IMPRESSED CURRENT CATHODIC PROTECTION AUTOMATIC SYSTEMS FOR SHIPS HULLS
THE CORROSION PROCESS
Corrosion is a spontaneous electrochemical process in which a metal reacts with its environment to form an oxide or other compound, the commonest example being the pitting and rusting of steel. This undesirable process is initiated by the formation of a corrosion cell which has three essential components: an anode and a cathode coupled in an electrically conductive solution (electrolyte).
CORROSION CELL
Corrosion always develops at the anode, where current leaves the metal and enters the electrolyte, whilst a protective effect occurs at the cathode. Thus if the whole metal surface is made sufficiently Corrosion Cell cathodic, corrosion will not occur. This is the basic principle of Cathodic Protection. In marine structures, such corrosion cells may Current Flow result from the use of dissimilar metals. Usually, Rust Cathode however, localised anodic and cathodic areas arise on the surface of the same metal through Corroding Anode differences in the metal itself, variations in protective films or changes in the electrolyte. ie: aeration, temperature and salinity.
Electron Flow Corrosion may be prevented by removing one or more of these corrosive elements and for marine structures, the most practicable method is to apply a protective coating, thus introducing an electrical resistance between the metal and the electrolyte. Paint in various forms normally provides the first level of protection. However, even the most efficient coatings are subject to defects during application or service, with inevitable corrosion of the exposed metal.
It is therefore generally accepted that cathodic protection, in conjunction with a high performance paint system provides the most effective and economic safeguard against corrosion.
MG Duff International Ltd. 1 Timberlaine Estate, Gravel Lane, Quarry Lane, Chichester, West Sussex. PO19 8PP Tel: 00 44 [0] 1243 533336 Fax: 00 44 [0] 1243 533422 Email: sales@[Link]
CATHODIC PROTECTION
A technique for preventing corrosion which is the most important of all methods used to control corrosion of marine structures, including ships hulls. The essential factor in cathodic protection is to ensure that the unwanted anodic reactions are suppressed by the application of an opposing current. This opposing current can be achieved by either of two techniques: 1. Sacrificial Anodes - By corroding away a more reactive (base) metal.
Anodes based on alloys of Zinc, Aluminium and occasionally Magnesium, are attached to the structure and corrode in preference to the protected metal. Consequently these anodes require renewal at routine intervals.
2.
Impressed Current - A protective current is impressed on the structure through semi-inert anodes.
The M G Duff system converts the ships a.c. supply into a controlled low voltage d.c. output, which is then delivered onto the metal surface by long life anodes attached to, but insulated from the hull structure. Various factors affect the amount of current required, therefore to ensure the correct level of protection is CONTROL accurately controlled it is necessary to PRESET measure the potential of the steel against a LEVEL known and reliable reference cell. REFERENCE This potential is monitored by reference ELECTRODE electrodes mounted on the underwater hull surface. The number of electrodes and their TRANSFORMER locations is carefully selected in conjunction RECTIFIER with the anode configuration and hull SEA (ELECTROLYTE) geometry. Solid state circuitry within an automatic control unit compares the reference potential against a desired and ANODE pre-set optimum. Any difference between CATHODE these will induce a resultant error signal, (STRUCTURE) which is electronically conditioned to provide suitable regulation of the d.c. power supply to the anodes.
ANODES P.1 & S.1 PORT ELECTRODE R.1 ANODES P.2 & S.2
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SHIPS AC SUPPLY 440V/1PH/60HZ.
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MAIN CATHODE CONNECTION TO ADJACENT FRAME OR HULL MEMBER.
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ST'BD ELECTRODE R.2
MG Duff Impressed Current Cathodic Protection systems are also available for protection of piled jetties, dolphins, sheet piling and similar harbour or offshore structures.
MG Duff International Ltd. 1 Timberlaine Estate, Gravel Lane, Quarry Lane, Chichester, West Sussex. PO19 8PP Tel: 00 44 [0] 1243 533336 Fax: 00 44 [0] 1243 533422 Email: sales@[Link]
AUTOMATIC POWER/CONTROL UNITS
A comprehensive range of high specification units are available as wall mounted models or floor standing arrangements for large capacity systems. The whole range features rugged, sheet steel enclosures with double door protection as standard. Designed for ease of installation, these compact, functional units are fully rated for ambient/operating temperatures between 0-50 C and accept standard a.c. inputs; 380/440 volt; Single or three phase, 50/60Hz Standard Features: ; Protection to IP.42 ; Output ripple: 5% max ; Input circuit breaker: Magnetic trip & Thermal overload ; Fully automatic control with Manual override facility ; Automatic Reference Electrode Selection ; Automatic Current Limiting ; Reference Signal Buffering ; Calibration Feasibility ; Unit Spares Kit Design Options: ; Alarm condition detector ; Shaft bonding condition meter ; R.F. Suppression (meets VDE.0875 Level K & BS.800) ; Remote monitoring and alarm facilities
UNDERWATER COMPONENTS
The whole range of M G Duff anodes and electrodes is manufactured to high performance and low maintenance specifications. Innovative design combines proved cathodic protection materials with advanced plastics technology. High strength uPVC encapsulations resist chemical attack and take advantage of superior insulation characteristics to replace outmoded GRP based systems. Watertight integrity at anode and electrode penetrations is maintained by heavy grade steel housings and cofferdams. Lighter grade assemblies are available for light hull vessels.
ANODES
A wide range of capacities and types achieves a high degree of flexibility. Manufactured with active elements of Lead Silver alloy with platinised bielectrodes or Mixed Metal Oxide on a titanium substrate, the whole range anticipates a normal service life in excess of 10 years. To ensure effective current distribution and avoid coating damage adjacent to the anodes, all M G Duff anodes are complemented by a durable primary dielectric shield. This shield comprises a trowelled on mastic which completely eliminates the complicated and time consuming brackets and frames required for installation of pre-formed GRP shields.
REFERENCE ELECTRODES
These flush mounted sensors are manufactured from high purity zinc alloy to provide a robust, non passivating reference source, with the distinct advantage of reliability under the variable conditions encountered in marine environments.
MG Duff International Ltd. 1 Timberlaine Estate, Gravel Lane, Quarry Lane, Chichester, West Sussex. PO19 8PP Tel: 00 44 [0] 1243 533336 Fax: 00 44 [0] 1243 533422 Email: sales@[Link]
BONDING SYSTEMS
M G Duff Shaft Earthing Systems meet the requirements of BS Code of Practice CP.1021 as well as major engine manufacturers recommendations. High efficiency silver tracked Sliprings and silver graphite brushes effectively extend cathodic protection to exposed propeller and shaft surfaces whist at the same time reducing spark erosion damage to shaft bearings. (A more economic, but less efficient copper based version is available). The effectiveness of the shaft bonding may be monitored by an optional Shaft Condition Monitor. Rudder and stabiliser bonding cables are provided as standard
SYSTEM CONTROL AND PERFORMANCE
All metals immersed in an electrolyte have a potential relative to the electrolyte and the reference half cell (electrode). The table lists the natural potentials in a sea water electrolyte of the various metals Zn Ag/Ag/Cl used in ship construction, relative to both a - 0.55 V. - 1.6 V. silver/silver chloride (Ag/AgCI) reference electrode, which is used for test purposes by - 0.45 V. - 1.5 V. Magnesium anodes corrosion engineers, or a zinc reference - 0.35 V. - 1.4 V. electrode used as part of an impressed current - 0.25 V. - 1.3 V. system. - 0.15 V. - 1.2 V. The installation of a cathodic protection system, whether by means of sacrificial anodes or an - 0.9 V. + 0.15 V impressed current system, alters the potential of Zone of cathodic protection - 0.8 V. + 0.25 V the protected metals. It is this change in for mild steel in seawater. potential which can be detected by the reference + 0.35 V - 0.7 V. electrode (sensing electrode) which allows an + 0.45 V - 0.6 V. Freely corroding mild steel impressed current system to be automatically + 0.55 V - 0.5 V. Bronze with Cathodic Protection controlled. Much work has been done by many + 0.65 V. - 0.4 V. authorities on determining the correct potential Bronzes + 0.75 V. - 0.3 V. required for complete protection from corrosion. Copper Nickel Alloys + 0.85 V - 0.2 V. Based on this information and our own Stainless steel 304 Passive + 0.95 V - 0.1 V. experience, we have produced the Potential Monel Stainless steel 316 Passive + 1.05 V 0.0 V. Table, from which it can be seen that freely + 1.15 V + 0.1 V. corroding steel displays a natural potential of +0.45 to +0.55 volts, with respect to a zinc reference electrode. However, the application of cathodic protection will depress this potential into the range +.0.30 to +0.20 volts when all corrosion is suppressed.
+ 0.05. - 1.0 V. Aluminium with Cathodic Protection - 0.05 V. Aluminium with Cathodic Protection - upper limit Aluminium Alloy Anodes Zinc Alloy Anodes - 1.1 V.
The M G Duff Automatic Impressed Current System of cathodic protection is supplied with zinc reference 40Amps 500mV electrodes which monitor the potential of the steel hull and adjust the automatic 1. Navy Vessel 30Amps controller to maintain the hull at the correct 350mV pre-set protected potential. This is Ideal Protection Zone 20Amps indicated on the Performance Graphs which show two examples of automatic controls. 200mV Anode Current 10Amps (1) Navy Vessel. Wide variation in anode current output (5-28 amps) as vessels speed alters, but only slight variation of potential. Well within the protective zone. (2) Tanker. Again wide variation in anode current output (0-300 amps) as vessel goes to sea or returns to port. Variation of potential is greater than with the navy vessel due to the vessel entering a fresh water river, when the system is virtually shut off automatically by the high resistivity of the fresh water electrolyte.
Actual level of protection achieved
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2. 40,000 DWT Oil Tanker
300Amps 350mV 200Amps 200mV 100Amps
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MG Duff International Ltd. 1 Timberlaine Estate, Gravel Lane, Quarry Lane, Chichester, West Sussex. PO19 8PP Tel: 00 44 [0] 1243 533336 Fax: 00 44 [0] 1243 533422 Email: sales@[Link]