K.C. LTD.

DRAWING TITLE FINAL DRAWING & OPERATION MANUAL

IMPRESSED CURRENT CATHODIC
ITEM PROTECTION (I.C.C.P) SYSTEM &
SHAFT GROUNDING DEVICE
SHIPYARD SHANHAI GUAN SHIPYARD
HULL No. SHG-025
VESSEL TYPE 30K GREAT LAKE BULK CARRIER
K.C. LTD. REF. No. 3905/B
K.C. LTD. MODEL No. KC1T 720
K.C. LTD. MODEL No. KC1T 715

0 ORIGINALLY PREPARED H.J.S JAN.13,09

REV DESCRIPTION DWN. APP. DATE

K.C. LTD.
1589-6, Songjung-dong, Kangsu-ku, CAUTION
THIS DOCUMENT CONTAINS CONFIDENTIAL
Busan 618-818, Korea AND PROPRIETARY INFORMATION OF
K.C. LTD.
THIS DOCUMENT ALWAYS REQUIRES PRIOR
Tel : +82 51 831 7720 WRITTEN CONSENT OF K.C. LTD.
FOR
Fax : +82 51 831 7726 (1)ITS REPRODUCTION BY ANY MEANS,
(2)ITS DISCLOSURE TO A THIRD PARTY,
E-mail : kcind@iccp-mgps.com (3)ITS USE FOR ANY PURPOSE OTHER THAN

Web : http://www.iccp-mgps.com THOSE FOR WHICH IT IS SUPPLIED

K.C. LTD.

INDEX

No. List Page No

1 Specification & Scope of Supply 1-3

2 Introduction 4-7

3 General Descriptions 8-11

4 Power Supply Unit Operating Instructions 12-18

5 Routine Operating Procedure 19-20

6 Service and Fault finding 21-22

7 Shaft grounding Device Installation & Operation 23-29

8 Log sheet 30

9 Drawing for I.C.C.P system & Shaft grounding device 31-49

10 Spare Parts List 50

K.C. LTD.
(REV.1: DEC.06,07)

SPECIFICATION & SCOPE OF SUPPLY

CLIENT SHANHAIGUAN SHIPYARD

PROJECT No SHG-024/25/26/27/28/29/30/31 (30K GREAT LAKE BULK CARRIER)

1. TOTAL WETTED SURFACE AREA : 6,700 m2 (as stipulated by client)

DESIGN BASE
2. CURRENT DENSITY : 35mA/ m2 (as stipulated by client)

3. TOTAL SYSTEM REQUIRED : : 234.5 Amp

4. TOTAL SYSTEM PROVIDED BY K.C. LTD.

350 Amp (200 Amp for AFT & 150 Amp for FWD)

QUANTITY DESCRIPTION FOR AFT SYSTEM :

ONE(1) 200 AMPERE KC1T720 POWER SUPPLY CONTROL UNIT :

INPUT : AC 440V/60HZ/1PH
OUTPUT : 200A/24V DC
PROTECTION CLASS : IP44
PAINTED : MUNSELL NO. 7.5 B G 7/2 △ 1

SUPPLIED COMPLETE WITH EARTHING CABLE

TWO (2) 100 AMPERE CIRCULAR ANODE ASSEMBLY

EACH COMPLETE WITH :
EPOXY PUTTY FOR DI-ELECTRIC SHIELD
COFFERDAM WITH DOUBLER PLATE
CABLE GLANDS

TWO (2) PURITY ZINC REFERENCE ELECTRODE CELL ASSEMBLY

EACH COMPLETE WITH :
COFFERDAM
CABLE GLAND

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K.C. LTD.

SPECIFICATION & SCOPE OF SUPPLY

CLIENT SHANHAIGUAN SHIPYARD

PROJECT No SHG-024/25/26/27/28/29/30/31 (30K GREAT LAKE BULK CARRIER)

QUANTITY DESCRIPTION FOR FWD SYSTEM :

ONE(1) 150 AMPERE KC1T715 POWER SUPPLY CONTROL UNIT :

INPUT : AC 440V/60HZ/1PH
OUTPUT : 150A/24V DC
PROTECTION CLASS : IP44
PAINTED : MUNSELL NO. 7.5 BG 7/2 △1

SUPPLIED COMPLETE WITH EARTHING CABLE

TWO (2) 75 AMPERE CIRCULAR ANODE ASSEMBLY

EACH COMPLETE WITH :
EPOXY PUTTY FOR DI-ELECTRIC SHIELD
COFFERDAM WITH DOUBLER PLATE
CABLE GLANDS

TWO (2) PURITY ZINC REFERENCE ELECTRODE CELL ASSEMBLY

EACH COMPLETE WITH :
COFFERDAM
CABLE GLAND

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 SPECIFICATION & SCOPE OF SUPPLY

CLIENT SHANHAIGUAN SHIPYARD

PROJECT No SHG-024/25/26/27/28/29/30/31 (30K GREAT LAKE BULK CARRIER)

QUANTITY DESCRIPTION FOR ASSOCIATED EQUIPMENT

SHAFT GROUNDING DEVICE CONSISTING OF SLIP RING,

ONE (1) BRUSH (SILVER GRAPHITE), mV METER (0~150mV) WITH GLAND,
BRUSH HOLDER, EARTHING CABLE AND BAND

EPOXY PUTTY FOR MOUNTING ANODES

ONE (1)
AND FILLING IN COFFERDAM OF REF ELECTRODE CELL

RUDDER STOCK BONDING ASSEMBLY

ONE (1)
6m OF 70 m2 CORE FLEXIBLE CABLE △ 1

SYSTEM SPARES WITH BOX AS PER MANUFACTURER’S

ONE (1)
STANDARD SUPPLY

ONE (1) SYSTEM LOGSHEET (ELECTRIC FILE)

SIX (6) OPERATION / INSTRUCTION MANUALS

K.C. LTD. will dispatch one service engineer to the shipyard for one visit /
Service engineer 3 day commissioning work together with ANTI-FOULING SYSTEM(M.G.P.S)
upon 2 weeks prior notice from the shipyard.

The equipment provided by K.C. LTD. shall be guaranteed

Warranty service for 18 months after delivery to the shipyard or 12 months after
the vessel delivery, whichever occurs earlier.

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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 a 500V Megger. Read the relevant section in this manual
before carrying out any tests.

c) There is no need of protective current as far as ship is well enclosed by a good hull coating
(newbuildings or just repaired ships) or the temporary sacrificial anodes around ship’s bow
and stern hull area are still alive, which means our system dissipates no current under fully
automatic control realizing ship is well protected from corrosion. Then you may see
protective current when ship's hull coating gets thinner and thinner or partly damaged.

d) Should any information be required which is not covered by this manual, please contact
K.C. LTD. immediately. (Address on cover)

CAUTION
Customers are recommended for the purchase of genuine parts from us.
Imitated parts make the system get fatally damaged.

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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, 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.

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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, 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 solis. 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.

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Typical example 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 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 ref cell indicates that
cathodic protection is achieved. This is equivalent to -0.80 volts measured against
silver / silver chloride ref cell and + 0.24 volts against a zinc ref cell 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 preferentialy, 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 essential part of their function and they are therefore
termed sacrificial.

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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 ref
cell with a power source is introduced and that the current flow from this ref cell
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 dielectrodes, 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.

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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 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. 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, 75, 100 and 175
Ampere recessed anodes are available.

Materials now used by Anodes have now gone beyond lead alloy with specialist
coated titanium based Anodes now available.
All anode designs utilise a tough, chlorine resistant, but slightly flexible plastic
carrier.

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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 3.5.4

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 full sealed and provided with watertight cable glands,
all conforming to the requirements of Classifications Societies.

2.2.2 IMPRESSED CURRENT REFERENCE ELECTRODE

The high purity, high stability, zinc ref cell 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 preset levels of protection.

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

The minimum number of ref cell 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 200 metres from the bows, one ref cell may be located in the bows.

A novel feature of the 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.

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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.

2.2.3 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 as optional items. 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 track is silver plated as standard and in addition silver graphite
brushes are used to minimize contact resistance.

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3.0 POWER SUPPLY UNIT OPERATING INSTRUCTIONS

3.0.1 When main power is ON the LCD works as per following steps.
`Each step is shown on LCD for approximately 10 seconds.
1) The phase and frequency of input AC
source, system capacity (OOOA) and type
of ref. cell are displayed.

2) Company logo of K.C.Ltd. is displayed.

3) Company name (K.C.LTD.) is displayed.

4) System is ready to work.

5) AUTO on OP MODE (Operation Mode) is

displayed according to initial setting.
System should be kept on AUTO.

6) Otherwise Press ESC KEY and select OP

MODE by turning ESC KEY and then
pressing ENTER KEY.

7) Then select AUTO by turning ESC KEY and

pressing ENTER KEY.

8) Then the LCD displays OP MODE and

press ESC KEY.

9) YES / NO to save AUTO is displayed and

then select YES by pressing ENTER KEY.

※ Please keep system on AUTO.

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3.0.2 Details of Controller

3.0.3 MODE Description

Display on LCD Description

OP MODE (Operation Mode)

- OP MODE SELECTION
OP MODE returns by pressing ESC KEY in AUTO or MANUAL.
OP MODE is selected by turning ESC KEY and accessed in AUTO
or MANUAL by pressing ENTER KEY.

 - AUTO or MANUAL on OP MODE

The display indicates OP MODE to access AUTO or MANUAL.
AUTO or MANUAL is selected by turning ESC KEY and pressing
ENTER KEY.

- AUTO on OP MODE
The display indicates the values on percentage of total system
capacity, ref.cell, output current in Ampere and voltage. Each ref.
cell value is scrolled one by one and also selected by pressing
ENTER KEY. All readings vary automatically on ref.cell value.
System should be left on AUTO.
- MANUAL on OP MODE
The display indicates the set value on percentage of total system
capacity, ref.cell, output current in Ampere and voltage. Each
ref.cell value is scrolled one by one and also selected by pressing
ENTER KEY.
All readings vary on the percentage set manually by user.
The percentage of total system capacity is increased by turning
ENTER KEY clockwise and decreased by turning anti clockwise.

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SET MODE

- SET MODE SELECTION

SET MODE returns by pressing ESC KEY in AUTO or MANUAL.
The SET MODE is selected by turning ESC KEY and accessed in
FAULT SET or UNIT SET by pressing ENTER KEY.

- FAULT SET or UNIT SET on SET MODE

The display indicates system setting to access FAULT SET or
UNIT SET.
FAULT SET or UNIT SET is selected by turning ESC KEY and
PASSWORD is accessed by pressing ENTER KEY.

- PASSWORD REQUEST
This mode provides access to the service functions provided in the
system setting. Access to this mode is only available from the
permission of maker.
Press ESC KEY to escape this mode.

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3.1 CHANGING OPERATION MODE

3.1.1 There are two MENU on operation mode. Thus ;

1) AUTO
In this mode the output current from the system is varied to maintain optimum ref.cell
value. The display indicates the values on percentage of total system capacity, ref.cell,
output current in Ampere and voltage. Each ref. cell value is scrolled one by one and also
selected by pressing ENTER KEY. All readings vary automatically on ref.cell value.
System should be left on AUTO.

2) MANUAL
In this mode the output current from the system is manually set by user and maintained at
a constant level. The display indicates the set value on percentage of total system capacity,
ref.cell, output current in Ampere and voltage. Each ref.cell value is scrolled one by one
and also selected by pressing ENTER KEY.
All readings vary on the percentage set manually by user.
The percentage of total system capacity is increased by turning ENTER KEY clockwise
and decreased by turning anti clockwise. 
○
1 OR ○
2

○
3

○
4 ○
5

<Figure 2-1 flow chart diagram for changing OPERATION MODE>

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3.1.2 The system is controlled by using two keys on controller with the information
showed on the 4 line display.

To change AUTO or MANUAL take following step referring to figure 2-1 and 2-2.

1) Upon main power on the LCD displays ① or ② in figure 2-1.

2) By pressing ESC KEY the LCD displays ③ in figure 2-1.
3) By pressing ESC KEY in display ③ in figure 2-1 the LCD displays ① or ② back.
By pressing ENTER KEY in display ③ in figure 2-1 the LCD displays ④ or ⑤ in
figure 2-1.
4) The display ④ in figure 2-1 indicates AUTO and ⑤ indicates MANUAL. By pressing
ENTER KEY in display ④ in figure 2-1 the LCD displays ③ back after setting AUTO
which should be kept unless otherwise specially notified.
5) By pressing ENTER KEY in display ⑤ in figure 2-1 the LCD displays ③ back after
setting MANUAL.
6) By pressing ESC KEY in display ③ in figure 2-1 the LCD displays YES / NO to save as
per in figure 2-2.
7) By pressing ENTER KEY in display ⓐ in figure 2-2 the display approaches ⓑ saving
any change. After saving any change the LCD displays ① or ② in figure 2-1.
8) By pressing ENTER KEY in display ⓒ in figure 2-2 the display approaches ⓓ and
displays ① or ② in figure 2-1.

○
a ○
c

○
b ○
d

<Figure 2-2 flow chart diagram to save YES/NO >

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3.2 FAULT STATUS

This mode as shown in figure 3-1 displays the status of fault.

In case external alarm is provided for vessel’s alarm system the alarm triggers.

<Figure 3-1 Display of fault status >

The LCD displays as below ;

Display on LCD Description

No message and alarm triggers in case power supply

fails.

CELL 1 UNDER PROTECTION No.1 ref. cell reads UNDER PROTECTION of system.

CELL 2 UNDER PROTECTION No.2 ref. cell reads UNDER PROTECTION of system.

CELL 1 OVER PROTECTION No.1 ref. cell reads OVER PROTECTION of system.

CELL 2 OVER PROTECTION No.2 ref. cell reads OVER PROTECTION of system.

ANODE OPEN STATUS Anode cable is open circuit.

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ANODE SHORT STATUS Anode cable is short circuit.

PCB BOARD PROBLEM Control PCB gets faulty.

NEED A/S FROM MAKER

Kindly contact K.C.Ltd. for the remedy in case above fault status occurs.

- Address : 1589-6, Songjung-dong, Kangsu-ku, Busan 618-818, Korea

- Tel : +82 51 831 7720
- Fax : +82 51 831 7726
- E-mail : kcas@iccp-mgps.com

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4.0 ROUTINE OPERATING PROCEDURE:

The K.C. LTD.. 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.

4.0.1 EVERY DAY:

Check that the LCD of the Power Supply unit display is illuminated.

Record the out put Current & Voltage and the ref cell reading on the log sheets
provided.

4.0.2 EVERY WEEK:

Once weekly the slipring should be checked for cleanliness, for wear on the
brushes and to confirm that the brushes 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.

4.0.3 EVERY MONTH:

Each log sheet has space for a complete month after which the copies should be
returned to K.C. LTD. for scrutiny and comment.

4.0.4 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.

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4.0.5 30 DAYS PRIOR TO DRY-DOCKING :

One month before the dry docking ensure that daily log sheets have been
maintained and forwarded to K.C. LTD. 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 reading up to the time the
vessel enters the dry dock. It is advised that an Engineer from K.C. LTD. be in
attendance during drydocking to check and service the System.

4.0.6 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 ref cell potentials may indicate under protection. However, this has
been taken care of by our computer and is explained in a seperate paragraph in
5.1 The system will return the hull to the optimum protective level as soon as the
vessel returns to the seawater.
During ship’s sailing in fresh water or blackish water it’s recommended to cut
off the system since the high system voltage under zero output current can
reduce anode life significantly.

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5.0 SERVICING AND FAULT FINDING:

5.0.1 RECOGNITION OF A PROBLEM:

5.0.2 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.

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

5.0.4 The D.C. output voltage is the driving potential that produces the protective
current. The standard K.C. LTD. Marine Impressed Current System has a
maximum voltage output of 24V DC but this is automatically regulated
according to the current requirement.

5.0.5 Bearing the above points is mind, it is clearly important to maintain the daily log
and return the copies to K.C. LTD. for scrutiny at the end of each month. Thus
any abnormality in the readings will be noted and diagnosed and
recommendations can be forwarded for action to be taken without undue delay.

5.0.6 In reviewing the daily log sheets it is necessary first to check that the ref cells are
within the range of protection and then to asses the output current and volts for
variations in the level of protection applied.

5.0.7 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.

5.0.8 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 K.C. LTD.

5.0.9 When any of the alarm conditions are found to be displayed contact K.C. LTD.
giving full details of the alarm.

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K.C. LTD. 
ICCP DOCUMENT
REV(E) : 14/04/06 

5.1 VESSEL IN FRESH WATER:

ICCP systems have experienced problem in the past when the vessel has to enter a
harbour or estuary where the water is either fresh or brackish. The computer
controller has been programmed to identify this situation by analysing the voltage
reading, the amperage reading and the ref cell inputs. In fresh water the amperage
goes to zero, the ref cell readings go high and the voltage tends to go to maximum
to compensate.

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``C:\Manual\ICCP\ICCP Document.doc
K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04

SPECIFICATION & SCOPE FOR Shaft Earthing Device

SHIPYARD SHANHAI GUAN SHIPYARD

SHAFT
Ø 380
OUT DIAMETER
TOTAL WEIGHT APPROX. 11.0 kgs

NO OFF PART NO DESCRIPTION

1 KCS0044 MILLI-VOLT METER WITH CABLE GLANDS

1 KCS005 SILVER ALLOY SLIP-RING

1 KCS0032 SHAFT EARTHING DOUBLE BRUSH HOLDER

1 KCS0022 SHAFT MONITORING SINGLE BRUSH HOLDER

1 KCS009 BRUSH HOLDER SUPPORT BAR

1 KCS010 INSULATED BRUSH HOLDER SUPPORT BAR

3 KCS0014 HIGH DENSITY SILVER GRAPHITE BRUSH

1 KCS006 1.5m x 50mm2 SHAFT EARTH CABLE

2 KCS011 STAINLESS STEEL BAND

1 KCS0151 PRESSURE TAPE (50mm)

1 KCS015 PRESSURE TAPE (19mm)

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K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04

1. Introduction

A turning propeller shaft on a ship becomes 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. When the shaft is insulated in this way an electrical potential can be
measured between the shaft and the hull and this can accelerate corrosion in the ship.
If the ship has a system of cathodic protection, whether it is sacrificial anode or an
impressed current system, the shaft insulation will prevent the propeller and the boss
from receiving protection.

The electrical potential between the shaft and the hull can also cause a heavy current
to flow in bearings when the oil film breaks down or is contaminated with seawater.
This current can cause deep pitting of the bearing surface. Excessive wear on the shaft
bearings can often be traced to this cause.

Now in addition it’s necessary to reduce the spark erosion causing the excessive wear
on main engine metal bearings and this shaft earthing is the most appropriate method.

All the troubles can be avoided and cathodic protection can be extended to the
propeller if the shaft is properly earthed with a propeller shaft slip ring. The
effectiveness of the shaft earthing system should ensure a maximum contact resistance
of no greater than 0.001 ohms for a water filled bearing and 0.01 ohms for an oil filled
bearing.

Our own tests indicate that high silver content brushes running on a silver track have
repeatable low conductivity that can maintain these limits and ensure a low resistance
contact is maintained even under dirty conditions.

The shaft earthing assembly comprises a pair of high silver content / graphite
compound brushes mounted in balanced brush holder, running on a silver alloy slip
ring.

Each brush holder has a adjustable spring tensioner which is supplied preset to the
minimum, and results in a pressure of 225g/cm2.
At this pressure the expected life of the brush is in excess of one year.

2. Design base

- Intermediate shaft diameter : Ø 380 mm

3. Installation work by shipyard

- Assembling the intermediate shaft earthing assembly

- Attaching the intermediate shaft monitoring millivoltmeter & wiring
- Welding the brush holder support bar & Assembling the brush holder

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 K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04

4. Installation

4.1 Slip ring

CAUTION : It is strictly required to install slip ring correctly according to following procedure
for the good performance of shaft earthing and longer life time of brushes.
4.1.1. Make clean the area where slip ring is positioned.
The area should be cleaned and prepared for a bright bare steel.

KEEP CLEAN

SHAFT

Approx.130mm

4.1.2. Fasten stainless steel bands (A & B) temporarily.

BAND (A) BAND (B)

130mm

SHAFT

KEEP CLEAN

4.1.3. Wrap the slip ring around the shaft and mark the overlapped part.
Cut the overlapped part at an angle of 45 O carefully, which is very important job.

MARK FOR CUT

BAND (A) BAND (B)

SHAFT

SLIP RING

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 K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04

- After cutting properly rub the both edges of inner surface of slip ring with a fine-mesh file or
sand paper as below. Then secure slip ring very tightness around shaft;

SLIP RING
SLIP RING
45

45
°

°
SHAFT
SECURE SLIP RING
VERY TIGHTNESS
AROUND SHAFT.
FINE-MESH
FILE OR
SAND PAPER

CORRECT INSTALLATION
FILE INNER SURFACE OF SLIP RING

4.1.4. Wrap the slip ring around the shaft and fasten with the stainless steel band(B).

When the slip ring is tightly installed no protrusion or gap is found.

In case there happens with protrusion or gap smoothly rub the protrusion with sand paper.

BAND (A) BAND (B)

SHAFT

4.1.5. Wrap the both edges of slip ring with 3/4” pressure tape for a preparation of tight
fastening of stainless steel band.
Apply the tape to the slip ring five times at the opposite direction of the shaft rotation.

BAND (A) BAND (B)

SHAFT

PRESSURE TAPE
(5 TIMES)

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 K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04

4.1.6. Fasten the stainless steel band(A) over the pressure tape tightly around the edge of slip
ring.
BAND (A) BAND (B)

SHAFT

4.1.7. Fasten the stainless steel band(B) over the pressure tape tightly around the edge of slip
ring.
After tightening bands (A, B), bend the end part of band to the opposite direction to
prevent loosening during the shaft rotates.

BAND (A) BAND (B)

SHAFT

BAND

BAND TIGHTENING BOLT

BEND TO THE OPPOSITE

DIRECTION FINALLY

4.1.8. Apply 2” tape over both stainless steel bands (A & B) at the opposite direction of the shaft
rotation finally.
2" TAPE

SAHFT

MIN.30
WIDTH OF SLIP RING
AFTER FINAL INSTALLATION
WHERE BRUSHES RUN.

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K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04

4.2. Brush holder

4.2.1. Carefully study the drawing for correct installation and keep the distance of 3mm
between bottom of brush holder and slip ring surface.

4.2.2. Fit the brush holder to the support bar and align the assembly so that the brushes
will run centrally on the slip ring, and the brush holders assembly is to be clear of
the slip ring securing brackets when the shaft rotates.
Secure the assembly in this position by tightening the hexagon headed bolt at the
top of the brush holder body.

4.2.3. Do not adjust the tension of spring without approval from K.C.Ltd.

4.3. Shaft monitoring millivolt meter

4.3.1. The system comprises a bulkhead mounted panel that incorporate terminals, a
display meter and a separate monitor brush holder. The system is self contained
and requires no external power supply.

4.3.2. For ease of interpretation the display meter is scaled up to 150mV.

As the meter reading rises above 80mV it is recommended that the slipring and
brushes be checked and cleaned.

5. Operation

5.1 The millivolt meter normally reads 150mV full scale.

5.2 Reading of below 80mV when shaft is turning at sea indicates proper grounding.
If readings are above 80mV, clean the faces of slip ring and brush with a clean
cloth.

5.3 The millivolt meter will read '0' when shaft is at rest because of the current
entering the propeller will return to the hull through main engine bearings and
engine foundation.

5.4 A millivolt meter reading of '0' when shaft is turning at sea indicates a faulty
millivolt meter installation. Checks for connections of all the terminals and
tightness of all the fitting are required.

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K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04

6. Maintenance and service

6.1 This grounding assembly should be checked at least twice a week for cleanliness.

6.2 If there has been a build-up of oil, dirt, scale and rust on the slip ring face or
between slip ring and shaft, this should be removed with a degreaser, emery paper
and clean cloth.

6.3 Inspect and clean the brushes and brush holder to prevent their moving due to dirt
build-up. Inspect the brush copper leads (pig tails) to ensure they have not
become loose or corroded. The brush wear-down should be noted.

6.4 At the time of every dry dock, disassemble the slip ring and clean the surface of
the shaft right thereunder.

7. The life time of brushes

7.1 The brushes are getting worn out by metal touch with slip ring.
Therefore it’s strictly required to keep clean and smooth surface of slip ring, also to
carry out proper installation / alignment of brush holders as per our manual and
drawing. Otherwise it’s very hard to obtain the proper earthing and the proper life
time of brushes.

7.2 The brushes are consumable parts with wearing ratio approximately 5~10mm per
1,000 hours shaft rotation under proper installation.
the replacement time is shown by engraving the line (15mm from the top) on the
brushes.
Customer is requested to replace brushes with spares when the time comes.

7.3 Brushes are consumable parts as stated above and they are often consumed earlier but
it’s not a matter of guarantee claim for supplying extra brushes.

7.4 Use only our genuine silver graphite brushes.

Contact K.C. LTD. for purchasing and indicate part number.

CAUTION
Customers are recommended for the purchase of genuine parts from us.
Imitated parts make the system get fatally damaged.

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K.C. LTD.
1589-6, Songjung-dong, Kangsu-ku, Busan 618-818, Korea.

Tel) 82 51 831-7720 Fax) 82 51 831-7726 Web : http://www.iccp-mgps.com E-mail : kcas@iccp-mgps.com Rev.1 (Aug.03,2006)
Daily Log for Impressed Current Cathodic Protection System
Vessel Name Pjt No.
Voyage Number After system capacity Amp 24 Volts
Date from to Forward system capacity Amp 24 Volts
Last Drydock Planned Drydock Last renewal of Brush

▶ Keep shaft potential below 80mV. Slip ring to be cleaned and brushes to be in tight contact.

Area of Draft Sea temp Aft output sensing electrode(mV) Fwd output sensing electrode(mV) Shaft
date
operation m °C Amp Volt CELL 1 CELL 2 Amp Volt CELL 1 CELL 2 mV
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
Remark
Submitted by Chief Engineer
Customers are recommended for the purchase of genuine parts from us.
CAUTION
Imitated parts make the system get fatally damaged.
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