ICCP Hull Corrosion

Protection Systems
 The Problem of
Corrosion
Corrosion takes many forms in the marine environment. It
can be seen as pitting on hull plates; in the disintegration
of weld seams; around bow thrusters and on the surfaces
of rudders and other vital components.

A well designed ICCP system can eliminate these

problems, safeguarding the structural integrity of the
vessel and significantly reducing maintenance costs
throughout its operational life.

By installing a Cathelco system you can have the

advantage of world leading ICCP technology combined
with the expertise which goes with wide understanding of
corrosion problems and the most effective way of solving
them.

Pitting corrosion around exhaust discharge. General corrosion on hull plate.

Corrosion around bow thruster. Corrosion blisters on hull plate.

Background image Corrosion on propeller shaft bracket arm

Cathelco ICCP systems for
vessels of every type
Cathelco C-Shield impressed current cathodic protection (ICCP)
systems have now been fitted to more than 10,000 vessels
around the world, establishing a record of effective performance
and reliability on ships of every type:-
Cruise Ships
Container Vessels
VLCCs
Ferries
FPSOs
Ice Class Vessels

The systems continue to advance through the introduction of a

wider range of control panels. These take advantage of the latest
advances in technology to provide systems which are not only
effective, but economical to install.
Cathelco have also developed an unusually wide range of
anodes covering elliptical, circular and linear loop designs to suit
various hull profiles with the aim of simplifying installation time
and reducing costs.
Other developments have included the introduction of ICCP
systems which are specifically designed to protect bow and
stern thruster tunnels. Alongside this has gone the design of
more sophisticated shaft earthing systems and rudder bonding
equipment to provide reliable protection for propulsion and
steering systems on todays vessels.
In the case of smaller vessels, the Minitek and Alutek systems
are compactly designed to protect steel and aluminium hulls,
respectively.
Cathelco serves customers globally through a well established
network of over 40 agents who can provide on-the-spot access
to technical advice and commercial support.
Following a series of takeovers, Cathelco incorporates the
following product ranges:-
Cathelco
Corrintec
Jotun
Morgan Berkeley
Wilson Taylor
F.A.Hughes
Impressed Current Cathodic
Protection Systems

RUDDER BONDING

REFERENCE CELL

LINEAR LOOP ANODE

REMOTE MONITORING UNIT

SHAFT EARTHING ASSEMBLY

CONTROL PANEL

Linear Loop Anodes Circular Anodes Elliptical Anodes

Produce a powerful output from Ideally suited to vessels where a The elliptical shape enhances current
a relatively small surface area. smooth hull profile is required. Can distribution. Provides the flexibility to
Lightweight and easy to install. be flush mounted in areas where fit into complex hull profiles.
space is limited.
 Most operators recognise the need to combine modern
hull coatings with a purpose designed impressed
current cathodic protection system. The C-Shield
system suppresses corrosion on the wetted surface of
the hull using an arrangement of hull mounted anodes
and reference cells connected to a control panel. This
neutralises corrosion cells and eliminates problems
that arise through dissimilar metals and the proximity of
components such as propellers.

CONTROL PANEL

ELLIPTICAL ANODE
REFERENCE CELL

Diver Change Anodes Reference Cell

Can be changed from the outside of Designed to measure the electrical
the hull by a diver. Ideal for FPSOs and potential at the seawater/hull
vessels with long intervals between interface.
drydocking.
A choice of control
panels
Thyristor Panels
C-Shield thyristor control panels combine cost effectiveness with
rugged reliability that has been proved on vessels of all sizes
worldwide.
They also incorporate the latest computerised information systems
enabling the status of the ICCP system to be monitored by ships
computers.
Thyristor control panels can be used for systems of up to 1,000 amps
with 8 anodes and 4 reference cells being controlled by an individual
panel. They are ideal for the requirements of cruise ships, VLCCs
and many types of container and cargo vessels.
The popularity of these panels means that they can
generally supplied within relatively short lead times.
l For ICCP systems of up to 1,000 amps.
l Reliable performance with minimum attention.
l Economical control for systems of all sizes.
l Combines computerised output displays, alarms and
information systems.
l Up to 8 anodes and 4 reference cells per panel.
l Easily configured to clients requirements.

Modular Panels
The C-Shield modular control panel, based on advanced computerised
electronics, is designed for installations of up to 350 amps.
Extremely lightweight and compact in design, it can be easily installed
in engine rooms and requires the minimum of attention from the crew.
One of the major advantages of the unit is that the modules are
interchangeable and can be quickly removed and replaced if
necessary, thereby offering greater reliability.
l For ICCP systems of up to 350 amps.
l Modular design for greater reliability and flexibility.
l Extremely lightweight and compact.
l Clear digital output displays.
l Incorporates under and over protection alarms
l Can be linked to bridge information systems

Minitek Panels Alutek Panels

The Minitek system has been The Alutek system provides
designed to protect smaller steel carefully controlled protection
hulled vessels against corrosion. for aluminium hulls using
It has been widely installed an arrangement of flush
on tugs, fishing vessels and mounted anodes, monitoring
workboats where engine room electrodes, controlling
space is at a premium. electrodes and di-electric
shield sensors.
l Operates from 230V a.c.
electrical supply. l Operates from 230V or
l Control panel measures 600mm x 600mm x 210mm 115V a.c. electrical supply.
l Far superior to sacrificial anode systems where l Control panel measures 400mm x 500mm x 210mm.
output cannot be verified. l Lower yard installation cost than recessed sacrificial
anode systems
 C-Shield - the savings

Additional fuel consumption

Sacs vs ICCP 500
.00
0
Over a ten year period, significant savings
Notes result from the use of C-Shield impressed

Cost in US Dollars
375
1. Ship Types: A - 25,000 dwt General Cargo .00
0 current cathodic protection.
B - 150,000 dwt Bulk Carrier
2. Costings based on data for increased drag 250 It used to be the case that ICCP systems
.00
contained in BS CP1021 0
were more expensive to install than
3. Escalation: 3% pa compound sacrificial anode systems, but the
125
.00
0 escalating price of zinc has reduced the
cost differential making ICCP systems an
even more attractive proposition.
10
Yea
rs
8Y
ear
s
One of the main disadvantages of sacrificial
BS 6Y
anodes is that they have to be renewed
AC ear
s
4Y
ear
s
at periodic drydocking intervals as they
2Y
AS ear become consumed, resulting in on-going
AC s
replacement costs.

In contrast C-Shield anodes last for many

years and achieve a more much reliable
Capital cost comparison for level of protection without the extra weight
or drag which is inevitably associated with
equipment installed
sacrificial methods.
Notes
1. Ship Types: A - 25,000 dwt General Cargo 125
.00
In addition, major operational savings result
0
B - 150,000 dwt Bulk Carrier from the use of C-Shield. A smooth hull,
2. Design Basis: Sacrificial 15mA/m2, Impressed free from corrosion ensures the lowest
100
Current 30mA/m2 .00
0 fuel consumption for the vessel. Data has
shown that unprotected vessels, after as
Cost in US Dollars

3. Escalation: Materials & Labour 3% pa compound

75. little as 2.5 years, can require an additional
4. SAC Anodes: Zinc purchased at $3.6/kg 000
30% increase in shaft power to maintain
service speed.
50.
000
Throughout the design of the C-Shield
system, every care has been taken to
25.
000
ensure the highest reliability commensurate
with minimal installation time. The lowest
10
cost system may leave the installer with the
Yea
rs highest work load.
BS 8Y
ear
AC s
6Y
B IC ear
s
CP 4Y
AS ear
s
AC 2Y
ear
A IC s
CP
Shaft Earthing

Even on ships fitted with ICCP or

sacrificial anode systems, propeller
shaft bearings are vulnerable to
corrosion.
This is because turning propeller shafts are electrically
insulated from the hull by the lubricating oil film in the
bearings and by the use of non-metallic bearing materials in
the tail shaft.

The problem can be eliminated if the shaft is earthed to

the hull using a propeller shaft slipring. Cathelco supply
complete shaft earthing assemblies consisting of a pair of
high silver content/graphite compound brushes mounted in
a balanced brush holder, running on a copper slipring with
a solid silver inlay track. This combination has been proved
to give the optimum electrical continuity. The number of
brushes depends on the size of the vessel. Smaller craft
have a single brush holder.

Installation
The shaft slipring is supplied as two matched Propeller shaft
halves, complete with band and clamping
arrangement and can be readily installed by potential monitoring
competent engineering personnel.
Cathelco supply compact millivolt meters to
The balanced brush holder is supplied ready monitor the potential between the shaft and the
for fitting to a shipyard-supplied 20mm hull and verify the effectiveness of the system.
diameter rod and mounting bracket. The meters can be located in a convenient
position for monitoring by the crew.
Each brush holder has an adjustable
tensioner to ensure good electrical contact
and maximum brush utilisation.

Earthing Cable
Brush Holder
Brush
Hull Anode

Slip Ring assembly

Silver Inlay Track

Current Flow
 Anode 3 Anode 1
Top

Anode 1

Ref 2 Ref 1
Stbd. Port
Stern Bow

Anode 2 REF Electrode

Bottom
Anode 4 Anode 2

Large Thruster Tunnel

ICCP Systems
Bow and stern thruster protection is
a specialised area where Cathelco
have developed a system which The Star Ismene is fitted with

is uniquely effective in providing bow and stern thruster tunnel

ICCP Systems
corrosion protection.
Problems of corrosion arise because of the dissimilarity
of the materials used in the hull and thruster tunnel
construction and remain unchecked because they are
outside the scope of conventional ICCP systems.

Cathelcos thruster tunnel systems are installed on

ocean going vessels, harbour tugs and in offshore oil
and gas applications.

The equipment consists of a power unit/controller

and an arrangement of reference cells and anodes
positioned on either side of the tunnel. The anodes and
reference electrodes are flush mounted to maintain the
optimum performance of the thrusters and reduce the
effects of turbulence which can accelerate corrosion.

This has a number of advantages in comparison with

sacrificial anode systems where anodes are much
heavier, have to be checked at regular intervals
and replaced at each drydocking. In contrast, the
Cathelco system provides carefully monitored,
precisely delivered corrosion protection for a design
life of up to 15 years.

The system operates continuously when the vessel

is at sea, but when the impeller is activated during
docking, the equipment is automatically shut down
using a fail-safe switching system which is installed
by the shipyard. This prevents any stray current
damage occurring to the bearings and seals.
Example of corrosion in and around thruster tunnel.
A system specifically designed to
protect your ship against corrosion

System Design Quality Approvals

C-Shield systems are specifically designed for the particular The manufacture of C-Shield systems
requirements of individual vessels and their operating conforms to the highest standards of
conditions. They can be installed at newbuilding or retrofitted quality.
to existing tonnage during scheduled drydocking.
Cathelco Ltd has been assessed by
With comprehensive experience of ICCP system design Lloyds Register Quality Assurance and is
and the factors which influence hull corrosion, Cathelcos registered under BS EN ISO 9001:2000
engineers will formulate the most effective arrangement
of hull anodes, reference cells and control panel(s). An The C-Shield system fully complies with all British and
important part of the service is the preparation of detailed International Standards.
installation drawings and instructions covering every aspect In particular, BS7361: Part 1: 1991 Cathodic Protection, and
of the system. is approved by all leading ship classification societies.
All systems are provided with comprehensive manuals as
part of the standard package. These include sections on
theory, installation, operation, maintenance, fault finding, Replacement Anodes
drawings and spare part listing. C-Shield anodes can be used as direct replacements for
any ICCP system currently used in the world. They are
also designed to be totally compatible with the full range of
Customer support manufacturers control systems.
Cathelco engineers, based world-wide, provide on-going
service support for customers including:-
This enables operators to benefit from the latest
l Commissioning systems. developments in anode technology, whilst providing
l On-site instruction for operating staff. considerable cost savings in comparison with replacement
l Attending service call outs and routine drydocking. using conventional designs from the original equipment
manufacturer.

Log sheet analysis

Our service extends to a life-time log sheet analysis service.
Log sheets with daily readings completed by the ships staff
are returned to us by e-mail and analysed by our engineers.
Reports with comments are then e-mailed back to the
operator, ensuring that the system continues to operate
effectively.
Easier installation
The installation of C-Shield systems follows well
established principles which have been approved by
all of the leading classification societies.

Depending on the type of anodes being fitted, work

begins by cutting holes in the hull to accommodate
bosses or doubler plates. These are welded in position
ready to receive cofferdams, enabling watertight
electrical connections to be made to the anode.

Elliptical anode being fitted

Di-electric shield surrounding elliptical anode

For surface mounted anodes, a mounting plate or mounting studs

are welded to the exterior hull surface in preparation for fitting the
anode. At this stage, the surrounding area is carefully grit blasted
to a white metal finish. Next, a layer of mastic is applied to the
anode mounting surface in order to create a watertight seal when
the anode is fitted and the studs are tightened. Finally, mastic is
applied to the area surrounding the anode to produce a di-electric
shield which is essential to ensure the maximum spread of current
over the hull surface.

Elliptical anode with di-electric shield

Linear loop anode with di-electric shield

Marine Worldwide Service Network
pipework Our worldwide network of sales and service centres can provide
anti-fouling immediate advice and assistance on the complete range of
Cathelco products. Agents contacts details are available on our
systems website: www.cathelco.com
Cathelco is the worlds
largest manufacturer Abu Dhabi Israel
of seawater pipework Algeria Italy
anti-fouling systems.
Argentina Japan
The systems provide Australia Korea (Seoul & Pusan)
complete protection Belgium Malaysia
against blockages
caused by barnacles and mussels which result
Brazil Mexico
in engines overheating, increased fuel usage Bulgaria New Zealand
and costly pipework cleaning and renewal
Canada (East & West Coast) Norway
work.
Chile Philippines
Based on the electrolytic principle, Cathelco China (Dalian, Guangzhou, Poland (Gdansk & Szczecin)
systems are easy to install, automatic in Shanghai, Hong Kong)
Portugal
operation and have a record of effectiveness Croatia
on more than 20,000 vessels of every type. Romania
Cyprus
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Jotun Marine Denmark
Singapore
Coatings Egypt
South Africa (Durban & Cape
In more than 50 Finland Town)
countries Jotun France (Atlantic & Mediterranean Spain
Marine Coatings Coasts)
Sweden
assists and advises Germany
customers on the Taiwan (Kaohsiung & Taipei)
most effective Greece
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solutions to the Holland
prevention of Turkey
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corrosion and fouling. United Arab Emirates
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USA (East, West & Gulf Coasts)
Jotun is active in every aspect of coating Indonesia
technology. This expertise is built on Vietnam
investment, innovation and practical Iran
Venezuela
knowledge earned in the protection of more Ireland
than 15,000 vessels throughout the world.
Jotun is recognised as the leading supplier
of high technology coatings and the most
advanced TBT free antifoulings.
CATHELCO S.E.A PTE LTD
Jotun Marine Coatings and Cathelco can 59 UBI AVE 1
offer customers a complete package where #05-06 BIZLINK CENTRE
the combination of both coatings and
SINGAPORE 408938
cathodic protection will give the most effective
prevention against corrosion and fouling. Tel: +65 67422446/ 62982036
Fax: +65 62983419
Email: sales@cathelco.com.sg

We recommend Jotun coatings

Jotun AS
PO Box 2021
3248 Sandefjord
Cathelco Ltd, Marine House, Dunston Road,
Norway
Chesterfield S41 8NY United Kingdom
Tel: +47 33 45 70 00 Fax: +47 33 45 79 00
Web: www.jotun.com Telephone: +44 (0) 1246 457900
Fax: +44 (0) 1246 457901
Email: sales@cathelco.com
Web: www.cathelco.com