS

DRG NO. C1102 DRG NO. C1162 DRG NO. C2128 DRG NO. C1190 DRG NO. C1470 DRG NO. M1004 DRG NO. M1046 DRG NO. M1043

SHAFT & RUDDER EARTHING DETAILS:-

SHAFT EARTHING GENERAL ARRANGEMENT DETAILS SHAFT EARTHING BAND CLAMP DETAILS SHAFT EARTHING BRUSH HOLDER DETAILS (STD) MILLI-VOLT METER BRUSH HOLDER DETAILS TYPICAL SHAFT EARTH HOLDER MOUNTING POST (STD) MILLI-VOLT METER DETAILS (SWITCHABLE) SHAFT EARTHING WIRING (SWITCHABLE) DIAGRAM RUDDER BONDING CABLE DETAILS 3M LONG

Section 0.1 Page 1 of 2

DRG NO. M1191 DRG NO. M1192 DRG NO. C1181 DRG NO. C1157 DRG NO. C2158 DRG NO. M1100 DRG NO. C1159 DRG NO. C1165 3M

POWER SUPPLY UNIT DETAILS:THYRISTOR CH TYPE

100-300A POWER SUPPLY UNIT (STD) 350-600A POWER SUPPLY UNIT (STD) 100-300A CABLE COAMING INLET DETAILS 350-1000A CABLE COAMING INLET DETAILS TERMINAL LAYOUT DETAILS (2 ANODE) KEYPAD &DISPLAY DETAILS SCHEMATIC CIRCUIT DIAGRAM FOR PSU

DRG NO. C2130 DRG NO. C2131 DRG NO. C2291 DRG NO. C2258 DRG NO. C2082 DRG NO. C1623 DRG NO. C2083

REMOTE MONITOR

FLUSH MOUNTED TWO WAY TYPICAL WIRING DIAGRAM FOR TWO WAY MONITOR

DRG NO. M1238 DRG NO. C1204

GENERAL INFORMATION DRAWINGS:-

SPARE PARTS LIST PORTABLE REFERENCE ELECTRODE DETAILS ELECTRICAL SPARE PARTS CH PANEL

DRG NO. C1273 DRG NO. C1606 DRG NO. C1288/CH

WIRING DIAGRAM (CH)

SYSTEM WIRING DIAGRAM THYRISTOR FWD & AFT, C/W REMOTE DRG NO. C2109 SYSTEM LAYOUT

SYSTEM EQUIPMENT LAYOUT (FWD & AFT)


DRG NO. C1849

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.

Section 1 Page 1 of 3

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. The specific power supply unit supplied is illustrated on the drawing included with this manual. The system comprises of a control PCB, a Thyristor PCB and a Thyristor unit (consisting of a transformer, a choke and a thyristor bridge) ranging in size from 100 Amperes upto 800 Amperes. The supply requirements are 415 Vac +/-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 o f the system. It comprises of o f a 2 line 16 character cha racter backlit ba cklit LCD display, 4 push button switches and an Alarm LED. LED. This is mounted 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.


3.3

ELLIPTICAL RECESSED ANODE:

3.3.01

Select the required area and mark out using a template the steelwork location. Make sure that the internal stiffening will not be touched. Ensure the ellipse will be located within a steel plate and not interfere with existing weld seams.

3.3.02

Cut an elliptical hole. The ellipse may be easily marked out by positioning the anode on the hull and scribing around it and allowing a margin of 6mm around the anode periphery. Alternatively, a template may be made using the doubler plate. Refer to Drg. C1186 (Plain Outlet) or C2126 (Flange Outlet).

3.3.03

Clean the profile of the elliptical hole and grind a nominal 3mm radius on the outer edge and a weld preparation on the inner edge to match the one provided on the doubler plate

3.3.04

Position the doubler plate internally and line it up with the ellipse. Tack weld the doubler plate in position. When you are sure that the doubler plate is correctly located and that the anode will fit cleanly into the recess continuously weld the doubler plate to the inboard and outboard surface of the hull plating. Grind the recess weld flush as shown.

3.3.05

Place the cofferdam concentrically over the cable gland hole in the rear of the doubler plate. Position the cable exit tube from the cofferdam to suit site conditions and weld internally and externally in position with penetration welds with single bevel full penetration weld complete with a backing run.

3.3.06

Cover the anode holding studs with plastic tubing to prevent damage from shot blasting.

3.3.07

Shot blast the doubler plate and recess to SA 2 1/2 minimum

3.3.08

Fit a suitable cable gland into the doubler plate from the inboard side inside the cofferdam recess.

3.3.09

Mix equal quantities of the 2 part epoxy filler material supplied. Apply epoxy to back of anode and spread evenly.

3.3.10

Prepare an Anode for installation. The dimensions of the Anode are shown by drg.C1202. Carefully insert the Anode Cable through the centre hole in the doubler plate and through the cable gland taking care not to damage the insulation. Locate the anode over the six fixing points in the backing plate.

3.3.11

Slowly draw anode into recess by tightening the Anode fixing nuts. The epoxy filler will slowly ooze out of the sides as anode settles into position, ensure the Anode cable does not become trapped. When anode is flush with hull and the bolts are resting within anode


fixing point recess ensure the head of the holding nut is below the top level of the anode. Fill stud holes with epoxy and smooth level. 3.3.12

Smooth epoxy at edge of anode so that gap between anode and steelwork is completely filled.

3.3.13

Inside the Ship fully tighten the gland onto the cable.

3.3.14

Before proceeding further, ensure that all other welding work, either inboard or outboard, has been completed for the entire area to be covered by the di-electric shield. Any welding carried out after the application of the di-electric shield will damage the shield material even if the welding is not associated with the cathodic protection system.

3.3.15

The dimensions of the di-electric shield are shown on Drg. C1196.

3.3.16

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

3.3.17

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

3.3.18

Ensure that the anode face is protected with masking tape or similar. Abrasive blast clean the entire area to a white metal finish, SA 2 1/2 Swedish standard using grit or sand. Check the surface profile height using test tape and that it is within the range 50 - 70 micron.

3.3.19

Form the primary di-electric shield by applying the anode epoxy mastic within four hours of blasting and before the formation of any visible rust bloom. Fill the four threaded temporary anode retaining mounting holes with mastic. Technical details and health precautions for the anode mastic are available on request from Cathelco.

3.3.20

Thoroughly mix the contents of each can before mixing the two parts together. Follow the mixing instructions on the epoxy mastic material packs, using a power driven mixer if possible.

3.3.21

Apply by trowel to produce a film 4mm thick at the edge of the anode surface tapering to 1mm thick at the shield edge. Form a circular shield of mastic of 900mm radius. A one coat application is essential.

3.3.22

Ensure that the di-electric shield mastic covers the resin of the anode but do not allow mastic on the metal anode face. Allow the mastic to harden fully before painting over. Remember to remove the protective tape from the surface of the anode.

3.3.23

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


3.3.24

Apply thread tape to the second anode cable gland, make sure the neoprene 'O' ring is fitted and pass the gland over the anode cable to fit it into position as detailed below. Tighten the main body fully into position, then tighten on to the cable.

3.3.25

Dry Compartment Installation. Pass the cable through the side entry hole in the cofferdam and fit the cable gland in the same way as before, to the outside of the cofferdam, leaving slack cable between inner and outer glands.

3.3.26

Fit the junction box at some convenient point adjacent to the cofferdam and connect the anode cable to the transformer/rectifier via shipyard supply cable, see power supply unit instructions.

3.3.27

Wet Compartment Installation. Pass the shipyard cable through the side entry hole into the cofferdam. Note that any cables running in tanks should be in heavy wall conduit pipe. Fit the cable gland in the same way as before, to the inside of the cofferdam side entry, over the shipyard cable.

3.3.28

Connect the anode cable tail to the shipyard cable internally in the cofferdam. Use a recognised splice kit or a C-Shield splice kit can be provided. Refer to Drg. M1043 for full instructions. Where cables are spliced in a cofferdam it is recommended that the cofferdam be filled with paraffin wax or similar. Connect the shipyard cable to the power supply unit.

3.3.29

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 power supply unit before this test or permanent damage may occur.

3.3.30

Make a final visual check of all connections and finally fit the blind flange and gasket to seal the cofferdam. Do not over paint the anode when painting over the dielectric shield area.

3.3.31

Note all welds used during installation should meet the Yard or Classification Society rules.


3.3

ELLIPTICAL RECESSED ANODE:

3.3.01

Select the required area and mark out using a template the steelwork location. Make sure that the internal stiffening will not be touched. Ensure the ellipse will be located within a steel plate and not interfere with existing weld seams.

3.3.02

Cut an elliptical hole. The ellipse may be easily marked out by positioning the anode on the hull and scribing around it, allowing a margin of 6mm around the anode periphery. Alternatively, a template may be made using the doubler plate. Refer to Drg. C2025 (plain outlet) or C2127 (flanged outlet).

3.3.03

Clean the profile of the elliptical hole and grind a nominal 3mm radius on the outer edge and a weld preparation on the inner edge to match the one provided on the doubler plate

3.3.04

Position the doubler plate internally and line it up with the ellipse. Tack weld the doubler plate in position. When you are sure that the doubler plate is correctly located and that the anode will fit cleanly into the recess continuously weld the doubler plate to the inboard and outboard surface of the hull plating. Grind the recess weld flush as shown.

3.3.05

Place the cofferdam concentrically over the cable gland hole in the rear of the doubler plate. Position the cable exit tube from the cofferdam to suit site conditions and weld internally and externally in position with penetration welds with single bevel full penetration weld complete with a backing run.

3.3.06

Cover the anode holding studs with plastic tubing to prevent damage from shot blasting.

3.3.07

Shot blast the doubler plate and recess to SA 2 1/2 minimum

3.3.08

Fit a suitable cable gland into the doubler plate from the inboard side inside the cofferdam recess.

3.3.09

Mix equal quantities of the 2 part epoxy filler material supplied. Apply epoxy to back of anode and spread evenly.

3.3.10

Prepare an Anode for installation. The dimensions of the Anode are shown by Drg.C2008. Carefully insert the Anode Cable through the centre hole in the doubler plate and through the cable gland taking care not to damage the insulation. Locate the anode over the six fixing points in the backing plate.

3.3.11

Slowly draw anode into recess by tightening the Anode fixing nuts. The epoxy filler will slowly ooze out of the sides as anode settles into position, ensure the Anode cable does not become trapped. When anode is flush with hull and the bolts are resting within anode


fixing point recess ensure the head of the holding nut is below the top level of the anode. Fill stud holes with epoxy and smooth level. 3.3.12

Smooth epoxy at edge of anode so that gap between anode and steelwork is completely filled.

3.3.13

Inside the Ship fully tighten the gland onto the cable.

3.3.14

Before proceeding further, ensure that all other welding work, either inboard or outboard, has been completed for the entire area to be covered by the di-electric shield. Any welding carried out after the application of the di-electric shield will damage the shield material even if the welding is not associated with the cathodic protection system.

3.3.15

The dimensions of the di-electric shield are shown on Drg. C2022.

3.3.16

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

3.3.17

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

3.3.18

Ensure that the anode face is protected with masking tape or similar. Abrasive blast clean the entire area to a white metal finish, SA 2 1/2 Swedish standard using grit or sand. Check the surface profile height using test tape and that it is within the range 50 - 70 micron.

3.3.19

Form the primary di-electric shield by applying the anode epoxy mastic within four hours of blasting and before the formation of any visible rust bloom. Fill the four threaded temporary anode retaining mounting holes with mastic. Technical details and health precautions for the anode mastic are available on request from Cathelco.

3.3.20

Thoroughly mix the contents of each can before mixing the two parts together. Follow the mixing instructions on the epoxy mastic material packs, using a power driven mixer if possible.

3.3.21

Apply by trowel to produce a film 4mm thick at the edge of the anode surface tapering to 1mm thick at the shield edge. Form a circular shield of mastic of 2700mm diameter. A one coat application is essential.

3.3.22

Ensure that the di-electric shield mastic covers the resin of the anode but do not allow mastic on the metal anode face. Allow the mastic to harden fully before painting over. Remember to remove the protective tape from the surface of the anode.

3.3.23

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


3.3.24

Apply thread tape to the second anode cable gland, make sure the neoprene 'O' ring is fitted and pass the gland over the anode cable to fit it into position as detailed below. Tighten the main body fully into position, then tighten on to the cable.

3.3.25

Dry Compartment Installation. Pass the cable through the side entry hole in the cofferdam and fit the cable gland in the same way as before, to the outside of the cofferdam, leaving slack cable between inner and outer glands.

3.3.26

Fit the junction box at some convenient point adjacent to the cofferdam and connect the anode cable to the transformer/rectifier via shipyard supply cable, see power supply unit instructions.

3.3.27

Wet Compartment Installation. Pass the shipyard cable through the side entry hole into the cofferdam. Note that any cables running in tanks should be in heavy wall conduit pipe. Fit the cable gland in the same way as before, to the inside of the cofferdam side entry, over the shipyard cable.

3.3.28

Connect the anode cable tail to the shipyard cable internally in the cofferdam. Use a recognised splice kit or a C-Shield splice kit can be provided. Refer to drg. M1043 for full instructions. Where cables are spliced in a cofferdam it is recommended that the cofferdam be filled with paraffin wax or similar. Connect the shipyard cable to the power supply unit.

3.3.29

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 power supply unit before this test or permanent damage may occur.

3.3.30

Make a final visual check of all connections and finally fit the blind flange and gasket to seal the cofferdam. Do not over paint the anode when painting over the dielectric shield area.

3.3.31

Note all welds used during installation should meet the Yard or Classification Society rules.


3.4

REFERENCE ELECTRODE CELLS

3.4.01

Cut a 170mm diameter hole in the hull at each electrode location. This is to enable installation of the cell mounting cofferdam as shown by drawing C1190

3.4.02

Grind off any surplus metal to ensure that the cofferdam body will locate flat to the internal shell plating at the inboard side of the hole.

3.4.03

Locate the cofferdam centrally over the hole, inside the hull.

3.4.04

Secure the cofferdam in the position by a continuous fillet weld internally to give a weld section at least equal to the plating thickness. Drawing C1162 gives a rough guide for welding and electrode cell installation.

3.4.05

Clean off all weld splatter from the surfaces including the cofferdam recess, and grind flat all welds in the area to be occupied by the reference electrode.

3.4.06

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

3.4.07

Apply thread tape or sealing compound to the M20 threaded mounting sleeve of the reference electrode. The reference electrode cell is shown by drawing C1102. Remove the nut, dished washer and neoprene washer from the M20 sleeve but leave the neoprene sealing ring in place.

3.4.08

From the outboard of the shell thread the cable through the gland plate at the back of the cofferdam recess.

3.4.09

Apply sealing compound to the recess and screw the reference electrode firmly into place in the cofferdam using the spanner provided to fit the recesses in the front face of reference electrode carrier. Do not Over Tighten !!

3.4.10

Inside the ship, remove the blank flange from the Cofferdam and check the cable insulation for any possible damage.

3.4.11

On completion of the inspection caulk the gap between the reference electrode carrier and the outer shell with sealing compound, to leave a smooth uniform surface.

3.4.12

From the inboard of the shell fit the neoprene washer within the dished steel washer and locate over the reference electrode mounting sleeve within the cofferdam. Ensure that the neoprene washer faces outboard and is in contact with the gland plate in the cofferdam.


3.4.13

Fit the M20 full locking nut on the reference electrode mounting sleeve and tighten until the neoprene washer is fully compressed and the dished washer is in contact with the gland plate.

3.4.14

Pass the cable through the side entry hole in the cofferdam.

3.4.15

Dry Compartment Installation: Apply thread tape to the reference electrode cable gland, and pass the gland over the anode cable to fit it into position outside the cofferdam as shown in the drawing. Tighten the main body fully into position then tighten onto the cable leaving slack cable inside the cofferdam.

3.4.16

Fit a junction box at some convenient point adjacent to the cofferdam and connect the reference electrode cable to the power supply unit via shipyard supplied cable see the Power Supply Unit instructions in section 3.5

3.4.17

Wet Compartment Installation: Pass the shipyard cable through the side entry hole into the cofferdam. Any cables, which run through tanks, must be housed in heavy walled conduit pipe. Fit the cable gland in the same way as before but to the inside of the cofferdam over the shipyard cable.

3.4.18

Connect the anode cable tail to the shipyard cable using a cable splice kit. Use an industry recognised kit or a C-shield splice kit as shown by drawing M1043. After splicing in submerged cofferdams it is recommended that the cofferdam recess void be filled with paraffin wax or similar. Connect the shipyard cable to the Power Supply Unit see section 3.5

3.4.19

Check installation of the reference connection circuit to the hull using 500 Volt earth insulation meter. If the electrode is submerged then this test will show a short circuit.

Disconnect from the power supply unit before this test or permanent damage may occur. 3.4.20

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

3.4.21

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


3.4

REFERENCE ELECTRODE CELLS

3.4.01

Cut a 170mm diameter hole in the hull at each electrode location. This is to enable installation of the cell mounting cofferdam as shown by drawing C1470

3.4.02

Grind off any surplus metal to ensure that the cofferdam body will locate flat to the internal shell plating at the inboard side of the hole.

3.4.03

Locate the cofferdam centrally over the hole, inside the hull.

3.4.04

Secure the cofferdam in the position by a continuous fillet weld internally to give a weld section at least equal to the plating thickness. Drawing C1162 gives a rough guide for welding and electrode cell installation.

3.4.05

Clean off all weld splatter from the surfaces including the cofferdam recess, and grind flat all welds in the area to be occupied by the reference electrode.

3.4.06

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

3.4.07

Apply thread tape or sealing compound to the M20 threaded mounting sleeve of the reference electrode. The reference electrode cell is shown by drawing C1102. Remove the nut, dished washer and neoprene washer from the M20 sleeve but leave the neoprene sealing ring in place.

3.4.08

From the outboard of the shell thread the cable through the gland plate at the back of the cofferdam recess.

3.4.09

Apply sealing compound to the recess and screw the reference electrode firmly into place in the cofferdam using the spanner provided to fit the recesses in the front face of reference electrode carrier. Do not Over Tighten !!

3.4.10

Inside the ship, remove the blank flange from the Cofferdam and check the cable insulation for any possible damage.

3.4.11

On completion of the inspection caulk the gap between the reference electrode carrier and the outer shell with sealing compound, to leave a smooth uniform surface.

3.4.12

From the inboard of the shell fit the neoprene washer within the dished steel washer and locate over the reference electrode mounting sleeve within the cofferdam. Ensure that the neoprene washer faces outboard and is in contact with the gland plate in the cofferdam.


3.4.13

Fit the M20 full locking nut on the reference electrode mounting sleeve and tighten until the neoprene washer is fully compressed and the dished washer is in contact with the gland plate.

3.4.14

Pass the cable through the side entry hole in the cofferdam.

3.4.15

Dry Compartment Installation: Apply thread tape to the reference electrode cable gland, and pass the gland over the anode cable to fit it into position outside the cofferdam as shown in the drawing. Tighten the main body fully into position then tighten onto the cable leaving slack cable inside the cofferdam.

3.4.16

Fit a junction box at some convenient point adjacent to the cofferdam and connect the reference electrode cable to the power supply unit via shipyard supplied cable see the Power Supply Unit instructions in section 3.5

3.4.17

Wet Compartment Installation: Pass the shipyard cable through the side entry hole into the cofferdam. Any cables which run through tanks must be housed in heavy walled conduit pipe. Fit the cable gland in the same way as before but to the inside of the cofferdam over the shipyard cable.

3.4.18

Connect the anode cable tail to the shipyard cable using a cable splice kit. Use an industry recognised kit or a C-shield splice kit as shown by drawing M1043. After splicing in submerged cofferdams it is recommended that the cofferdam recess void be filled with paraffin wax or similar. Connect the shipyard cable to the Power Supply Unit see section 3.5

3.4.19

Check installation of the reference connection circuit to the hull using 500 Volt earth insulation meter. If the electrode is submerged then this test will show a short circuit.

Disconnect from the power supply unit before this test or permanent damage may occur. 3.4.20

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

3.4.21

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


3.5

POWER SUPPLY UNIT:

3.5.1

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

3.5.2

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

3.5.3

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

3.5.4

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

TABLE OF CABLE LENGTHS FOR DIFFERENT ANODE SIZE TO MAINTAIN MINIMUM 3-VOLT DROP

50A

75A

100A

150A

175A

200A

300A

CONDUCTOR SIZE SINGLE CORE CABLE 2

45M

16MM

2

70M

47M

25MM

100M

67M

50M

125M

83M

62M

41M

180M

120M

90M

60M

51M

45M

250M

167M

125M

83M

71M

62M

41M

95MM2

315M

210M

158M 105M

90M

79M

53M

120MM2

2

35MM

2

50MM


70MM2

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 will supply a suitable cable size to suit the capacity of the power unit.

3.5.6

Provide and terminate single core screened cables with a sectional area of minimum 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 16mm Core Cable.

3.5.9

PLEASE ENSURE THAT WHEN WELDING WORK IS BEING CARRIED OUT ON THE VESSEL THAT THE

PANEL

SYSTEM

IS

SWITCHED

NEGATIVE

DISCONNECTED.


OFF

EARTH

AND CABLE

THE IS

3.5A

REMOTE MONITORING UNIT: FLUSH MOUNTED

3.5.09

For details of remote monitor panel please see below. This type is designed for flush mounting: 1) Aft only reading unit: Refer to drawing M1184 for enclosure and terminal details and drawing C1205 for general wiring details. 1) Fwd and Aft reading unit: Refer to drawing M1238 for enclosure and terminal details and drawing C1204 for general wiring details.

3.5.10

To interconnect the subject PSU with the remote monitor refer to the specific wiring diagram noted in 3.5.09. These are typically: A) Power Cable: Use 2 x 1.5 mm2 core cable or similar. B) Data Cable: Use 2 x 2mm 2 core screened twisted pair cable or similar.

3.5.11

For terminal & specific wiring information refer to the drawings contained in this manual as full details will vary from vessel to vessel.

3.5.12

Once installed the unit will display the same text information as shown on the actual power supply unit it is connected to.

Section 3.5A Rev 0 Page 1 of 1

Iss 2

3.6

19.08.05

PROPELLER SHAFT EARTHING ASSEMBLY

3.6.01. The propeller shaft bonding kit comprises a split slipring and brush assembly that must be fitted close to the final shaft bearing, ideally between the bearing and and stern seal (where space permits). A mounting bracket or support pillar for the brush holder should be supplied by the yard and mounted to a suitable frame or bearing pedestal, Ensure that the mating faces are cleaned to bright metal before fixing in position. For the General Arrangement of the Shaft Earthing Assembly see Drg.M1191. 3.6.02. The brushgear unit is shown on Drg C1181 or C2144 dependant on the type supplied (See Drg list in this manual). Weld into position on the support pillar a brushgear support bar of the correct size at the correct distance from the centre of the bar to the the outside diameter of the slipring (See Drg). The centre of the bar should be parallel to the axis of the shaft in both planes. 3.6.03. Mark a line around the shaft at approximately 60mm spacing from the bearing block, ensuring that this is perpendicular to the axis of the shaft. Thoroughly clean the shaft down to bright metal to a distance of 80mm from this line away from the bearing block. 3.6.04. The slipring is made up of two matching bi-metal strips that are rolled to the required shaft diameter. All sliprings are supplied slightly oversized to allow some degree of tolerance for final fitting. All excess material shall be removed by filing down at the joint faces, see Drg. M1191 for details. 3.6.05. Ensure the shaft surface & inside face of the slip ring are clean and free from raised imperfections. Loosely fit the clamps to the shaft and fit the 2 halves of the slip ring inside the clamps. Ensure the end of one of the slip rings is butted tightly to the other half, allowing the other end to overlap the adjacent half ring. 3.6.06. Tighten the clamps carefully, ensuring the two halves of the ring remain in alignment. Do not overtighten the clamps at this stage. Using the edge of the overlapping ring as a guide, mark the cutting line onto the surface of the other half ring. 3.6.07. Carefully remove the excess material, taking care not to distort or mark the ring, and remove all sharp edges. Re-assemble and recheck, adjusting the fit by filing the ends of the half rings as necessary. 3.6.08. Once completed, thoroughly re-clean the inside of the slipring and shaft and immediately fit to the shaft to ensure that no further contamination of the cleaned surfaces takes place. Refer to Drg M1191. Carefully check that there is no gap between the shaft and the slip ring, as this would adversely affect the functioning of the system.

Section 3.6A Page 1 of 4

Iss 2

19.08.05

3.6.09. It is essential that there is no step or gap at the joints between the 2 halves of the slip ring. To ensure that the brushes can ride smoothly over the slipring joint, it may be necessary to lightly tap the strips into the best form with a rubber or hide mallet, or a piece of soft wood, followed by very light polishing of the surface. If necessary any small gaps can be infilled with soft electrical solder and polished flush after checking continuity as below. 3.6.10. Check the continuity between the shaft and the silver strip inlay with a calibrated multimeter. The reading should be a maximum of 0.1 ohms. 3.6.11. Fit the brush holder as shown on the drawing to the support bar and align the assembly so that the brushes will run centrally on the silver track of the slipring. Check that the brushgear assembly will be clear of the slipring securing brackets when the shaft rotates. Secure the assembly in this position by tightening the hexagon headed bolt at the top of the brushgear body. 3.6.12. Ensure that each brush is mounted tangentially to the shaft to avoid uneven wear. Adjustment is provided by means of alignment bolts – see appropriate drg of Brush holder for details. 3.6.13. Pull back the pressure spring on the brush holders and fit the brushes into position. Recheck & adjust the brush gear as necessary until the brushes sit correctly on the slipring. Ensure the brushes are free to move in the holder. 3.6.14. Connect the wires from the brushes to the two hexagon headed bolts on the brushgear. 3.6.15. Check the continuity between the shaft and the brush holder body with a calibrated multimeter. The reading should be a maximum of 0.7 ohms. 2

3.6.16. A length of 35mm flexible cable may be included in the C-Shield Cathodic Protection package for connecting the brushgear to the hull. Connect one end to the brushgear by the large hexagon headed bolt at the top of the assembly, then securely bolt the other down to the hull at some convenient point close by, ensuring contact faces are cleaned to bright metal before fixing. Full wiring details for the assembly are shown on Drg C1159. 3.6.17. Check the continuity between the shaft and the final hull earthing point with a calibrated multimeter. The reading should be less than 1.0 ohms. 3.6A

SHAFT MONITORING

3.6.18. This extension to the standard shaft earthing system comprises a bulkhead mounted panel that incorporates terminals, a scale switch and a display meter and a separate monitor brush holder with brush. The system requires no external power supply.


Iss 2

19.08.05

3.6.19. The brush holder is insulated from the main hull structure and is connected to one side of the meter, the other side of the meter is connected to the main ships structure. The meter has a high internal resistance that restricts current flow in the circuit to minimal levels and thus minimises the volt drop between the slipring and the monitor brush. The meter therefore accurately displays the potential difference between the shaft and hull. 3.6.20. For ease of interpretation the display meter has high and low switchable scales up to 250mV. The shaft mV meter is shown on either Drg M1100, M1101 or M1106 dependant on type supplied (See Drg list in this manual) 3.6.21. The monitoring brushgear is to be installed such that it runs on the existing slipring track. See drawing M1191 for general arrangement. 3.6.22. Using the dimensions shown on drawing C1157 fabricate an additional support for the monitor brush. The brush gear fitted to this support MUST be insulated. This may be best achieved by using a mounting bar of 12mm diameter sleeved with an insulating plastic to produce a finished diameter of 16mm. This bar should be typically 125mm long. Mount the bar as detailed in section 3.6 above. 3.6.23.

Fit the monitor brush holder as shown on drawing C1157 over the plastic sleeve such that it runs centrally on the silver track of the slipring. Check that the brush gear assembly will be clear of the slipring securing brackets when the shaft rotates. Secure the assembly in this position by tightening the hexagonal headed bolt at the top of the brushgear body.

3.6.24. Ensure that the brush is mounted tangentially to the shaft to avoid uneven wear. Adjustment is provided by means of an alignment bolt – see drg of Brush holder for details. 3.6.25. Pull back the pressure spring from the brush holder and fit the brush into position. Recheck & adjust the brush gear as necessary until the brush sits correctly on the slipring. Ensure the brush is free to move in the holder. 3.6.26. Connect the wire from the brush to the hexagon headed bolt on the brush gear. 3.6.27. Check the continuity between the shaft and the brush holder body with a calibrated multimeter. The reading should be a maximum of 0.7 ohms. 3.6.28. Using a megger tester, check that the brush holder is isolated from the mounting post. NB: Ensure that the brush is not in contact with the shaft by removing from the holder, and that the cable from the brush holder to the meter (if fitted) is disconnected at the holder. Refit the brush into the holder after checking.


Iss 2

19.08.05

3.6.29. At a convenient location adjacent to the slipring install the mV meter panel. See the appropriate drg for hole diameters and centres (Refer to 3.6.13). The location chosen should ensure that the meter is clearly visible to the ships operating staff. WIRING OF METER

3.6.30. Connect a length of flexible cable of cross sectional area minimum 2 1mm between the monitor brush gear and the terminal inside the monitor panel using the bottom entry cable gland provided. 2

3.6.31. Install a flexible cable of cross sectional area minimum 1mm from the second terminal within the monitor panel connecting the other end to the main ships structure at a suitable point adjacent to the panel. Ensure the mating faces are cleaned to bright metal before fixing. See Drg.C1159 for further wiring details. 3.6.32.

Using a calibrated multimeter, check the continuity between the brush gear earth terminal inside the meter and the earth connection at the hull. The reading should be a maximum of 0.1 ohms. OPERATION OF SYSTEM:

3.6.33. Upon completion of the installation the complete assembly should be checked in accordance with the Checklist in Section 7.1 Shaft Commissioning. 3.6.34. For ease of interpretation the display meter is scaled up to 250mV. Every week or if the meter reading rises above 50mV it is recommended that the following checks are carried out: a)

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

b)

Clean and degrease slipring track.

c)

Slipring free from indentations.

d)

Clean and check brushes for wear and check freedom of movement in holders.

3.6.35. Please note that the silver graphite brushes are a consumable item, and depending on the rpm of the shaft, shaft diameter and the running hours, the brushes will wear and require replacing on average at 4 to 6 monthly intervals. Ensure that the brushes are regularly inspected and replaced before they are totally consumed, otherwise the shaft earthing assembly will not operate correctly.


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 MCBswitch 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 Z INC 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

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 NUMB ER mode below.

4.0.3

MODE DESCRIPTIONS : STANDB Y MODE: In this mode all output current from the equipment is shut down to zero. The display indi cates 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:Section 4 Page 2 of 11

STAND-BY V????V EL4 ????mV

stepping to:STAND-BY V????V

(see 4.0.6)

ALARMS

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 £££% 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 0000

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


4.1

CHANGING CONTROLLER SET POINTS:

4.1.1

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 Zis 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 SIZ E This parameter will allow the user to define the siz e 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 NUMB ER 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 x

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 Z inc 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 iZnc 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 iZnc Electrode a nd 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

U QIT 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 ezro 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 Dunston Road Chesterfield S41 8NY United Kingdom Telephone (01246) 457900 Fax (01246) 457901

_____________________________________________________________________________ Daily log for C-Shield Impressed Current Cathodic Protection System. Vessel SHIP NAME Voyage number Date from

01/05/97

Aft system capacity

400

amps 24

Forward system capacity

23A

To

volts

100

amps 24

volts

31/05/97 nd

Complete in triplicate and distribute as follows: 1st copy to owner’s file, 2 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 Month 2 1 2 3 4 5 6 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

Wk1

Area of operation Sea Aft output temp. o C Amp Volt Pacific 26 15 2.8 Coral Sea 29 15 2.8 " " 29 15 2.7 Torra St 28 14 2.7 Arufura Sea 28 14 2.7 Serum Sea 27 15 2.8

Wk2

Wk3

Sensing electrode (mV) S1 210 212 212 210 211 212

S2 220 220 220 220 220 220

Wk4

For’d output

Amp 5 5 4 4 5 5

Volt 2.8 2.7 2.7 2.7 2.8 2.8

Figure 5.1: Typical LogSheet with Entries


Sensing Notes electrode (mV) S3 221 220 221 220 220 221

S4 215 215 214 214 214 215

light draft light draft light draft light draft light draft light draft

6.0

6.1

SERVICE AND FAULT FINDING:

6.0.1

RECOGNITION OF A PROBLEM:

6.0.2

From consideration of section 1 it will be appreciated that the d.c. output current of the system is the factor that provides the Cathodic Protection of the hull. In a correctly functioning system the level of current output gives an indication of the state of the paint system.

6.0.3

The voltage or potential reading on the reference electrode circuit is the voltage of the hull with respect to the reference electrode. Application of protective current changes this potential in a negative direction as indicated in figure 1.3 to a level of +0.20 volt for optimum protection. This example gives levels with respect to zinc electrodes.

6.0.4

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

6.0.7

Do not megger, or high voltage test this equipment. The DC and control circuits are low voltage only and will be seriously damaged if high voltage test equipment is used. To check insulation of any cables outside the Power Supply Unit disconnect them at both ends.

6.0.8

If the LCD display is not illuminated then first check the mains supply to the cabinet and that the system is switched on. If no fault can be found then report conditions to Cathelco (Chesterfield).

6.0.9

If the Power Supply Unit On/Alarm LED is not lit, then note any of the alarm conditions that are found to be displayed and contact Cathelco (Chesterfield) giving full details of the alarm.

VESSEL IN FRESH WATER

ICCP systems have experienced problems in the past when the vessel has to enter a harbour or estuary where the water is either fresh or brackish. The C-Shield computer controller has been programmed to identify this situation by analysing the voltage reading, the amperage reading and the reference electrode inputs. The ICCP system remains in automatic mode and endeavours to provide the maximum available protection level around the hull in this water condition. In fresh water conditions it is normal for the output voltage from the system to increase and for current outputs to decrease. This is caused by the increase in resistivity of the sea water solution. When the vessel returns to normal sea water the output voltage should begin to decrease and current outputs should begin to increase.


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. For a newly painted installation the readings will be in the range of 200 mV - 300 mV. For a hull in bad painted condition the readings will be higher i.e. 300 mV +.

Re- connect reference electrode cable inputs to terminal block. Measure -v terminal to ground.

______ ohms (Should be zero)


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 1 ***mV

VOLTS ______ 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

I

=

10%

=

15%

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

EL 1_______mV EL 2_______mV EL 3_______mV EL 4_______mV Voltage_____V Current_____A

I

I

=

20%

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

=

25%

EL 1______mV EL 2______mV EL 3______mV EL 4______mV Voltage____V 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 EL 2 ***mV

I V

*A *V

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

EL 1 _______ EL 2 _______ Amps_______ Volts _______

mV mV A V

After 30 minutes record readings again. EL 1 _____ EL 2 _____ Amps ____ Volts ____

mV mV A V

After One (1) Hour record readings. EL 1 _____ EL 2 _____ Amps ____ Volts ____

After Two (2) Hours record readings.

mV mV A V

EL 1 _____ EL 2 _____ Amps ____ Volts ____


mV mV A V

C - Shield Commissioning Check List Cont'd

After six (6) Hours record readings. After twenty four (24) Hours record readings. EL 1 _____ EL 2 _____ Amps ____ Volts ____

mV mV A V

EL 1 _____ EL 2 _____ Amps ____ Volts ____

mV mV A V

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

Please review the instruction manual for "Alarm Conditions"

If there are any problems relating to these instructions or else the computer control unit does not function as it should then please immediately contact Cathelco head office for further instructions.

C - Shield Systems Cathelco Limited Marine House Dunston Road Chesterfield S41 8NY U.K. Telephone : Fax: E-mail:

(01246) 457900 (01246) 457901 [email protected]


C - SHIELD COMMISSIONING CHECK LIST SHAFT EARTHING SYSTEM Vessel

:

________________________

Shipyard

:

________________________

Newbuilding No.

:

________________________

Owner

:

________________________

Confirm Slip ring and Brush gear are installed correctly as follows – refer to Drgs M1191, C1159 & C1181.

1. Assembly is clean and free from oil and grease.

______

2. Slip ring a tight fit to the shaft over its entire length with no gap between ring and shaft.

______

3. Ensure no bumps or indentations can be felt over the whole of the working surface.

______

4. Joints are a good fit with no gap.

______

5. Brush holder is secure on shaft.

______

6. Brush holder and mounting are solid and will not be affected by vibration.

______

7. Brush faces are tangential to the Slip ring.

______

8. Brushes are free to move in their holders.

______

9. Check Electrical continuity (Shaft-Slip ring track max 0.1 ohms)

______

(Shaft-Brush holder max 0.7 ohms)

______

(Shaft-Hull earth point <=1.0 ohms)

______


C - SHIELD COMMISSIONING CHECK LIST SHAFT EARTHING SYSTEM OPTIONAL mV METER

1. Brush holder is secure on shaft.

______

2. Brush holder and mounting are solid and will not be affected by vibration.

______

3. Brush face is tangential to the Slip ring.

______

4. Brush is free to move in the holder.

______

5. Check Electrical continuity (Shaft–Brush holder max 0.7 ohms)

______

(mV Meter Brush Gear Earth terminal –to Hull earth point max 0.1 ohms)

______

6. Check Electrical isolation with Brush removed & mV cable disconnected. (Brush holder – Mount Post)

______

7. In operation, with vessel afloat & shaft rotating, reading showing on meter is under 50mV.

______

8. In operation, check across both terminals inside mV Meter with Multimeter. (Reading same as shown on meter)

______


8.0

WORLD WIDE AGENCIES

8.0.1

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

8.0.2

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

8.0.3

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

CATHELCO LTD MARINE HOUSE DUNSTON ROAD CHESTERFIELD DERBYS S41 8NY UK

Tel: 00 44 (0)1246 457900 Fax: 00 44 (0)1246 457901 E-Mail: [email protected]


A

D E V S O R S P P 6 A 1 1 0 E T 2 / A 7 D 0 / 4 0

N I 6 P C C I 5 M 2 A M D R E F : F E O L T I C T

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D E V O S R S P P A

8

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1 1 0 E T 2 / A 3 D 0 / 3 0

D E T A D P U S R E N O D I R S I O V B E & 7 R N S K O R I T O P I R W I C D S L E O D S N O D 3 N I N W A R D E R

P O T S D 5 N 5 2 E 2 S M M R : R : M F F O O E X T T E E T I O R R C C B D E E D G N N N N N I N N N O A A I W L O T L O A G C C G C R E E E E N D L L L L U J B B B B O T 6 A A A A Y K C C C C E . . . . . 1 2 3 4 5 K

6

. V 4 E R

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0 0 1

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0 0 2 2


5

S R C 0 8 1

3

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S R C 0 4 1

D E V O M E R D I L S W O H S W E I V

0 6 1

A

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D E T A D P U R E D R S N O B O I S & I 5 V S E N K R O I R T O P I R W D I C L S E O D S N O D 3 N I N W A R D E R 4

C

B

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S E C A . F S R G U N S I . O L K C . 2 L L R N 1 E A A O i H I , T S T l S M A A E C A C E L I L - M G P B I P Y O D S A E I O R F L L T P V O L A R R A V O O A N R I O M R H P % P N U S S I P 5 I T A E N A D I T A T S N M U I N N U O M A O M A L H A T R S C T A I N R W G R / D O A Y D N C O N T E U I L B A M : L G I S K L H O A N R S A U H 1 L T F E 0 Q C . A O E E N 1 E O E F R H E B : V N K A / E M B G T T I I N O C O S O H N H E N O T H : G M T : L N B : S A I E E C E R G C G G A I L : D I A N N R I A W L N F I I R T D U T U E R T H S I T E O A S A L T R N E A A A I H O L L O M M P F S C A C W D

CATHELCO LIMITED STANDARD TERMS AND CONDITONS 1. INTERPRETATION 1.1 The following definitions and rules of interpretation apply in these terms and conditions (“the Conditions”):Authorised Person: any director of Cathelco. Buyer : the person, firm or company who purchases the Goods from Cathelco. Cathelco: Cathelco Limited, a company registered in England and Wales under registered company number 562740 and whose registered address is 18 Hipper Street South, Chesterfield, Derbyshire, S40 1SS United Kingdom. Commercial Arbitration: an arbitration process conducted by (and in accordance with the rules of) the London Court of International Arbitration:i) consisting of one arbitrator; ii) taking place in London; iii) conducted in the English language; and iv) seated in England Contract: any contract between Cathelco and the Buyer for the sale and purchase of the Goods incorporating the Conditions. Date of Commissioning: the date that the vessel to which the Goods have been fitted is completed and the commissioning report has been signed. In the case of retrospective fittings on vessels that are already operating, the Date of Commissioning will be the date upon which either the fitting is completed or (in the event that the vessel is in dry dock during fitting) the vessel is returned to the water. Delivery Documents: means the delivery receipt, bill of lading, airway bill or such other document as specified in the Contract as to be passed to the Buyer on delivery as receipt of delivery. Delivery Point: such location as is specified in the order confirmation issued by Cathelco or as advised by the Buyer. Goods: any goods agreed in the Contract to be supplied to the Buyer by Cathelco (including any part or parts of them). Incoterms: Incoterms 2000 as published by the International Chamber of Commerce. Intellectual Property Rights: all copyright, database rights, topography rights, design rights, trade marks, patents, domain names and any other intellectual property rights of a similar nature (whether or not registered) subsisting anywhere in the world in or associated with the Goods. 1.2 A reference to a particular law is a reference to it as it is in f orce for the time being taking account of any amendment, extension, application or reenactment and includes any subordinate legislation for the time being in force made under it. 1.3 Words in the singular include the plural and in the plural include the singular. 2. APPLICATION OF TERMS 2.1 Subject to any variation under Condition 2.2 , the Contract shall be on these Conditions to the exclusion of all other terms and conditions (including any terms or conditions which the Buyer purports to apply under any purchase order, confirmation of order, specification or other document) other than those specified by Cathelco in their quotation. 2.2 These Conditions apply to all Cathelco's sales and any variation to these Conditions and any representations about the Goods shall have no effect unless expressly agreed in writing and signed by an Authorised Person. The Buyer acknowledges that it has not relied on any statement, promise or representation made or given by or on behalf of Cathelco which is not set out in the Contract. Nothing in this Condition shall exclude or limit Cathelco's liability for fraudulent misrepresentation. 2.3 Each order or acceptance of a quotation for Goods by the Buyer from Cathelco shall be deemed to be an offer by the Buyer to buy Goods subject to these Conditions. No order placed by the Buyer shall be deemed to be accepted by Cathelco until a written acknowledgement of order is issued by Cathelco or (if earlier) Cathelco delivers the Goods to the Buyer. 2.4 Any quotation is given on the basis that no Contract shall come into existence until Cathelco despatches an acknowledgement of order to the Buyer. 3. DESCRIPTION/PRICE 3.1 Subject to Condition 3.4 below, the quantity, description and price of the Goods shall be as set out in Cathelco's quotation or acknowledgement of order subject to availability. 3.2 The Buyer shall ensure that the terms of its order and any specifications are complete and accurate. The specification shall include the waters that the vessel will operate in as well as a full specification of the vessel to which the Goods will be fitted along with any such other details or information requested by Cathelco. 3.3 Unless the quotation specifies otherwise, all quoted prices for Goods are inclusive of packing, but exclusive of carriage, insurance, VAT and all other duties, fees and taxes. 3.4 All samples, drawings, descriptive matter, specifications and advertising issued by Cathelco (other than those provided in the written quotation provided by Cathelco) and any descriptions or illustrations contained in Cathelco's catalogues, brochures or website are issued or published for the sole purpose of giving an approximate idea of the Goods described in them. They shall not form part of the Contract. 4. DELIVERY 4.1 Delivery of the Products shall take place at the Delivery Point. Acceptance of any change to the Delivery Point requested by the Buyer shall be at Cathelco’s sole discretion and the Buyer shall be liable for any additional expenses incurred by Cathelco as a result of such change. Cathelco shall arrange for suitable transport to the Delivery Point. 4.2 On delivery Cathelco (or its appointed carrier) shall where necessary provide the Buyer with any UK licence required for the export of the Goods along with Delivery Documents. 4.3 Any dates specified by Cathelco for delivery of the Goods are intended to be an estimate and time for delivery shall not be made of the essence by notice unless otherwise agreed in writing by Cathelco. If no dates are so specified, delivery shall be within a reasonable time taking into account all relevant factors (including without limitation the distance and chosen method of delivery). The Buyer shall take delivery of the Goods on receipt of adequate notice from Cathelco (being not less than 4 days) that the Goods are ready for delivery. 4.4 Cathelco may deliver the Goods by separate installments unless otherwise stipulated on the Purchase Order. Each separate instalment shall be invoiced and paid for in accordance with the provisions of the Contract. Each instalment shall be a separate Contract and no cancellation or termination of any one Contract relating to an instalment shall entitle the Buyer to repudiate or cancel any other Contract or instalment. 4.5 If for any reason the Buyer fails to accept delivery of any of the Goods when they are ready for delivery, or Cathelco is unable to deliver the Goods on time because the Buyer has not provided appropriate instructions, documents, licences or authorisations: (a) risk in the Goods shall pass to the Buyer (including for loss or damage caused by Cathelco's negligence); (b) the Goods shall be deemed to have been delivered; and (c) Cathelco may store the Goods until the Buyer takes possession of the Goods, whereupon the Buyer shall be liable for all related costs and expenses (including, without limitation, storage and insurance). 4.6 Unless agreed otherwise in the quotation (including by way of reference to a relevant Incoterm) the Buyer shall provide at the Delivery Point and at its expense adequate and appropriate equipment and manual labour for unloading the Goods. 4.7 The Buyer shall examine the Goods as soon as reasonably practicable after delivery and shall immediately notify Cathelco of any incomplete or failed delivery or any loss or damage during carriage. Unless the Buyer so notifies Cathelco within 30 days after the date at which the Buyer became or ought reasonably to have become aware of the incomplete or failed delivery or loss or damage to the Goods during carriage, the Buyer will be treated as having waived all claims connected with the matter. 4.8 Where the Buyer has entered into more than one Contract with Cathelco failure to deliver the Goods under this Contract will not affect the Buyer’s obligation to comply with the terms of any other contracts 5. IMPORT AND EXPORT LICENCES If appropriate, Cathelco undertakes to obtain any UK licence required for the export of the Goods from the UK by Cathelco. The Buyer shall comply with any such licence and shall obtain and comply with all other necessary licences, permits and consents. If required by Cathelco, the Buyer shall make any such licences or consents available to Cathelco prior to delivery. 6. RISK/TITLE .

6.1 The Goods are at the risk of the Buyer from the time of delivery. The condition and security of the Goods from the date of delivery to the Date of Commissioning is the sole responsibility of the Buyer. 6.2 Ownership of the Goods shall not pass to the Buyer until Cathelco has received in full (in cash or cleared funds) all sums due to it in respect of the Goods and all other sums which are or which become due to Cathelco from the Buyer on any account. Cathelco shall be entitled to recover payment for the Goods notwithstanding that ownership of any of the Goods has not passed from Cathelco. 6.3 Until ownership of the Goods has passed to the Buyer, the Buyer shall: (a) hold the Goods on a fiduciary basis as Cathelco's bailee; (b) store the Goods (at no cost to Cathelco) separately from all other goods of the Buyer or any third party in such a way that they remain readily identifiable as Cathelco's property; (c) not destroy, deface or obscure any identifying mark or packaging on or relating to the Goods; and (d) maintain the Goods in satisfactory condition and keep them in a safe and secure manner. 6.4 The Contract and the Buyer's right to possession of the Goods shall terminate immediately if: (a) the Buyer commits a breach of any term of any Contract and (if the breach is capable of remedy) fails to remedy it within 30 days after receipt of notice in writing requiring it to do so; or (b) the Buyer makes any voluntary arrangement with its creditors or (being an individual or firm) becomes bankrupt or (being a company) becomes subject to an administration order or goes into liquidation (otherwise than for the purpose of amalgamation or reconstruction) or an encumbrancer takes possession or a receiver is appointed of any of the property or assets of the Buyer, or the Buyer ceases, or threatens to cease, to carry on business; or (c) any event analogous to those described in condition 6.4(b) which occurs in relation to the Buyer in any jurisdiction in which the Buyer is incorporated, resident or carries on business. 6.5 The Buyer grants Cathelco, its agents and employees an irrevocable licence to enter any of its premises or vessels where the Goods are or may be stored in order to recover Goods when the Buyer’s right to possession of the Goods has terminated. 6.6 On termination of the Contract, howsoever caused, Cathelco’s rights contained in this Condition 6 shall remain in effect. 7. PAYMENT 7.1 Subject to Conditions 7.2 and 7.5 and unless otherwise agreed in writing in accordance with Condition 2.2, invoices shall be settled within 30 days of the date of the invoice and time for payment shall be of the essence. 7.2 Should Cathelco stipulate a requirement for security for payment before dispatch of the Goods, Cathelco shall have the right to withhold delivery of the Goods until such security has been r eceived. 7.3 No payment shall be deemed to have been received until Cathelco has received cleared funds in the currency stated on the invoice. In the event of any failure to pay Cathelco any sum due pursuant to the Contract and without prejudice to any other remedies available to Cathelco under the Conditions, the Buyer shall be liable to pay interest to Cathelco at 6% above HSBC Bank Plc base rate for the time being per annum accruing on a daily basis until payment is made, whether before or after judgement. 7.4 All payments payable to Cathelco under the Contract shall become due immediately on its termination despite any other provision. 7.5 All payments under the Contract are due in full without deduction by way of set-off, counterclaim, discount, or otherwise unless the Buyer has a valid court order requiring an amount equal to such deduction to be paid by Cathelco to the Buyer. 7.6 Where the Buyer has entered into more than one contract with Cathelco, failure to pay Cathelco any sum due pursuant to the Contract will entitle Cathelco to terminate all other contracts with and/or suspend any deliveries to the same Buyer and seek payment of all outstanding sums. 7.7 The Buyer shall indemnify Cathelco against all costs, charges and expenses (including legal costs) incurred by Cathelco in recovering sums owing by the Buyer (including but not limited to seizure of vessels). 8. QUALITY 8.1 Cathelco warrants that (subject to the other provisions of the Conditions) the Goods will conform in all material respects to the specification provided by the Buyer in accordance with Condition 3.2. Cathelco further provides a one year warranty applying to all Cathelco systems but excluding all consumable items. The warranty period starts from the delivery date. Consumable items are not included in the warranty unless they fail before their recommended operating period. The condition and security of the equipment from the date of receipt to the date of commissioning is the sole responsibility of the purchaser. All other warranties or conditions (whether express or implied) as to quality, condition, description, compliance with sample or fitness for purpose (whether statutory or otherwise) other than those expressly set out in this agreement are excluded from this agreement to the fullest extent permitted by law. 8.2 Cathelco shall not be liable for a breach of the warranty in Condition 8.1 unless the Buyer gives written notice of the defect to Cathelco within 30 days of the date of which the Buyer became or ought reasonably to have become aware of the breach and Cathelco is given a reasonable opportunity after receiving the notice to examine such Goods. The Buyer shall as far as possible preserve the Goods for inspection by Cathelco. 8.3 Cathelco shall not be liable for a breach of the warranty in Condition 8.1 if: (a) the Buyer makes any further use of such Goods after giving such notice; or (b) the Buyer alters or repairs such Goods without the written consent of Cathelco; or (c) the defect was caused in any way by the Buyer’s failure to provide a full and accurate specification of the vessel that the Goods would be applied to and/or the waters that the Goods would be used in (as required by Condition 3.2); or (d) the defect was caused in any way by the Buyer’s failure to follow good trade practice or the Cathelco’s oral or written instructions as to storage, installation, use or maintenance of the Goods. 8.4 Subject to Conditions 8.2 and 8.3, if any of the Goods do not conform with the warranty in Condition 8.1, Cathelco shall at its option repair or replace such Goods (or the defective part) or refund the price of such Goods at the pro rata Contract rate provided that, if requested, the Buyer shall return the Goods to Cathelco. 8.5 If Cathelco complies with Condition 8.4 (or if Cathelco’s reasonable attempts to comply with its preferred remedy under Condition 8.4 are obstructed by the Buyer), Cathelco shall have no further liability for a breach of the warranty in Condition 8.1 in respect of such Goods. 8.6 Where Goods are returned to Cathelco, Cathelco will accept no responsibility for the condition of the Goods received from the Buyer. It is the responsibility of the Buyer to ensure that the packing is sufficient to protect the Goods during transit. The Buyer will be required to pay for the replacement of Goods received which are damaged beyond economical repair or for repairs where such damage is caused by transit. 9. INSTALLATION AND TESTING 9.1 It is the sole responsibility of the Buyer to ensure that the Goods are installed correctly and in compliance with Cathelco’s instructions. Cathelco can accept no responsibility for any damage or loss to Goods or otherwise arising as a result of incorrect installation. The conditions of warranty may be extended if the installation is supervised by a Cathelco approved engineer but any such extensions of warranty must be agreed in writing and signed by an Authorised Person. The supervision will not apply to the structural applications involving preparation, cutting or welding of the vessel for the purposes of mounting and securing the installed equipment. 9.2 Cathelco accepts no responsibility for testing and commissioning unless it is carried out by a Cathelco-approved engineer. In such cases, Cathelco warrants that the engineer will exercise reasonable care and skill within the meaning of the Supply of Goods and Services Act 1982. This warranty will run for one year from the Date of Commissioning where the Cathelco-approved engineer has signed the commissioning report and it has also been countersigned by a recognised representative of the shipyard. 10. LIMITATION OF LIABILITY – THE BUYER’S ATTENTION IS PARTICULARLY DRAWN TO THE CONTENTS OF THIS CONDITION 10.1 All warranties, conditions and other terms implied by statute or common law (save for the conditions implied by section 12 of the Sale of Goods Act 1979) are, to the fullest extent permitted by law, excluded from the Contract. 10.2 Nothing in the Conditions excludes or limits the liability of Cathelco: (a) for death or personal injury caused by Cathelco's negligence; or (b) under section 2(3) or any other applicable section under the Consumer Protection Act 1987; or (c) for any matter which it would be illegal for Cathelco to exclude or attempt to exclude its liability; or (d ) for fraud or fraudulent misrepresentation.

ICCP Installation Manual 38658AE 'S1163' REV1

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