ICCP – IMPRESSED CURRENT CATHODIC PROTECTION

Before the ICCP system came into play for rust prevention, “SACRIFICIAL
ANODES” were fitted all around the hull of the ship. These anodes used to get
consumed fairly rapidly and thus needed replacement each time, which could be
done only during dry-docking of the ship. In the interim, the hull used to corrode until
the next dry-dock. It was also expensive as each time the anodes had to be
replaced entirely. The ICCP system overcame this problem as it a completely
automatic system and did not require replacement of anodes, keeping the hull
protected at all times.

The principle of cathodic protection system is to create a potential

gradient opposing the flow of electrons from the surface to be protected. It makes
the entire hull “CATHODIC” (MORE NEGATIVE) in nature and thus prevents
corrosion.

THEORY OF CORROSION:-
The iron hull of the ship is made of sheets of iron, welded
together. Being not 100% pure iron there will be other metals
whose atoms together with that of iron, have loosely bonded electrons
which they tend to lose.
Seawater in this case, acts as an ELECTROLYTE, thus it will conduct
electricity (or the electron flow). Therefore, the electrons will flow from
the +ve (Anode) area to the –ve areas (Cathode) on the ship’s hull. The
loss of electrons from the metal +ve areas leads to its dissolution or
corrosion at the +ve area. The chemical reaction that takes place is
explained below. Therefore, in order to prevent corrosion from taking
place, the entire ship’s hull should be made Cathodic and thus prevent
this electron flow. This is done by the ICCP system.

Chemical reaction causing corrosion

The hull plates or Iron Fe is split into +ve and –ve ions. Due to this, the
seawater is split into +ve Hydrogen(H) ions and –ve Hydroxyl (OH) ions.

OH- - (-ve ions) combines with FE++ (+ve ions) to give FE(OH)2 or Ferrous
Hydroxide.

The Oxygen (O2) dissolved in the seawater further oxidises the Ferrous
Hydroxide to produce FERRIC HYDROXIDE. THIS IS “RUST” or
FE(OH3).
In the above figure, Lead or Platinised Titanium are used for the ANODES. These
anodes are insulated from the hull of the ship. A current is sent to these anodes via
MANUAL or AUTO modes (normally about 20A), making the anodes MORE +VE
WRT THE SHIP’S HULL. This would then make the electrons flow towards the hull
of the ship, thus preventing rusting. It should be noted, that if operated in manual
condition, the current should not be kept too high as it would damage the hull paint
and cause it to flake increasing the chances of rusting.

In the AUTO mode, for proper protection to happen, a means to determine how –
ve the hull is, either ZINC or SILVER are used as REFERENCE ANODES.

OUTSIDE WATER, Zinc is -450mV wrt the hull (Fe)

Silver is +600mV wrt the hull

For satisfactory protection, the protection current WILL MAKE THE HULL 200mV
MORE NEGATIVE.

THEREFORE IN SEAWATER,
Zinc is effectively -250mV wrt the hull(Fe)
Silver is effectively 800mV more +ve wrt the hull

These give the feedback signal to the Electronic regulator which in turn gives the
signal to the Control Amplifier to either INCREASE the protection current or
DECREASE it accordingly.

For example, if the Hull becomes LESS –VE, in other words, more Anodic in nature,
the Protective Anodes are made correspondingly more +ve and therefore in
relation, making the hull appear more –ve. The –ve Hydroxyl ions that were earlier
attracted to the +ve(Anodic) areas of the hull are now attracted to the more +ve
anodes and thus rusting is prevented.

Q: Why is Lead (Pb) mostly used as an Anode?

A: It is cheaper than Platinized Titanium,
It does not dissolve in water
It is not affected by the Chemical reaction and therefore last longer
Q: What would happen if REFERENCE ANODES are non functional?
A: If they are non functional, there is no feedback given to control amplifier for
regulation of the protecting current. Therefore there may be extra current
provided when not needed and can cause flaking of the hull paint or
conversely, less protective current may be supplied thus under protecting the
ship’s hull and corrosion will take place.