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    S0600-AA-PRO-190: Cathodic Protection Systems

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    Leonardo
    This document provides guidance on inspection and repair of cathodic protection systems on naval vessels. It describes the principles of corrosion and cathodic protection, and gives procedures for planning inspection and repair tasks. The document outlines inspection of anodes, reference cells, and dielectric shields using diving techniques. It also provides repair procedures for replacing damaged anodes, reference cells, and repairing dielectric shields using underwater epoxy and sandblasting. Safety precautions are included for working on cathodic protection systems while diving.

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    S0600-AA-PRO-190: Cathodic Protection Systems

    Uploaded by

    Leonardo
    388 views64 pages
    This document provides guidance on inspection and repair of cathodic protection systems on naval vessels. It describes the principles of corrosion and cathodic protection, and gives procedures for planning inspection and repair tasks. The document outlines inspection of anodes, reference cells, and dielectric shields using diving techniques. It also provides repair procedures for replacing damaged anodes, reference cells, and repairing dielectric shields using underwater epoxy and sandblasting. Safety precautions are included for working on cathodic protection systems while diving.

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    Manual Protección Catódica US Navy.

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    Protección Catódica

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    This document provides guidance on inspection and repair of cathodic protection systems on naval vessels. It describes the principles of corrosion and cathodic protection, and gives procedures for planning inspection and repair tasks. The document outlines inspection of anodes, reference cells, and dielectric shields using diving techniques. It also provides repair procedures for replacing damaged anodes, reference cells, and repairing dielectric shields using underwater epoxy and sandblasting. Safety precautions are included for working on cathodic protection systems while diving.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    388 views64 pages

    S0600-AA-PRO-190: Cathodic Protection Systems

    Uploaded by

    Leonardo
    This document provides guidance on inspection and repair of cathodic protection systems on naval vessels. It describes the principles of corrosion and cathodic protection, and gives procedures for planning inspection and repair tasks. The document outlines inspection of anodes, reference cells, and dielectric shields using diving techniques. It also provides repair procedures for replacing damaged anodes, reference cells, and repairing dielectric shields using underwater epoxy and sandblasting. Safety precautions are included for working on cathodic protection systems while diving.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 64
    At a glance
    Powered by AI
    The key takeaways are the principles of corrosion and cathodic protection systems, including galvanic series and impressed current protection.

    Cathodic protection systems are used to protect metal surfaces from corrosion by making them the cathode of an electrochemical cell.

    Galvanic systems use more electronegative 'anodes' to protect metal structures, while impressed current systems use an external power source to induce a current that protects structures. The galvanic series indicates how metals behave in the cell.

    S0600-AA-PRO-190

    0910-LP-730-7400

    UNDERWATER SHIP HUSBANDRY MANUAL

    CHAPTER 19 CATHODIC PROTECTION SYSTEMS

    DISTRIBUTION STATEMENT A: This document has been approved for public release and sale; its distribution is unlimited.

    Published by direction of Commander, Naval Sea Systems Command

    15 JUNE 1997

    S0600-AA-PRO-190

    LIST OF EFFECTIVE PAGES

    Page No.

    * Change No. Page No.

    * Change No.

    Title and A . . . . . . . . . . . . . . . . . . . . . . . . 0 Certification Sheet . . . . . . . . . . . . . . . . . . 0 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Flyleaf-1 (Flyleaf-2 blank) . . . . . . . . . . . . 0 i through iii . . . . . . . . . . . . . . . . . . . . . . . . 0 iv blank . . . . . . . . . . . . . . . . . . . . . . . . . . 0 v through viii . . . . . . . . . . . . . . . . . . . . . . 0

    19-1 through 19-11 . . . . . . . . . . . . . . . . . 0 19-12 blank . . . . . . . . . . . . . . . . . . . . . . . 0 19-13 through 19-41 . . . . . . . . . . . . . . . . 0 19-42 blank . . . . . . . . . . . . . . . . . . . . . . . 0 A-1 through A-2. . . . . . . . . . . . . . . . . . . . 0 B-1 through B-8. . . . . . . . . . . . . . . . . . . . 0

    NAVSEA TECHNICAL MANUAL CERTIFICATION SHEET


    Certification Applies to: Applicable TMINS/Pub. No. New Manual
    X

    1
    Change

    of

    Revision

    S0600-AA-PRO-190

    Publication Date (Da, Mo, Yr) 15 June 1997 Title: Chapter 19, Cathodic Protection

    TMCR/TMSR/Specification No.: CHANGES AND REVISIONS: Purpose:

    Equipment Alteration Numbers Incorporated: TMDER/ACN Numbers Incorporated: Continue on reverse side or add pages as needed.

    CERTIFICATION STATEMENT
    This is to certify that responsible NAVSEA activities have reviewed the above identified document for acquisition compliance, technical coverage, and printing quality. This form is for internal NAVSEA management use only, and does not imply contractual approval or acceptance of the technical manual by the Government, nor relieve the contractor of any responsibility for delivering the technical manual in accordance with the contract requirement.
    Authority Acquisition Name Signature Organization Code Date

    M. S. DEAN A. BLAKEY

    NAVSEA

    00C5

    Technical

    NAVSEA

    00C57

    Printing Release

    DERIVED FROM NAVSEA 4160/8 (5 - 89)

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    RECORD OF CHANGES
    CHANGE NO. DATE OF CHANGE ENTERED BY

    TITLE AND/OR BRIEF DESCRIPTION

    Flyleaf-1/(Flyleaf-2 blank)

    S0600-AA-PRO-190

    TABLE OF CONTENTS
    Paragraph SECTION 1 INTRODUCTION 19-1.1 19-1.2 19-1.3 19-1.4 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1 APPLICABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1 PRINCIPLES OF CATHODIC PROTECTION SYSTEMS . . . . . . . . . . . . . . . . . . . 19-1 19-1.4.1 19-1.4.2 19-1.4.3 19-1.4.4 19-1.4.5 19-1.4.6 Theory of Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1 The Galvanic Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1 The Principle of the Impressed Current Cathodic Protection System. . 19-2 Anti-Corrosion Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 Hull Areas Most Likely to Corrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 The Hull-Mounted Components of the ICCP System . . . . . . . . . . . . . . 19-3 Page

    SECTION 2 PLANNING AND PREPARATION 19-2.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9 19-2.1.1 19-2.1.2 19-2.2 19-2.2.1 19-2.2.3 19-2.2.4 19-2.2.5 19-2.3 19-2.4 19-2.5 19-2.6 19-2.7 19-3.1 19-3.2 Isolation of the ICCP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9 Identifying the Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9 Ship Drawing Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9 Technical Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10 Military Specifications and Standards. . . . . . . . . . . . . . . . . . . . . . . . . 19-10 Records and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10

    REFERENCE DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9

    SHIP CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10 INSPECTION DIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10 CHOOSING THE APPROPRIATE ANODE REPLACEMENT PROCEDURE . . . 19-11 TYPICAL REPAIR TASK DURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-11 TOOLS, MATERIALS, AND EQUIPMENT REQUIREMENTS. . . . . . . . . . . . . . . 19-11 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-13 INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-13 19-3.2.1 19-3.2.2 Inspection Dive Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-13 Anode and Dielectric Shield Inspection . . . . . . . . . . . . . . . . . . . . . . . 19-15

    SECTION 3 INSPECTION

    SECTION 4 REPAIRS 19-4.1 19-4.2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-17 ANODE REMOVAL AND REPLACEMENT PROCEDURE - DRY. . . . . . . . . . . . 18-17

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    19-4.2.1 19-4.2.2 19-4.3 19-4.3.1 19-4.3.2 19-4.4 19-4.5 19-4.6

    Anode Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-17 Anode Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-23 Anode Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-26 Anode Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-30

    ANODE REMOVAL AND REPLACEMENT PROCEDURE - WET . . . . . . . . . . . 19-26

    REFERENCE CELL REMOVAL AND REPLACEMENT PROCEDURE. 32 DIELECTRIC SHIELD REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-38 POST-REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-41

    APPENDIX A: UNDERWATER EPOXY PAINTS APPENDIX B: SETUP AND OPERATION OF THE SANDBLASTER

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    LIST OF ILLUSTRATIONS
    Figure 19-1 19-2 19-3 19-4 19-5 19-6 19-7 19-8 19-9 Page Electromechanical Corrosion Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 Basic Impressed Current Cathodic Protection System . . . . . . . . . . . . . . . . . . . . . . . . 19-3 Impressed Current Cathodic Protection System Units . . . . . . . . . . . . . . . . . . . . . . . . . 19-4 Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-5 Reference Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7 Capastic Dielectric Shield for a 4-Foot Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8 Diver Hull Inspection Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-14 Anode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-19 Anode Gland Assembly Internal Blanking Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-21

    19-10 External Blanking Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-23 19-11 Reference Cell and Gland Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-33 19-13 Blanking Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-36 19-14 Guide Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-37

    LIST OF TABLES
    Table 19-1 19-2 19-3 Page Materials for Anode Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-18 Materials for Reference Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-32 Material for Dielectric Shield Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-39

    19-12 High Hat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-35

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    SAFETY SUMMARY
    GENERAL SAFETY PRECAUTIONS. The following general safety precautions supplement the specific warnings and cautions throughout this chapter. These general precautions are related to the task of underwater maintenance of ship fitted Impressed Current Cathodic Protection (ICCP) systems. In addition to the following precautions, personnel must be familiar with and observe safety precautions set forth in the following publications. a. Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 (series). b. Naval Ships (NSTM). Technical Manual Equipment in Motion. Remain clear of equipment in motion. A safety watch shall be posted if equipment requires adjustment while in motion. The safety watch shall have full view of operations and immediate access to controls that can stop the equipment. If at any time the auxiliary propulsion unit appears to be moving out of control, stop equipment immediately. Limit Switches and Interlocks. Limit switches and interlocks are provided to protect personnel and equipment. They should not be overridden or modified except by an authorized person. Do not depend solely upon limit switches for protection. Disconnect power at the power distribution source before adjusting limit switches if possible. First Aid. Attend to all injuries, however slight, by obtaining first aid or medical attention immediately. Resuscitation. Personnel working with or near high voltage shall be familiar with approved resuscitation methods. Begin resuscitation immediately if someone is injured and stops breathing. A delay could cost the victims life. Resuscitation procedures shall be posted where electrical hazards exist. Minimizing Relative Motion. Test Equipment. Make certain electrical test equipment is in good condition and personnel are familiar with its safe operation. Handheld test equipment must be grounded, if possible, to prevent shock injury. Since some types of equipment cannot be grounded, avoid holding them to prevent injury. Relative motion is the movement of two or more objects in relation to each other. This poses unique hazards to divers. A common example is a nest of ships swaying and bouncing against each other due to wind and wave action. This motion would easily crush a diver caught between the two ships. To reduce the hazards of relative motion and to simplify the

    c. Technical/operating manuals for equipment. d. U.S. Navy Diving Manual, Volume I, NAVSEA 0944-LP-001-9010. Do Not Repair or Adjust Alone. Do not repair or adjust energized equipment alone. The presence of a qualified individual capable of rendering aid is required. Always protect against grounding hazards and make adjustments with one hand free and clear of equipment. Be aware that even after equipment has been de-energized, dangerous electrical hazards can exist due to capacitors retaining electrical charges. Circuits must be grounded and capacitors discharged.

    S0600-AA-PRO-190

    task, suspend the work platform and rigging from fittings on the ship. WARNINGS AND CAUTIONS. Specific warnings and cautions appearing in this chapter are summarized below for emphasis and review. The page number where each warning or caution appears is given in parentheses following the warning or caution. WARNINGS

    Op e r a t o r s o f s a n d b l a st i n g equipment must be familiar with and observe the Warnings an d C a u ti on s co n ta in e d i n Appendix B to this chapter (pages 19-22, 19-29, and 1936). Divers must wear protective headgear and breathing apparatus while sandblasting inside the habitat (page 19-22). Epoxies, paints, and solvents are toxic and can cause serious injury to eyes and skin. Wear protective goggles, coveralls, and impervious rubber gloves during mixing and application. Epoxies, paints, and solvents emit toxic fumes. Ensure adequate ventilation for personnel during mixing, application, or cl e a n u p o f to x i c m a t e r i a l s (pages 19-24, 19-30, and 1937). Im p r o p e r u s e o f t h e s a n d blaster can be extremely hazardous (pages B-1 and B-5). Always depressurize the blast tank whenever the unit is left unattended (pages B-1 and B-5). For safe operation the deadman control switch should be located not more than 6 inches from the blast nozzle coupling (page B-2). To prevent the operator from receiving static electricity generated by the abrasive flow, the blast tank must be grounded (page B-3). Topside personnel must wear ear and eye protection when

    Underwater electrical equipment must be secured while divers are working over the side. Hull deterioration is most severe while the ICCP system is de-energized and the effects are irreversible. The appropriate zone of the ships ICCP system must be secured, ta gg ed o ut , an d con fi rm e d secure d before diver s may work on an ICCP device (anode, dielectric shield, or reference cell). When divers are required to work in close proximity to an active ICCP anode and risk o f contact with a n anode exists, that part of the system must be secured. In other than these situations the ICCP system is to remain active. Divers working within 15 feet of an active system must wear a full dry suit, unisuit, or wet suit with hood and gloves. Clear communications among divers, surface personnel, and inboard ships force personnel are crucial for safe and effective coordination of tasks and the maintenance of watertight integrity at through-hull penetration sites (pages 19-17, 1926, 19-32, and 19-39).

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    o p e r a t i n g t h e s a n d b l a st e r (pages B-5). Do not exceed 120 psi inlet air pressure (pages B-3 and B-5). To prevent serious personnel injury, Exercise extreme caution when working around the sandblaster when the tank is pressurized (pages B-3 and B-4). To prevent serious personnel i n j u r y, c h e c k t h e s e a l i n g plunger and sealing O-ring from a safe distance (pages B-3 and B-5). To prevent serious personnel injury and equipment damage, do not point the blast nozzle at personnel or equipment (pages B-4 and B-6). Wearing a Mark 21 helmet, the maximum allowable time for a d i ve r to o p e r a te th e sa n d blaster is five hours (page B-5). Im p r o p e r u s e o f t h e s a n d blaster can be extremely hazardous (page B-5). To prevent the operator from receiving static electricity generated by abrasive flow, ensure that the blast tank is properly grounded (page B-5). Never shut off the main air supply to the blast tank until the tank is completely depressurized (page B-8). To prevent serious personnel injury, ensure that the main air supply valve is shut and the air supply hose is depressurized before disconnecting (page B-8).

    CAUTIONS It is essential that all tools and materials brought to the underwater job site are accounted for and removed at the completion of the job. Tools and materials inadvertently left at the job site can generate unacceptable noise and possibly cause seve r e da m a g e to sh i pb o a r d components. Locally generated work packages shall ensure that a general tool and material log sheet is prepared and maintained during all UWSH operations (page 19-11). Removal of the anode requires removal of at least some of the dielectric shield around the anode. Great care should be taken to avoid cracking or otherwise damaging the existing shield. Additional shield damage will require removal and subsequent additional application of epoxy (pages 19-21 and 19-28). The exposed anode securing studs are used to mount the replacement anode, and must not be damaged during sandblasting or repair of the dielectric shield (pages 19-22 and 1928). Uneven or extreme tightening of securing bolts will shatter the ceramic surface of the anode (pages 19-24 and 19-30). The careful application and successful bonding of Capastic epoxy is crucial to the repair (pages 19-25 and 19-30).

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    Do not tighten the packing nut down onto the top of the anode hub. If the correct number of packing rings have been fitted properly, this should not be possible (pages 19-25 and 1931). Capastic epoxy must be fully cured before the ICCP system is tested (page 19-25). Epoxy resin must be fully cured be for e th e IC CP syst em i s tested. Depending on ambient water temperatures, this could take several days (page 1931). Particular care must be exercised to protect the anode from damage during sandblasting (page 19-40). Do not overtighten the blast nozzle when installing it on the

    hose end threaded fitting. Do not use a wrench to tighten (page B-1). The carbide nozzle is very fragile and shatters easily. Do not drop or mishandle it (pages B-4 and B-6). To prevent accelerated wear on the plunger face and O-ring, do not overfill the blast tank w i t h a b r a si v e . T h e r e c o m mended level is no higher than the bottom edge of the sealing plunger (pages B-4 and B-7). To p r e v e n t t h e h o s e f r o m becoming clogged with abrasive, do not release the operating handle on the deadman switch until all abrasive has been discharged from the nozzle (page B-7).

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    CHAPTER 19 CATHODIC PROTECTION SYSTEMS SECTION 1 INTRODUCTION


    19-1.1 PURPOSE. This chapter provides commands with the technical information and NAVSEA-approved procedures for the underwater maintenance of the hull-mounted components of ship fitted Impressed Current Cathodic Protection (ICCP) systems. Strict adherence to the contents of this chapter will provide the best assurance that all tasks are completed safely and efficiently. 19-1.2 SCOPE. The ICCP system is one of two equipment systems that use the principle of cathodic protection to combat the electrochemical effects of hull corrosion. The underwater maintenance of the other cathodic protection system, the Sacrificial Cathodic Protection system, is not addressed in this chapter. Underwater Ship Husbandry (UWSH) requires standardization of practices to ensure safe and costeffective operations. This chapter provides NAVSEA-approved procedures and standardized instructions for the underwater inspection, cleaning and maintenance of ICCP system reference cells, anodes and dielectric shields. This chapter also provides detailed planning guidance for the installation of new reference cells, anodes, and dielectric shields. This chapter does not supersede information contained in the U.S. Navy Diving Manual or the Naval Ships' Technical Manual (NSTM). 19-1.2.1 This chapter is divided into four sections: an introduction to and description of the ICCP system, planning and preparation, inspection, and repair procedures. 19-1.3 APPLICABILITY. All personnel who are involved with the maintenance of the hull components of the ICCP system must be familiar with the appropriate sections of this chapter. This includes not only the fleet diving lockers, but also the ship- and shore-based maintenance activities responsible for the planning, implementation, and execution of maintenance for the ship-fitted ICCP system. 19-1.4 PRINCIPLES OF CATHODIC PROTECTION SYSTEMS. 19-1.4.1 Theory of Corrosion. The term corrosion refers to the destruction of a metal or alloy by chemical or electrochemical reaction. Corrosion of a ship's metal hull below the waterline is predominantly electrochemical. Corrosion occurs when the conditions are present to form an electrochemical corrosion cell. These conditions are always present on the underwater portion of a ship's metal hull (see Figure 19-1). Variations in the chemistry of metal, both within the same hull metal and between dissimilar hull metals, lead to electropotential differences. Seawater, acting as the electrolyte, links these areas of differing electropotential, forming a corrosion cell. The areas of the hull that are consumed electrochemically in the corrosion cell (releasing electrons to the seawater) are said to be anodic, and the areas of the hull where current reenters the hull are said to be cathodic. Hull corrosion occurs in those areas that are anodic. 19-1.4.2 The Galvanic Series. The rate at which the corrosion of a metal occurs depends to a large extent on the relative electropotentials of the two areas of metal linked in the corrosion cell. Within a given metal this difference

    19-1

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    Figure 19-1. Electromechanical Corrosion Cell.

    is minimal. For dissimilar metals it is much greater. A measure of the electropotential differences between dissimilar metals is given in the Galvanic Series (see NSTM Chapter 633). In a corrosion cell, the metal with the greater negative electrical potential acts as the anode and will corrode. 19-1.4.3 The Principle of the Impressed Current Cathodic Protection System. Anodes strategically positioned on the hull emit an electrical current that suppresses current flow from the anodic areas of the hull, thereby rendering the entire hull cathodic and free from corrosion; hence the term Impressed Current Cathodic Protection (see Figure 19-2). The direct current produced by the power supply is provided to the anode by a conductor housed in a through-hull penetration. The anode is connected to the positive side of the power supply and the hull is connected to the negative side. Hull-mounted reference cells sense the electropotential of the hull which is passed to a power controller to regulate the power supply. The ICCP system continuously

    monitors and controls the current output to provide optimum corrosion protection. Figure 19-3 shows the relationships of the individual ICCP units in a shipboard installation. 19-1.4.4 Anti-Corrosion Paint. The ICCP system is a secondary system of corrosion protection. The primary system is the ships Anti-Corrosion (AC) system of corrosion protection. The AC paint coating acts as an inert barrier preventing the seawater and the hull link-up from forming a corrosion cell. When this protective barrier is breached (i.e. the paint is cracked, eroded, peeled or in some other way damaged), the ICCP system impresses a current into the areas of bare metal to render the metal cathodic and prevent corrosion. 19-1.4.5 Hull Areas Most Likely to Corrode. It is clear that the hull is most at risk in areas where dissimilar metals are found and areas where the paint system is most susceptible to damage. These conditions are found throughout the ship but are particularly evident

    19-2

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    Figure 19-2. Basic Impressed Current Cathodic Protection System.

    around the stern tubes, shafts, propellers, rudders and the surrounding hull plate. 19-1.4.6 The Hull-Mounted Components of the ICCP System. The hull-mounted components of the ICCP system are: a. Anodes. Anodes (see Figure 19-4) used in the ICCP system are constructed of a single continuous platinum-coated tantalum wire rod woven through an insulating glass-reinforced polyester holder. Each anode is bolted on the outside of the ship hull, and has a single hub which projects into the ship, connecting with the power supply through a gland assembly. Anodes are manufactured in 2-foot, 4-foot and 8foot lengths. (The 2-foot anodes are not commonly used.) Typically, 4-foot anodes are found on smaller ships, such as the FFG and DDG classes, while the longer 8-foot anodes are found on the larger ships, such as the LHD and CV classes. The anodes are installed in sets along the hull. An anode set is comprised of two anodes of

    similar type located on opposite sides of the hull at the same frame number and distance above the baseline. A CV may have as many as 16 anodes on each side of the hull. An FFG may have only 6 anodes. NSTM Chapter 633, Cathodic Protection, provides the criteria for locating anodes on the hull. In general, they are located at the same depth, which must be greater than 5 feet below the light load line, in areas of minimum turbulence protected from mechanical damage, at least 15 feet from either a system intake or discharge. b. Reference Cell. The reference cell (see Figure 19-5) is an electrode constructed of a silver mesh screen that has been treated with silver chloride. It is mounted in a domed, 6-inch diameter circular polyvinyl chloride holder that electrically isolates the reference cell from the hull. The reference cell is secured to a base or sole plate by a pattern of screws. A series of holes in the reference cell permits passage of

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    Figure 19-3. Impressed Current Cathodic Protection System Units.

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    Figure 19-4. Anode.

    seawater at the hull, allowing the controller to detect electrochemical activity at the hull and measure the potential of the hull versus the reference electrode. The holes in the reference cell must remain open for the cell to function and should never be covered by paint or epoxy. Reference cells are installed approximately halfway between anodes powered by the same controllerpower supply. One acts as a primary control, while the other serves as an auxiliary to verify operation of the primary cell, verify system operation on both sides of the hull, and provide primary service if the first cell fails. c. Stuffing Tubes. Stuffing tubes are required for impressed current anodes and reference cells to establish

    through-hull watertight electrical connection of cables to pass current to the anodes and to pass voltage signals from the reference cells to the controller. Reference cell stuffing tubes are covered by MIL-S-23920. Anode stuffing tubes are not currently covered by a military specification. Stuffing tubes are supplied with reference cells and anodes as assemblies. If a stuffing tube penetrates into a fluid-filled compartment, such as a fuel tank, bilge, ballast tank or fresh water tank, the stuffing tube and the electrical cable leading to it must be enclosed in a protective cylindrical watertight cofferdam. d. Dielectric Shield. The dielectric shield is a high-solids epoxy coating applied to the hull around each anode (see Fig-

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    ure 19-6). Dielectric shield areas have an inner shield area with a thickness of 100 mils minimum and a thinner outer shield area with a thickness of 22 mils minimum. For 4foot anodes, inner shields extend to areas of 7 feet by 10 feet, and outer shields extend to areas 13 feet by 16 feet, as measured from the anode. For 8 foot anodes, inner shields extend to areas of 7 feet by 14 feet, and outer shields extend to areas 13 feet by 20 feet, as measured from the anode (see Figure 19-6). The dielectric shield prevents shorting of the anode current to

    the hull and aids in wider current distribution to the hull. Dielectric shield material is not covered by a military specification. The current NAVSEAapproved dielectric shield material is Capastic, provided by Engelhard Industries. Capastic, however, can only be applied in dry dock or in a dry chamber (cofferdam). There are underwater epoxies having excellent dielectric capability that can be applied in water to make repairs to damaged shields. Appendix A to this chapter provides a list of approved epoxies.

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    Figure 19-5. Reference Cell.

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    Figure 19-6. Capastic Dielectric Shield for a 4-Foot Anode.

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    SECTION 2 PLANNING AND PREPARATION


    19-2.1 GENERAL INFORMATION. Planning is essential to the successful completion of any underwater ship husbandry task. Proper planning should begin at the earliest possible time, involve all concerned parties, and result in a written operational plan. General planning guidelines are presented in NAVSEA S0600-AA-PRO-020, General Information and Safety Precautions. While each ICCP maintenance task is unique, the requirements of the planning process are identical. The following paragraphs list the requirements that need to be considered. They should be viewed as impacting three resource areas: technical, personnel and organizational. 19-2.1.1 Isolation of the ICCP System. Commands planning ICCP system maintenance tasks must be aware that any break in the ICCP system will result in general corrosion with all its manifestations, even though most of the components may be completely capable of their functions. In general, the ICCP system should remain switched on whenever possible. Guidance for switching off the ICCP system to allow divers to work in the vicinity of ICCP hull fittings is detailed in the U.S. Navy Diving Manual and restated in the safety summary to this chapter. The prudent implementation of this policy will avoid the unnecessary replacement of defective ICCP hull-mounted fittings and reduce the risk of corrosion. 19-2.1.2 Identifying the Task. Components of an ICCP system may be defective for many reasons and the significance of a defect on the overall system effectiveness will vary. It may not be necessary to conduct any maintenance on a component that is clearly defective until the ship dry docks. It is important that the factors relating to a defect are clearly and fully understood; only then can the task be identified and the correct maintenance decision be taken. In this respect a thorough inspection (both internal and external) is vital. ICCP system inspections are addressed more fully in section 3. 19-2.2 REFERENCE DOCUMENTS. Technical information and engineering data essential to proper planning, preparation and execution of ICCP system anode, reference cell, and dielectric shield repairs/replacements are available in a variety of source documents. No single document provides all needed information. Care should be taken to obtain and use the most current version of source documents. They must be used during the planning phase and should be available on site during the conduct of the operation. NAVSEA S0600AA-PRO-020 provides information on obtaining and using technical documents. 19-2.2.1 Ship Drawing Index. The Ship Drawing Index (SDI), maintained in the ship's log room or technical library, lists all the drawings applicable to that particular ship. Drawing numbers are arranged in the SDI by functional groups and they are numerically listed within these groups. The docking plan, shell expansion, and lines drawing may be of particular value. 19-2.2.2 Electrocatalytic, Inc. is the sole provider of U.S. Navy ship fitted ICCP systems. Their address is: Electrocatalytic, Inc., 2 Milltown Court, Union, NJ 07083. The following Electrocatalytic drawings are available on request from NAVSEA 00C5 and are valuable when planning and executing ICCP system repair and replacement: a. 72800, Installation drawing, Anode 2 ft. b. 36460-2L, Installation drawing, Anode 4 ft. c. 36460-2, Installation drawing, Anode 8 ft. d. 35754, Installation drawing, reference electrode assembly.

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    19-2.2.3 Technical Manuals. T h e N a v a l Ships' Technical Manual (NSTM) and other technical manuals provide operation and maintenance information, personnel qualifications, inspection criteria, technical and administrative information, and instructions to assist in managing ship systems and equipment. The technical manuals and other materials ap p l i ca b le f o r IC C P sy ste m r e p a ir a n d replacement are listed below: a. S9086-VF-STM-010, NSTM Chapter 633, Cathodic Protection b. NAVSEA S0600-AA-PRO-160, Underwater Ship Husbandry Manual, Chapter 16, Cofferdams c. NAVSEA S9086-CQ-STM-010, NSTM Chapter 081, Waterborne Hull Cleaning of Navy Ships d. NAVSEA S9086-VD-STM-020, NSTM Chapter 631 Volume 2, Preservation of Ships in Service - Surface Preparation and Painting. e. NAVSEA S9086-CH-STM-030, NSTM Chapter 074 Volume 3, Gas Free Engineering f. NAVSEA S0600-AA-PRO-170, Underwater Ship Husbandry Manual, Chapter 17, Inspection Procedures

    19-2.2.5 Records and Reports. The following records and reports, maintained in the ship's log room, often provide important information on ICCP system components: a. Underwater Repair/Working Reports. b. Ship Maintenance/Repair Records. c. Underwater Hull Inspection Reports. d. Underwater Hull Cleaning Reports. e. Diver Hull Inspection Data Sheet (NAVSEA Form 4730/7). 19-2.3 SHIP CHECK. A ship check is required to establish liaison with the ships Engineering Officer and the work center with responsibility for the ICCP system. This allows the planner to retrieve information on conditions that may exist with the ICCP system or an associated system that could affect the success of the repair. The planner should conduct a thorough internal inspection of the repair area for material condition, ease of access, and interference. If the compartment in which the anode or reference cell gland assembly is located is an enclosed compartment, consideration must be given to the requirement of obtaining gas-free access in accordance with NSTM 074 Volume 3, Section 20. In ballast and fuel tanks in particular, temporary scaffolding and lighting may be required. In all situations, portable communications must be established between personnel working at the hull penetration, the dive supervisor, and, if appropriate, a safety sentry who will be positioned at the entrance to the enclosed compartment. An external inspection is required to determine accessibility to the repair area, positioning of the ship and the availability of work area. 19-2.4 INSPECTION DIVE. A thorough inspection dive must be conducted in advance of the repair task. The dive should identify precisely the nature of the reported defect so that a proper assessment of the required maintenance can be developed. Sec-

    19-2.2.4 Military Specifications and Standards. a. OPNAVINST 5100.19 (series), Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat b. SSPC-SP-10, Steel Structures Paint Council, Visual Standards for Abrasive Blast Cleaned Steel c. MIL-E-23919, Electrodes, Reference, Circular, Corrosion Preventive d. MIL-S-24700, Stuffing Tubes for Reference Electrodes, Impressed Current Cathodic Protection

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    tion 3 covers this matter in more detail. The dive should also ascertain conditions at the underwater work site. This is particularly important if the resulting repair may require the use of a habitat. Detailed planning considerations for the use of habitats in support of UWSH are given in NAVSEA S0600-AA-PRO160, Cofferdams. 19-2.5 CHOOSING THE APPROPRIATE ANODE REPLACEMENT PROCEDURE. 19-2.5.1 There are two anode replacement procedures: a dry procedure and a wet procedure. The choice as to which is the most appropriate procedure is governed largely by the dielectric epoxy that is used to fair in the new anode. 19-2.5.2 The dry procedure uses a habitat to enclose the anode, creating a dry environment that permits the use of the epoxy Capastic. The wet procedure does not use a habitat. This precludes the use of Capastic and demands the use of an approved underwater epoxy (see Appendix A). 19-2.5.3 The dry procedure is more costly in both time and expense. The templating, construction, and fitting of the habitat combined with the requirement to maintain a dry environment for the Capastic epoxy to cure, adds approximately 48 hours to the repair task. The disadvantage of the wet procedure is the sensitivity of the underwater epoxy. It must be mixed exactly and the underlying hull prepared precisely. The epoxy, which is difficult to apply, must be adhered to the hull during a very narrow time window between epoxy mixing and hull preparation. Furthermore, underwater epoxy is unlikely to be applied successfully if the ambient temperature is below 50 F. In contrast, successful application of the epoxy Capastic is relatively easy and both cure times and the ease of application are independent of ambient temperature.

    19-2.6 TYPICAL REPAIR TASK DURATION. a. Anodes. Wet Procedure: One anode can be replaced in 2-3 days, dependent on environmental conditions, i.e. epoxy cure times. Dry Procedure: One anode takes 4-5 days. b. Reference Cells. One or two reference cells can be replaced in 2 days. c. Dielectric Shield Repair. Dependent on the extent of damage. 19-2.7 TOOLS, MATERIALS, AND EQUIPMENT REQUIREMENTS. CAUTION It is essential that all tools and materials brought to the underwater job site are accounted for and removed at the completion of the job. Tools and materials inadvertently left at the job site can generate unacceptable noise and possibly cause seve r e da m a g e to sh i pb o a r d components. Locally generated work packages shall ensure that a general tool and material log sheet is prepared and maintained during all UWSH operations. Removal and replacement of ICCP system anodes and reference cells and repairs to dielectric shields require the use of tools, materials, and equipment which should be made available in advance. Table 19-1 (in section 4) provides a listing of the tools, materials, and equipment required for anode replacement. Table 19-2 provides the same for reference cell replacement. Table 19-3 provides the same for dielectric shield repair.

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    SECTION 3 INSPECTION
    19-3.1 GENERAL. Diver inspection of the hull-mounted components of the ICCP system, reference cells, anodes, and dielectric shields is an essential component of the condition-based maintenance of the ICCP system. 19-3.1.1 Regular diver inspections will be conducted when a vessel receives a programmed hull cleaning and on occasions when a systemic failure or other problem indicates a condition that requires underwater examination of the ICCP system. 19-3.1.2 The inspection dive can only be successful if the diver knows what to look for and understands the significance of the findings. A thorough pre-dive brief by a competent person is essential. This should include the relevant information distilled from: (i) a review of the last inspection report (recorded on a Diver Hull Inspection Data Sheet NAVSEA Form 4730/7 (Figure 19-7), which will provide a bench mark for system condition, and (ii) a brief from the ships work center responsible for the ICCP system identifying any known problems. 19-3.1.3 Results from the inspection dive must be recorded on a Divers Hull Inspection Data Sheet NAVSEA Form 4730/7 and if appropriate supplemented by video or still photography. The form should be completed and, along with supporting data, forwarded to the activity requesting the inspection, with a copy for the ship. On occasion the report will indicate that maintenance is required, such as dielectric shield, anode, or reference cell cleaning; dielectric shield repair; or anode and reference cell replacement. Technical guidance to support a proposed maintenance plan can be obtained from Fleet Technical Support Center, Atlantic, 9280 10th Avenue, Norfolk, VA 23511-4396; Fleet Technical Support Center, Pacific, Box 85548, San Diego, CA 921865540; or Naval Sea Systems Command (SEA 03M or SEA 00C5). In such cases all of the above inspection data, along with the relevant data from the ships cathodic protection log (NAVSEA Form 9633/1) and any other relevant data must be made available to the above technical authorities. 19-3.2 INSPECTION PROCEDURES. Procedures for conducting an underwater ship husbandry inspection are provided in NAVSEA S0600-AA-PRO-170, Underwater Ship Husbandry Manual, Chapter 17. The following paragraphs provide supplementary details. Figure 19-7 is an example of NAVSEA Form 4730/7 that is used to record the results of all inspection dives on the ICCP system. A separate sheet of Form 4730/7 shall be used for each anode/shield inspected. 19-3.2.1 Inspection Dive Considerations. The following are the factors and considerations that support the requirements of the Divers Hull inspection data sheet. A review of these considerations will help focus the inspection dive. a. ICCP System Redundancy. Many ship-fitted ICCP systems are designed with a degree of redundancy. By design there are more anodes than are necessary to provide full cathodic protection. The importance of the ICCP system is as a backup to the anti-corrosion (AC) paint scheme. It protects the ships hull from the corrosion cell that could form in the event of a failure of the paint scheme In the free-flood areas both of these conditions are likely to be found. b. Anode Location. Paragraph a. above makes it essential that the location of the anode and the condition of the paint scheme are accurately recorded during an inspection. c. Anode Redundancy. Each anode has a degree of redundancy built in. If less

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    Figure 19-7. Diver Hull Inspection Data Sheet.

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    than 25 percent of the platinum coated tantalum wires are broken, the anode can still function satisfactorily. Similarly, up to 25 percent of each coating of platinum can be missing and each platinum anode will still function correctly. d. Position of Broken Anode Wires. Because each anode wire is a single continuous loop running from the center of the anode to the outer edges, and power to the anode comes from the center, a break in the wire becomes progressively more significant the closer it is to the center. Points c. and d. make it essential that the position of a damaged wire and the total percentage of platinum coating damage are recorded. e. Discoloration in The Dielectric Shield. The dielectric shield varies in color. The dielectric epoxy, Capastic, is gray. If the shield has been repaired underwater it may be another color (such as black). The overlying paint scheme can be many colors and the area of the dielectric shield above and to the stern of the anode may appear bleached (a product of the caustic water chemistry created by the anodes operation). 19-3.2.1.1 All of these patterns and color variations are normal. In the past they have been reported, erroneously, as evidence of electrical burning. 19-3.2.2 Anode Inspection. and Dielectric Shield

    been electrically isolated, i.e. de-energized. b. Conduct a detailed inspection of the anode. (1) Record the Fouling Rating (FR), its nature (soft or hard calcareous, soft or hard marine fouling), and any differential fouling (such as fouling just on the epoxy filler above the anode retaining nuts, or just on the tantalum wires). Inspect the tantalum wires: (a) Ensure that all wires present and count them. are

    (2)

    (b) If wires are damaged (missing, broken, or bent), provide the following details: position of the wire relative to the center of the anode and if the damage is in that portion of the wire that is coated with platinum. (3) Inspect the platinum coating on each wire: (a) Ensure that none of the coating is missing. (b) Ensure that the coating is tightly bonded to the wire. (c) Check for discoloration, peeling, or bonding. Report all defects as a percentage of the total platinum coating. (4) Inspect the glass-reinforced polyester holder: (a) Check for damage, chips, dents, cracks or erosion and report the position relative to the center of the anode.

    a. Begin the inspection procedure by conducting a cursory inspection of the anode, dielectric shield and the immediate hull out to a distance of 20 feet. Identify obvious damage and assess the overall condition of the system. Record how long the anode has

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    (b) Confirm that the plugs of epoxy that cover the anode retaining nuts/bolts are secure and undamaged. c. Conduct a detailed inspection of the Dielectric Shield. (1) Dielectric Shield - Anode Interface. This is the most critical area of the dielectric shield. Examine the area closely. (a) Check that the dielectric shield is evenly faired up to the top flat face of the anode. (b) Confirm that a solid bond exists between the dielectric shield and the anode holder. (c) Check for cracks/chips or other signs of damage in the dielectric shield. (2) Dielectric Shield

    (a) Record the location of all defects in the outer and inner shield. (b) Describe as either cracks, isolated pits/patches, flaking, or eroded, full or partial penetration. (c) Record the dimensions of each defect: total area, width and length. (d) Describe the pattern of cracks: radiating from the anode, circumferential or irregular. (e) Record the location of all fouling in the outer and inner shield (FR). (f) Describe as either hard or soft calcareous fouling or hard or soft marine growth. (g) Record the dimensions of all growth.

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    SECTION 4 REPAIRS
    19-4.1 INTRODUCTION. Divers are able to perform the following maintenance tasks on the hull-mounted components of the ICCP system: a. Anode Replacement: Depending on the particular conditions of the task, this may be conducted either with a habitat, using the dry procedure, or without a habitat, using the wet procedure. b. Reference Cell Replacement c. Dielectric Shield Repair 19-4.1.1 The detailed procedure for each of these repairs is included in this section. NOTE While the following procedures require topside, Ships Force, an d d i ver s t o w o rk clo se l y together, certain steps must be carried out by particular personnel. To clarify these steps, abbreviations are placed at the beginning of each step where the specific party needs to be identified: (DV) rep resents diver, (TOP) represents topside person nel, and (SF) represents Ships Force personnel. 19-4.2 ANODE REMOVAL AND REPLACEMENT PROCEDURE - DRY. 19-4.2.1 Anode Removal. WARNING severe while the ICCP system is de-energized and the effects are irreversible. The appropriate zone of the ships ICCP system must be secured, ta gg ed o ut , an d con fi rm e d secured before diver s may work on an ICCP device (anode, dielectric shield, or reference cell). When divers are required to work in close proximity to an active ICCP anode and risk o f contact with a n anode exists, that part of the system must be secured for the duration of the repair. In other than these situations the ICCP system is to remain active. Divers working within 15 feet of an active system must wear a full dry suit, unisuit, or wet suit with hood and gloves. Clear communications among divers, surface personnel, and inboard Ships Force personnel are crucial for safe and effective coordination of tasks and the maintenance of watertight integrity at through-hull penetration sites. 19-4.2.1.1 The activity conducting the anode removal and replacement shall: a. Ensure all required materials are on hand using Table 19-1 for guidance. b. Coordinate material, technical, and funding requirements. c. Conduct anode replacement training in accordance with Naval Ships Technical Manual, S9086-VF-STM-010/CH633, Cathodic Protection. d. Arrange with the ship for control and disposal of hazardous material.

    Underwater electrical equipment must be secured while divers are working over the side. Hull deterioration is most

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    Table 19-1. Materials for Anode Replacement.


    1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Anode with Gland Assembly Capastic Kit * Approved Epoxy Paint Habitat * Habitat Template * NAVSEA Dwg. No. 6697929 Habitat Upper Section Materials * NAVSEA Dwg. No. 6697929 Rigging for Habitat * Silicone Grease NSN 6856-00-702-4297 Sandblaster Hydraulic Grinder, Right Angle Blanking Plate, Anode Gland Connection Box and Strong Back Blanking Plate, External Scribe, Right Angle Socket Wrench with 1 3/8-inch Socket Crane Torque Wrench, 0-50 ft.-lbs. Forced Air Blower Spare Nuts for Anode Studs (2 per stud) Paraffin

    b. Tag out equipment and systems for conduct of diving operations. c. Control and dispose of hazardous materials as agreed with the performing activity. 19-4.2.1.3. (SF) Defuel and gas free the compartment / tank space in which the anode hull penetration is located, and other compartments as necessary to access the anode connection box. 19-4.2.1.4. (SF) Rig lighting, and establish ladders and scaffolding as necessary to access the anode. 19-4.2.1.5. (SF) If the anode hull penetration is in an enclosed compartment, provide a sentry in the nearest lit, ventilated compartment who is able to maintain verbal contact with working personnel, especially if they are in an enclosed compartment. 19-4.2.1.6. (SF) Verify that the appropriate zone of the ICCP system has been de-energized and tagged out. The rest of the ICCP system should remain energized. NOTE The de-energized zone will remain de-energized and tagged out until the epoxy is cured. 19-4.2.1.7. (SF, TOP, DV) Establish communications between the inboard side of the anode hull penetration (Ships Force sentry), the dive supervisor, and the divers. NOTE The dive supervisor must be satisfied that the preparatory steps 19-4.2.1.3 through 19-

    * Required for anode removal and replacement - dry only

    e. Prepare video and still cameras to document work throughout the procedure. Notify ship of any special precautions required in the performance of removal/replacement. 19-4.2.1.2. The Ships Force shall: a. Ensure that the ship is moored with the affected anode toward the pier.

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    4.2.1.7 have been completed before proceeding. NOTE Templating of the hull, top section construction, rigging and placement of the habitat should be done as early in the procedure as possible, independent of the internal Ships Force actions. Guidance for this task is provided in NAVSEA 0600-

    AA-PRO-016, Underwater Ship Husbandry Manual, Chapter 16, Cofferdams. NOTE Items listed in the following steps refer to the anode assembly shown in Figure 19-8 and the associated Electrocatalytic Anode installation drawing detailed in 19-2.2.2.

    Figure 19-8. Anode Assembly.

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    NOTE The actions in paragraphs 194.2.1.8 through 19-4.2.1.10 are required only if the anode connection box is located within a tank or void space. 19-4.2.1.8 (SF) Remove the cover plate of the anode cell high-hat cofferdam. 19-4.2.1.9 (SF) Remove and inspect the highhat cofferdam gasket. Replace the gasket if necessary. 19-4.2.1.10 (SF) Inspect the inside of the high-hat cofferdam for signs of corrosion or seepage of fuel or water. If there are such signs, determine the cause and if possible, rectify the defect. NOTE If the problem of liquid seepage into the cofferdam can not be corrected, Ships Force should b e n o ti f i e d a n d a d e ci s i o n made whether or not to continue with the anode replacement. If the root cause of a defective anode can not be corre cte d, r epl aceme nt of th e anode is of questionable value. 19-4.2.1.11 (SF) Ensure the ship is tagged out for diving. 19-4.2.1.12 (SF) Remove the electrical connection box cover. 19-4.2.1.13 (SF) Using a scribe or flat blade screwdriver, carefully remove the paraffin from inside of the electrical connection box, if present. Using a forced air blower, melt the remaining traces of paraffin to assist in its removal. Remove the nut, lock washer and disconnect the terminal lug. Then remove the electrical cable, flat washer, second nut, flat washer and insulating washer.

    19-4.2.1.14 (SF) box.

    Remove the connection

    19-4.2.1.15 (SF) Remove the gland gasket. 19-4.2.1.16 (SF) Remove the packing nut using a 1 3/8-inch socket wrench 19-4.2.1.17 (SF) Remove the female prong assembly. 19-4.2.1.18 (SF) Remove the truarc ring. 19-4.2.1.19 (SF) Remove the packing nut. NOTE The Teflon packing rings can not be removed at this stage because of the restrictive force of the anode hub. 19-4.2.1.20 (SF) Inspect the internal bore of the anode gland for corrosion and roughness. Clean as necessary. Coat the anode gland body with silicone grease. 19-4.2.1.21 (SF) Fit the anode gland assembly internal blanking plate (Figure 19-9). Open and shut the vent valve of the blanking plate. 19-4.2.1.22 (TOP, DV) Rig and lower the habitat template to the hull and adjust dowels to fit the anode location site. Return template to the surface and use measurements taken to construct the top section of the habitat. 19-4.2.1.23 (TOP, DV) Rig and lower the completed habitat to the hull and secure. Dewater the habitat to create a dry environment. 19-4.2.1.24 (DV) Remove the fairing epoxy from the anode securing nuts, using a hammer and chisel. Two-foot anodes have four mounting holes for the threaded weld studs and securing hex nuts. Four-foot anodes have 8 mounting holes for the threaded weld studs and securing hex nuts. Eight-foot anodes have 16 mounting holes for studs, nuts, and washers. 19-4.2.1.25 (DV) Working from the center outward, loosen hex nuts, one turn at a time.

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    Figure 19-9. Anode Gland Assembly Internal Blanking Plate.

    19-4.2.1.26 (DV) Completely remove all hex nuts and washers. CAUTION

    Removal of the anode requires removal of at least some of the dielectric shield around the anod e. G re a t car e sho ul d b e taken to avoid cracking or otherwise damaging the existing shield. Additional shield damage will require removal and subsequent additional application of epoxy.

    19-4.2.1.27 (DV) Using the right angle hydraulic grinder, grind out a band approximately 2 inches wide from the dielectric shield around the anode. If the dielectric shield has been damaged or is delaminating, it may be necessary to remove a wider band. It is important that the remaining shield present a well bonded surface to which the new epoxy can be married. NOTE Four-foot anodes weigh approximately 20 pounds. Eightfoot anodes weigh approximately 30 pounds. Both can be moved underwater by divers

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    without additional lifting equipment. 19-4.2.1.28 (DV) Using wooden wedges as appropriate, remove the anode from the hull. Recover the anode to the surface. 19-4.2.1.29 (DV) Pass the anode to the divers for transport to the habitat. Fit the anode loosely over the studs to ensure it fits correctly. If it does not, mark the top of the anode where it rubs and return it to the surface. If necessary, carefully file away the minimum amount of ceramic necessary to fit the anode over the studs. (See Figure 19-8.) On completion, make sure that the washers on the studs still provide adequate overlap on the enlarged hole. 19-4.2.1.30 (DV) Fit and secure the external anode gland assembly blanking plate. (See Figure 19-10.) Locating the predrilled holes of the blanking plate over the two studs on either side of the anode hull penetration, fit a nut to each stud and tighten with a torque wrench to 10 ft.-lbs. CAUTION The exposed anode securing studs are used to mount the replacement anode and must not be damaged during sandblasting or repair of the dielectric shield. 19-4.2.1.31 (DV) Thread two nuts on each of the exposed anode securing studs. The nuts will protect the stud threads. 19-4.2.1.32 (SF) Remove the internal blanking plate. 19-4.2.1.33 (SF) Noting both the number and original fitted order, remove the old Teflon rings with a right-angled or hook scribe.

    19-4.2.1.34 (SF) Clean the anode gland using clean dry rags, and if necessary, a handheld forced air blower. 19-4.2.1.35 (SF) The packing rings come taped together. Remove the plastic tape holding the Teflon packing rings and apply a layer of silicone grease to the outside and inside surfaces of the rings. Do not change the arrangement of the rings from the order in which they were originally taped. Insert all the packing at once into the body of the gland. The thick square end ring is placed inboard and the thin square ring is outboard. 19-4.2.1.36 (SF) Insert the packing nut into the gland and tighten until the nut just touches, but does not compress, the Teflon packing. 19-4.2.1.37 (SF) Refit the anode gland internal blanking plate and close the vent valve. 19-4.2.1.38 (DV) Remove the external blanking plate and fit two protection nuts to each of the anode studs adjacent to the hull penetration. Fit a presoaked DC plug, for secondary protection, into the anode gland. WARNING Op e r a t o r s o f s a n d b l a st i n g equipment must be familiar with and observe the Warnings an d C a u ti on s co n ta in e d i n Appendix B to this chapter. WARNING

    Divers must wear protective headgear and breathing apparatus while sandblasting inside the habitat. 19-4.2.1.39 (DV) Prepare the exposed hull area to receive the replacement anode by sandblasting the bare metal to a near-white metal finish in accordance with SSPC-SP-10.

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    Figure 19-10. External Blanking Plate.

    NOTE Capastic epoxy bonds most effectively to a slightly uneven (roughened) surface. A sandblasted surface is ideal. The edge of the dielectric shield should be faired by the sandblaster to a 20-30 degree angle to receive the epoxy. 19-4.2.1.40 (DV) Sandblast the edge of the existing dielectric shield to create a surface

    suitable for subsequent fairing in of the Capastic epoxy. 19-4.2.2 Anode Replacement. NOTE Apply duct tape layers in patterns that both protect and are easy to remove. 19-4.2.2.1 (TOP) Using duct tape, apply a protective layer of strips sufficient to cover the

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    outboard side of the replacement anode. This will keep epoxy from fouling the anode surfaces. Carefully cut out holes in the tape layer corresponding to the anode securing holes. The anode surface must be protected from epoxy fouling but must also provide accessibility to the securing studs. Fit a protective cover of duct tape over the male probe extending from the anode hub. WARNING

    19-4.2.2.4 (DV) Remove the nuts protecting the anode securing studs. Remove the presoaked DC plug from the anode gland hull penetration. 19-4.2.2.5 (TOP, DV) Place the prepared replacement anode into two watertight plastic bags, and pass the anode to the divers for transport into the habitat. WARNING

    Epoxies, paints, and solvents are toxic and can cause serious injury to eyes and skin. Wear protective goggles, coveralls, and impervious rubber gloves during mixing and application. Epoxies, paints, and solvents emit toxic fumes. Ensure adequate ventilation for personnel during mixing, application, or cleanup of toxic materials. 19-4.2.2.2 (TOP) Cement the neoprene mat to the anode by applying a layer of silicone rubber cement to one mat side and carefully laying that side onto the anode, carefully guiding the anode hub through the mat hub hole. Ensure that the anode hub is not damaged, and the mat holes are aligned with the anode stud holes. The neoprene mat will not completely cover the anode, and there will be an outer margin around the mat where the anode is exposed. Apply a layer of silicone rubber cement around the edge of the neoprene mat hull side, making sure not to plug the aligned stud holes. 19-4.2.2.3 (TOP) Apply a layer of Capastic epoxy to the exposed margin of the anode around the mat, building up this margin to the same height as the neoprene mat. The Capastic should form a frame around and flush with the neoprene mat.

    Epoxies, paints, and solvents are toxic and can cause serious injury to eyes and skin. Wear protective goggles, coveralls, and impervious rubber gloves during mixing and application. Epoxies, paints, and solvents emit toxic fumes. Ensure adequate ventilation for personnel during mixing, application, or cleanup of toxic materials. 19-4.2.2.6 (DV) Remove the prepared anode from the plastic bags. Remove the duct tape covering the male probe extending from the anode hub. Carefully locate the anode over the securing studs so that the anode hub projects into the anode gland hull penetration, and the securing studs project through the anode stud holes. CAUTION Uneven or extreme tightening of securing bolts will shatter the ceramic surface of the anode. 19-4.2.2.7 (DV) Place a washer and hex nut on each securing stud to hold the anode and, starting from the centermost studs, tighten each nut using only moderate torque. Tighten all nuts evenly, waiting several minutes between successive tightenings to permit the Capastic to squeeze against the prepared hull

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    surface and flow out from the back of the anode. Tighten all nuts to a torque of 10 ft.-lbs. CAUTION

    The careful application and successful bonding of Capastic epoxy is crucial to the repair. 19-4.2.2.8 (DV) Press the squeezed Capastic epoxy around the anode evenly, fairing in the anode and marrying the epoxy to the clean, roughened existing dielectric shield edge. Cover all metal hull areas. Add additional Capastic as necessary to completely fill and fair the gap between the old shield and the replacement anode. Evenly fill in any irregular or trimmed areas of dielectric shield so that the integrity of the shield is completely restored. 19-4.2.2.9 (DV) Apply Capastic epoxy to fill the securing nut holes in the tape layer above the anode securing nuts, fairing the epoxy to the upper surface of the anode. When all epoxy has been applied, carefully remove the duct tape from the anode. All epoxy must now cure for 24 hours before being exposed to water. 19-4.2.2.10 (SF) Vent and remove the internal blanking plate. CAUTION Do not tighten the packing nut down onto the top of the anode hub. If the correct number of packing rings have been fitted properly, this should not be possible. NOTE When Teflon is compressed it will creep, i.e. slowly distort and flow away from the compressive force. The Teflon packing rings are the primary watertight

    seal. To ensure that the Teflon rings form an effective watertight seal it is essential that the gl and nut co mpr essin g th e Teflon rings is retightened 24 hours after the initial compression. 19-4.2.2.11 (SF) Tighten the packing nut with a 1 3/8-inch socket wrench until the packing is compressed to the limit. Retighten at intervals until tight and the Teflon has creeped as far as possible. Repeat the operation one hour later and 24 hours later. 19-4.2.2.12 (SF) Assemble two O-rings to the female prong assembly. Lubricate the female prong assembly and O-rings with silicone grease. 19-4.2.2.13 (SF) Install the truarc ring, female prong assembly and packing nut, then tighten down the packing nut. 19-4.2.2.14 (SF) Install the gland gasket and the connection box. 19-4.2.2.15 (SF) Install the insulating washers, washer, nut, washer, anode cable lug (with cable), lock washer, and nut. 19-4.2.2.16 (SF) Install the gasket for the connection box cover and the connection box cover. 19-4.2.2.17 (SF) For protection against water, hull penetrations may have connection boxes fitted with a fill hole. Fill the connection box with paraffin. Insert the pipe plug in the tapped fill hole. 19-4.2.2.18 (SF) Replace the high-hat cofferdam cover (if in a void or tank). CAUTION Capastic epoxy must be fully cured before the ICCP system is tested.

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    19-4.2.2.19 (DV) Enter the habitat after the 24 hour Capastic cure period, and visually inspect the epoxy applications. Confirm that the epoxy has cured and appears properly bonded to the existing dielectric shield. 19-4.2.2.20 (DV) When the Capastic cure has been confirmed, the habitat must be flooded for ICCP system testing, but not removed in case further repairs are necessary. 19-4.2.2.21 (SF) Energize the ICCP system to assure the proper operation of the replacement anode. Procedures for inspection and adjustment of system operation following shutdown and testing replacement anodes are provided in NSTM 633, Section 6. 19-4.2.2.22 (SF, DV) When proper ICCP system operation is confirmed, unrig the habitat from the hull and rerig to the crane for retrieval from the water. Photograph the final repair. Remove the ship tag out for the ICCP system. 19-4.3 ANODE REMOVAL AND REPLACEMENT PROCEDURE - WET. 19-4.3.1 Anode Removal. WARNING

    anode exists, that part of the system must be secured for the duration of the repair. In other than these situations the ICCP system is to remain active. Divers working within 15 feet of an active system must wear a full dry suit, unisuit, or wet suit with hood and gloves. Clear communications among divers, surface personnel, and inboard Ships Force personnel are crucial for safe and effective coordination of tasks and the m a i n t e n a n ce o f w a te r ti g h t integrity at through-hull penetration sites. 19-4.3.1.1 The activity conducting the anode removal and replacement shall: a. Ensure all required materials are on hand using Table 19-1 for guidance. b. Coordinate material, technical, and funding requirements. c. Conduct anode replacement training in accordance with Naval Ships Technical Manual, S9086-VF-STM-010/CH633, Cathodic Protection. d. Arrange with the ship for control and disposal of hazardous material.

    Underwater electrical equipment must be secured while divers are working over the side. Hull deterioration is most severe while the ICCP system is de-energized and the effects are irreversible. The appropriate zone of the ships ICCP system must be secured, ta gg ed o ut , an d con fi rm e d secure d before diver s may work on an ICCP device (anode, dielectric shield, or reference cell). When divers are required to work in close proximity to an active ICCP anode and risk o f contact with a n

    e. Prepare video and still cameras to document work throughout the procedure. Notify ship of any special precautions required in the performance of removal/replacement. 19-4.3.1.2 The Ships Force shall: a. Ensure that the ship is moored with the affected anode toward the pier. b. Tag out equipment and systems for conduct of diving operations. c. Control and dispose of hazardous materials as agreed with the performing activity.

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    19-4.3.1.3 (SF) Defuel and gas free the compartment/tank space in which the anode hull penetration is located, and other compartments as necessary to access the anode connection box. 19-4.3.1.4 (SF) Rig lighting and establish ladders as necessary to access the anode. 19-4.3.1.5 (SF) If the anode hull penetration is in an enclosed compartment, provide a sentry in the nearest lit, ventilated compartment who is able to maintain verbal contact with working personnel, especially if they are in an enclosed compartment. 19-4.3.1.6 (SF) Verify that the appropriate zone of the ICCP system has been de-energized and tagged out. The rest of the ICCP system should remain energized, ionizing the hull which improves the adhesion of aquatic epoxy resins 19-4.3.1.7 (SF, TOP, DV) Establish communications between the inboard side of the anode hull penetration (Ships Force sentry), the dive supervisor, and the divers. NOTE The dive supervisor must be satisfied that preparatory steps 19-4.3.1.3 through 19-4.3.1.7 have been completed before proceeding. NOTE The actions in paragraphs 194.3.1.8 through 19-4.3.1.10 are required only if the anode connection box is located within a tank or void space. 19-4.3.1.8 (SF) Remove the cover plate of the anode high-hat cofferdam. 19-4.3.1.9 (SF) Remove and inspect the highhat cofferdam gasket. Replace the gasket if necessary.

    19-4.3.1.10 (SF) Inspect the inside of the high-hat cofferdam for signs of corrosion or seepage of fuel or water. If there are such signs, determine the cause and if possible, rectify the defect. NOTE If the problem of liquid seepage into the cofferdam cannot be corrected, Ships Force should b e n o ti f i e d a n d a d e ci s i o n made whether or not to continue with the anode replacement. If the root cause of a defective anode can not be corre cte d, r epl aceme nt of th e anode is of questionable value. 19-4.3.1.11 (SF) Ensure the ship is tagged out for diving. 19-4.3.1.12 (SF) Remove the electrical connection box cover. 19-4.3.1.13 (SF) Using a scribe or flat blade screwdriver, carefully remove the paraffin from inside of the electrical connection box, if present. Using a forced air blower, melt the remaining traces of paraffin to assist in its removal. Remove the nut, lock washer and disconnect the terminal lug. Then remove the electrical cable, flat washer, second nut, flat washer and insulating washer. 19-4.3.1.14 (SF) box. Remove the connection

    19-4.3.1.15 (SF) Remove the gland gasket. 19-4.3.1.16 (SF) Remove the packing nut using a 1 3/8-inch socket wrench. 19-4.3.1.17 (SF) Remove the female prong assembly. 19-4.3.1.18 (SF) Remove the truarc ring. 19-4.3.1.19 (SF) Remove the packing nut.

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    NOTE The Teflon packing rings can not be removed at this stage because of the restrictive force of the anode hub. 19-4.3.1.20 (SF) Inspect the internal bore of the anode gland for corrosion and roughness. Clean as necessary. Coat the anode gland body with silicone grease. 19-4.3.1.21 (SF) Fit the anode gland assembly internal blanking plate (Figure 19-9). Open and shut the vent valve of the blanking plate. 19-4.3.1.22 (DV) Remove the fairing epoxy from the anode securing nuts, using a hammer and chisel. Two-foot anodes have 4 mounting holes and securing nuts. Four-foot anodes have 8 mounting holes and securing nuts, while eight foot anodes have 16-mounting holes and securing hex nuts. CAUTION Removal of the anode requires removal of at least some of the dielectric shield around the ano de . Gr e at ca re sh ou ld b e taken to avoid cracking or otherwise damaging the existing shield. Additional shield damage will require removal and subsequent additional application of epoxy. 19-4.3.1.23 (DV) Using the right angle hydraulic grinder, grind out a band approximately 2 inches wide from the dielectric shield around the anode. If the dielectric shield has been damaged or is delaminating, it may be necessary to remove a wider band. It is important that the remaining shield present a well bonded surface to which the new epoxy can be married.

    NOTE Four-foot anodes weigh approximately 20 pounds. Eightfoot anodes weigh approximately 30 pounds. Both can be moved underwater by divers without additional lifting equipment. 19-4.3.1.24 (DV) Using wooden wedges as appropriate, remove the anode from the hull. Transfer the anode to the surface. 19-4.3.1.25 (DV) Fit and secure the external anode gland assembly blanking plate (Figure 19-10). Locating the predrilled holes of the blanking plate over the two studs to either side of the anode hull penetration, fit a nut to each stud and tighten with a torque wrench to a torque of 10 ft.-lbs. CAUTION The exposed anode securing studs are used to mount the replacement anode, and must not be damaged during sandblasting or repair of the dielectric shield. 19-4.3.1.26 (DV) Thread two nuts on each of the exposed anode securing studs. The nuts will protect the stud threads. 19-4.3.1.27 (SF) Open the vent valve on the anode gland internal blanking plug. Seawater which entered the stuffing tube when the anode was removed may be present, but it is important to confirm that there is no leak of seawater from the external blanking plate. When this has been confirmed, close the valve and remove the blanking plate. Evacuate any water in the gland body.

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    19-4.3.1.28 (SF) Noting both the number and original fitted order, remove the old Teflon rings with a right-angled or hook scribe. 19-4.3.1.29 (SF) Clean the anode gland using clean dry rags, and if necessary a hand-held forced air blower. 19-4.3.1.30 (SF) Remove the plastic tape holding the Teflon packing rings and apply a layer of silicone grease to the outside and inside surfaces of the rings. Do not change the arrangement of the rings from the order in which they were originally taped. Insert all the packing at once into the body of the gland. The thick square end ring is placed inboard and the thin square ring is outboard. 19-4.3.1.31 (SF) Insert the packing nut into the gland and tighten until the nut just touches, but does not compress, the Teflon packing. 19-4.3.1.32 (SF) Refit the anode gland internal blanking plug and close the vent valve. 19-4.3.1.33 (DV) Remove the external blanking plate and fit two protection nuts to each of the anode studs adjacent to the hull penetration. 19-4.3.1.34 (DV) Fit a pre-soaked DC plug into the anode gland for protection during hull cleaning. 19-4.3.1.35 (DV) Fit the anode loosely over the stud to confirm that it fits. If it does not, mark the anode where it rubs and return it to the surface. If necessary, file away the minimum of ceramic to fit the anode over the studs. (See Figure 19-8.) On completion,

    make sure the washers on the studs still provide adequate overlap on the enlarged hole. WARNING

    O p e r a t o r s o f sa n d b l a s ti n g equipment must be familiar with and observe the Warnings a nd C a ut io n s con ta i ne d i n Appendix B to this chapter. 19-4.3.1.36 (DV) Prepare the exposed hull area to receive the replacement anode by sandblasting the bare metal to a near-white metal finish in accordance with SSPC-SP10. NOTE Most underwater epoxies bond most effectively to a slightly uneven (roughened) surface. A sandblasted surface is ideal. T h e e d g e o f t h e d i e l e c tr i c shield should be faired by the sandblaster to a 20-30 degree angle to receive the epoxy. NOTE The supervisor must ensure that the time between surface preparation and epoxy paint application is kept to a minimum. If a prepared surface is left for a lengthy period without paint, it will begin to rust and the surface wil l have to b e sandblasted again before paint application. Similarly, an oily film can form in a very short time and prevent successful paint application. Wiping the prepared surface with a concentrated detergent (Joy)

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    immediately before paint application can help the paint to adhere. 19-4.3.1.37 (DV) Sandblast the edge of the existing dielectric shield to create a surface suitable for subsequent fairing in of the approved epoxy (see Appendix A). 19-4.3.2 Anode Replacement. NOTE Apply duct tape layers in patterns that both protect and are easy to remove. 19-4.3.2.1 (TOP) Using duct tape, apply a protective layer of strips sufficient to cover the top of the replacement anode. This will keep epoxy from fouling the anode surfaces. Carefully cut out holes in the tape layer corresponding to the anode securing holes. The anode surface must be protected from epoxy fouling but must also provide accessibility to the securing studs. Fit a protective cover of duct tape over the male probe extending from the anode hub. WARNING

    aged and the mat holes are aligned with anode stud holes. The neoprene mat will not completely cover the anode and there will be an outer margin around the mat where the anode is exposed. Apply another layer of epoxy to this exposed margin to build it to the same level as the edge of the neoprene mat. 19-4.3.2.3 (DV) Remove the nuts protecting the anode securing studs. Remove the presoaked DC plug from the hull penetration, exposing the stuffing tube. 19-4.3.2.4 (TOP, DV) Pass the prepared anode to the divers for transport to the hull. 19-4.3.2.5 (DV) Remove the duct tape covering the male probe extending from the anode hub. Carefully locate the anode over the securing studs so that the anode hub projects into the stuffing tube, and the securing studs project through the anode stud holes. CAUTION Uneven or extreme tightening of securing bolts will shatter the ceramic surface of the anode holder. 19-4.3.2.6 (DV) Place a washer and hex nut on each securing stud to hold the anode and, starting from the centermost studs, tighten each nut using only moderate torque. Tighten all nuts evenly, waiting several minutes between successive tightenings to permit the epoxy to squeeze against the prepared hull surface and flow out from the back of the anode. Tighten all nuts to a torque of 10 ft.-lbs. CAUTION The careful application and successful bonding of epoxy is crucial to the repair. 19-4.3.2.7 (DV) Press the squeezed epoxy around the anode evenly, fairing in the anode

    Epoxies, paints, and solvents are toxic and can cause serious injury to eyes and skin. Wear protective goggles, coveralls, and impervious rubber gloves during mixing and application. Epoxies, paints, and solvents emit toxic fumes. Ensure adequate ventilation for personnel during mixing, application, or cleanup of toxic materials. 19-4.3.2.2 (TOP) Apply a layer of epoxy to the back of the anode, keeping a margin 1 inch wide around the anode hub free of epoxy. Place the neoprene mat onto the anode carefully, guiding the anode hub through the mat hub hole. Ensure the anode hub is not dam-

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    and marrying the epoxy to the clean, roughened existing dielectric shield edge. Cover all metal hull areas. Add additional 20 mil layers of epoxy as necessary to completely fill and fair the gap between the old shield and the replacement anode. Evenly fill in any irregular or trimmed areas of dielectric shield so that the integrity of the shield is completely restored. 19-4.3.2.8 (DV) Apply the approved epoxy to fill the securing nut holes in the tape layer above the anode securing nuts (8 or 16), fairing the epoxy to the upper surface of the anode. When all epoxy has been applied, carefully remove the duct tape from the anode. All epoxy must now cure at a rate dependent upon ambient water temperature (see the graph in Appendix A). 19-4.3.2.9 (SF) Vent and remove the internal blanking plate. 19-4.3.2.10 (SF) If necessary, clear the anode gland of any water with an air hose (a whip leading from a scuba bottle would be appropriate). Dry and recoat the gland with silicone grease. NOTE When Teflon is compressed it will creep, i.e. slowly distort and flow away from the compressive force. The Teflon packing rings are the primary watertight seal. To ensure that the Teflon rings form an effective watertight seal it is essential that the glan d n ut com pressing the Teflon rings is retightened 24 hours after the initial compression. CAUTION Do not tighten the packing nut down onto the top of the anode hub. If the correct number of

    packing rings have been fitted properly, this should not be possible. 19-4.3.2.11 (SF) Tighten the packing nut with a 1 3/8-inch socket wrench until the packing is compressed to the limit. Retighten at intervals until tight and the Teflon has creeped as far as possible. Repeat the operation one hour later and 24 hours later. 19-4.3.2.12 (SF) Assemble two O-rings to the female prong assembly. Lubricate the female prong assembly and O-rings with silicone grease. 19-4.3.2.13 (SF) Install the truarc ring, female prong assembly and packing nut, then tighten down the packing nut. 19-4.3.2.14 (SF) Install gland gasket, connection box, gasket for the connection box cover, and the connection box cover. 19-4.3.2.15 (SF) Install insulating washers, washer, nut, washer, anode cable lug (with cable), lock washer, and nut. 19-4.3.2.16 (SF) For protection against water, hull penetrations may have connection boxes fitted with a fill hole. Fill the connection box with paraffin. Insert the pipe plug in the tapped fill hole. 19-4.3.2.17 (SF) Replace the high-hat cofferdam cover if the connection box is located in a tank or void space. CAUTION Epoxy must be fully cured before the ICCP system is tested. Depending on ambient water temperatures, this could take several days. 19-4.3.2.18 (DV) After an adequate cure period, visually inspect the epoxy applications. Confirm that the epoxy has cured and appears

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    properly bonded to the existing dielectric shield. 19-4.3.2.19 (SF) When the epoxy cure has been confirmed, the ICCP system is ready for testing. 19-4.3.2.20 (SF) Energize the ICCP system to assure the proper operation of the replacement anode. Procedures for inspection and adjustment of system operation following shutdown and testing replacement anodes are provided in NSTM 633, Section 6. 19-4.4 REFERENCE CELL REMOVAL AND REPLACEMENT PROCEDURE. WARNING

    Ships Force personnel are crucial for safe and effective coordination of tasks and the m a i n t e n a n ce o f w a te r ti g h t integrity at through-hull penetration sites. 19-4.4.1 The activity conducting the reference cell removal and replacement shall: a. Ensure all required materials are on hand using Table 19-2 for guidance.
    Table 19-2. Materials for Reference Cell Replacement. 1. 2. 3. Replacement reference cell and gland seal materials (Figure 19-11) Straight-threaded pipe plug (see Figure 19-13) Silicone grease compound (NSN 685600-702-4297) Epoxy fairing compound (P/N 532597A or equivalent) Approved underwater epoxy paint (see Appendix A) Calibrated torque wrench, 0-50 ft.-lbs. with extension and crows foot Sandblaster (see note following paragraph 19-4.4.25) Wire brushes Guide rods, 6, All Thread 1/4-20 UNC guide rods (see Figure 19-14) Electrical multimeter Right-angled and straight scribes Duct tape Flat-tipped screwdrivers Soft Wood Wedges

    Underwater electrical equipment must be secured while divers are working over the side. Hull deterioration is most severe while the ICCP system is de-energized and the effects are irreversible. The appropriate zone of the ships ICCP system must be secured, ta gg ed o ut , an d con fi rm e d secure d before diver s may work on an ICCP device (anode, dielectric shield, or reference cell). When divers are required to work in close proximity to an active ICCP anode and risk o f contact with a n anode exists, that part of the system must be secured for the duration of the repair. In other than these situations the ICCP system is to remain active. Divers working within 15 feet of an active system must wear a full dry suit, unisuit, or wet suit with hood and gloves. Clear communications among divers, surface personnel, and inboard

    4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

    b. Coordinate material, technical, and funding requirements. c. Conduct reference cell replacement training in accordance with Naval

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    Ships Technical Manual, S9086-VFSTM-010/CH-633, Cathodic Protection. d. Arrange with the ship for control and disposal of hazardous material. e. Prepare video and still cameras to document work throughout the procedure.

    Notify the ship of any special precautions required in the performance of removal/replacement. 19-4.4.2 The Ships Force shall: a. Ensure that the ship is moored with the affected cell toward the pier.

    Figure 19-11. Reference Cell and Gland Seal Assembly.

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    b. Tag out equipment and systems for conduct of diving operations. c. Control and dispose of hazardous material as agreed to with the performing activity. 19-4.4.3 (SF) Defuel and gas free the compartment in which the reference cell hull penetration is located, and other compartments as necessary to access the reference cell (if the cell is located outboard of a tank/void). 19-4.4.4. (SF) Rig lighting and establish ladders and scaffolding as necessary to access the reference cell. 19-4.4.5. (SF) Provide a sentry at the reference cell hull penetration who is able to maintain verbal contact with working personnel, especially if they are in an enclosed compartment. 19-4.4.6. Verify that the appropriate zone of the ICCP system has been de-energized and tagged-out. The rest of the ICCP system should remain energized, ionizing the hull. 19-4.4.7. (SF, TOP, DV) Establish communications between the inboard side of the reference cell hull penetration (Ships Force sentry), the dive supervisor, and the divers. NOTE The dive supervisor must be satisfied that the preparatory steps 19-4.4.3 through 19-4.4.7 have been completed before proceeding. 19-4.4.8 (SF) Remove the cover plate of the high-hat cofferdam housing the reference cell gland assembly (Figure 19-12). 19-4.4.9 (SF) Inspect and remove the highhat cofferdam gasket. Replace the gasket if necessary. 19-4.4.16 (DV) Remove the fairing epoxy from the six reference cell securing screws using a small hand-held chisel.

    19-4.4.10 (SF) Inspect the inside of the cofferdam/high hat for signs of corrosion or fuel/liquid ingress. If there are signs ascertain the cause of the ingress and, if possible, rectify the defect. NOTE If the problem can not be rectified then a decision should be made whether to continue with the replacement while a potential root cause for the defective reference cell exists. 19-4.4.11 (SF) Remove the gland nut. Because of its position inside the high-hat cofferdam it is necessary to use a wrench with an extension piece and a crows foot with an internal jaw diameter of 1 1/8 inch. 19-4.4.12 (SF) Remove the cable and packing assembly by hand. 19-4.4.13 (SF) Determine if the Teflon bushing is still in place. If it is loose, remove it. 19-4.4.14 (SF) Inspect the walls of the gland body for signs of water entry. 19-4.4.15 (SF) Fit a straight-threaded blanking plug into the gland body. NOTE The straight threaded blanking plug must be manufactured locally. It is fitted in place of the gland nut. It should be manufactured with a 1/4 turn vent valve and an O-ring, with a 1inch 12 UNF-1A thread pattern (see Figure 19-13). The old gland nut could be fitted with a 1/2-inch male with plain end vent valve to make this blanking plug. 19-4.4.17. (DV) Using a flat tip screwdriver, loosen the six screws in a star pattern, giving each screw one turn.

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    Figure 19-12. High Hat.

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    Figure 19-13. Blanking Plug.

    19-4.4.18. (DV) Completely remove all screws and lockwashers. Retain them at the work site. 19-4.4.19. (SF) Verify the inboard watertight integrity of the gland blanking plug by opening then closing the vent plug valve. There should be no flow of water before proceeding. 19-4.4.20. (DV) Using at least two soft wood wedges, slowly lift the reference cell from the sole/backing plate. 19-4.4.21. (DV) Remove the reference cell from the hull and verify the position of the Teflon bushing (if not removed earlier). Send the reference cell to the surface. 19-4.4.22. (SF) Inspect the internal bore of the gland body for corrosion/roughness. Hand clean with a cloth as necessary. 19-4.4.23. (DV) Fit a mechanical expandable plug or a pre-soaked DC plug into the mouth of the reference cell gland body. (The plug should fit a 1 1/8 inch I.D. opening and be no longer than 1 1/2 inches.). 19-4.4.24. (DV) Replace the screws removed in step 4.4.18. This will protect the internal

    threads of the bolt holes during hull preparation. WARNING

    Op e r a t o r s o f s a n d b l a st i n g equipment must be familiar with and observe the Warnings an d C a u ti on s co n ta in e d i n Appendix B to this chapter. 19-4.4.25. (DV) Using an underwater sandblaster, clean the sole/backing plate area of the hull onto which the reference cell mounts. Prepare it to a near-white metal finish (SSPC-SP-10). 19-4.4.26. (DV) Remove the reference cell securing screws fitted in step 4.4.24. Retain at the work site. 19-4.4.27. (DV) Screw six threaded guide rods into the securing bolt holes to help locate the replacement reference cell. Each rod should be 6 inches long, 1/4-20 UNC-2A all-thread. (See Figure 19-14).

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    Figure 19-14. Guide Rod.

    19-4.4.28 (DV) Remove the expandable plug or DC plug.

    mechanical

    NOTE The supervisor must ensure that the time between surface preparation and epoxy paint application is kept to a minimum. If a prepared surface is left for a lengthy period without paint, it will begin to rust and the surface wil l have to b e sandblasted again before paint application. Similarly, an oily film can form in a very short time and prevent successful paint application. Wiping the prepared surface with a concentrated detergent (Joy) immediately before paint application can help the paint to adhere. NOTE Apply duct tape layers in patterns that both protect and are easy to remove. 19-4.4.34 (TOP) Using duct tape, apply a protective layer of strips sufficient to cover the outboard side of the replacement reference cell. This will keep epoxy from fouling the reference cell surface or clogging the sensor holes. Carefully cut out holes in the tape layer corresponding to the six reference cell securing holes. Place the prepared replacement reference cell in a basket and pass to the divers for transport to the hull.

    19-4.4.29 (DV) Evacuate any water from the reference cell gland assembly using the divers pneumo. 19-4.4.30 (DV) Using a straight scribe, unseat the Teflon bushing by pushing it back up into the gland body penetration (as required). 19-4.4.31 (DV) Replace the expandable plug or DC plug. WARNING mechanical

    Epoxies, paints, and solvents are toxic and can cause serious injury to eyes and skin. Wear protective goggles, coveralls, and impervious rubber gloves during mixing and application. Epoxies, paints, and solvents emit toxic fumes. Ensure adequate ventilation for personnel during mixing, application, or cleanup of toxic materials. 19-4.4.32 (TOP) Prepare the epoxy and pass to the divers for application to sole/backing plate. 19-4.4.33 (DV) Coat the prepared backing/sole plate with epoxy.

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    19-4.4.35 (DV) Remove the mechanical expandable plug or DC plug. Heavily apply silicone grease to the O-rings of the reference cell and the internal bore of the gland body. 19-4.4.36 (DV) Locate the reference cell over the six guide rods, and push it into position onto the hull until it mates with the sole/backing plate. If an air lock is experienced in the gland body, release the pressure by venting the blanking plug. 19-4.4.37 (DV) Replace each guide rod with a securing screw and lockwasher, hand tighten each screw just until it touches the reference cell. 19-4.4.38 (DV) Using the star pattern, torque each screw to 10 ft.-lbs. 19-4.4.39 (SF) Slowly remove the gland blanking plug, checking for any signs of water entry past the reference cell O-rings. 19-4.4.40 (SF) If the Teflon bushing was not removed in previous steps, use a right-angled scribe to remove it at this time. If the Teflon bushing was not properly pushed in from the outboard side (paragraph 19-4.4.30), it could become wedged around the reference cell male probe and be difficult to remove. 19-4.4.41 (SF) Check the electrical voltage continuity of the reference cell by measuring the voltage between the steel hull and the reference cell using a multimeter. If the system is functioning correctly, the hull will be negative and the reference cell will be positive. The DC voltage should measure approximately 0.6 volt DC. NOTE If the voltage is zero, it indicates either an open wire or a shorted wire or cell. If the voltage is higher than indicated, the hull is receiving cathodic protection from some other source (zincs or electrical leak-

    age). On a newly painted steel hull the reading may be as low as 0.45 volt DC. 19-4.4.42 (DV) Fill the screw holes with epoxy and fair to the reference cell surface. When all epoxy has been applied remove the duct tape. 19-4.4.43 (SF) Clean and grease the internal surface of the gland body and insert a new Teflon bushing, packing assembly, and cable. NOTE When Teflon is compressed it will creep, i.e. slowly distort and flow away from the compressive force. The Teflon packing ring is the primary watertight seal. To ensure that the Teflon rings form an effective watertight seal, it is essential that the gland nu t com pressing the Teflon is retightened several times. 19-4.4.44 (SF) Insert the gland ring and lockwasher, then screw in the gland nut by hand. Using a torque wrench with an extension piece, a crows foot and an internal jaw diameter of 1 1/8 inch, tighten the gland nut to 25 ft.lbs. Retighten 6, 12, and 18 hours later. 19-4.4.45 Energize the ICCP system to ensure the proper operation of the replacement reference cell. Procedures for the inspection and adjustment of system operation following shutdown and for the testing of replacement reference cells are provided in Naval Ships Technical Manual, Chapter 633, Section 6. 19-4.5 DIELECTRIC SHIELD REPAIRS WARNING Underwater electrical equipment must be secured while divers are working over the

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    side. Hull deterioration is most severe while the ICCP system is de-energized and the effects are irreversible. The appropriate zone of the ships ICCP system must be secured, tag ge d ou t, a nd co nf ir m ed secured befor e divers ma y work on an ICCP device (anode, dielectric shield, or reference cell). When divers are required to work in close proximity to an active ICCP anode and risk of conta ct w ith an anode exists, that part of the system must be secured for the duration of the repair. In other than these situations the ICCP system is to remain active. Divers working within 15 feet of an active system must wear a full dry suit, unisuit, or wet suit with hood and gloves. Clear communications among divers, surface personnel, and inboard Ships Force personnel are crucial for safe and effective coordination of tasks. 19-4.5.1 The activity conducting the dielectric shield repair shall: a. Ensure that all required materials are on hand using Table 19-3 for guidance.
    Table 19-3. Material for Dielectric Shield Repair.
    1. 2. 3. 4. 5. Underwater epoxy coating (1 gallon kit per 50 ft2) Liquid immersion heating elements (2) Thermometers, dial (2) Metal buckets (2) Plastic containers, one quart (10 per 50 ft2)

    Table 19-3. Material for Dielectric Shield Repair.


    6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Plastic measuring containers, (4 per 50 ft2) Surgical gloves, latex (50 per 50 ft2) Latex gloves, all purpose, oversized (4 pair per day) Coveralls, disposable (5 per day) Oceanclean sandblaster Silica sand (500 lbs per 50 ft2) Air compressor (80-125 psi, 375 cfm with 1inch hose connection) Bale of rags Bags, plastic, heavy duty, 30 gallon (10) Mixing utensils (wooden sticks) (5 per 50 ft2) Methyl Ethyl Ketone (MEK) (1 gallon per 500 ft2) Abrasive pads, (Scotch-Brite) Liquid detergent, Joy brand only (1 pint per 50 ft2) Trowels, plastic, 2 or 3-inch wide (20 per 50 ft2) Paint brush, 3-inch wide, 2-inch bristle length (5 per 50 ft2)

    b. Coordinate material, technical, and funding requirements. c. Conduct dielectric shield repair training in accordance with Naval Ships Technical Manual, S9086-VF-STM-010/CH633, Cathodic Protection. d. Arrange with the ship for control and disposal of hazardous material. e. Prepare video and still cameras to document work throughout the procedure. f. Notify the ship of any special precautions required in the performance of the shield repair.

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    19-4.5.2 The Ships Force shall: a. Ensure that the ship is moored with the affected dielectric shield toward the pier. b. Tag out equipment and systems for conduct of diving operations. c. Control and dispose of hazardous materials as agreed to with the performing activity. 19-4.5.3 Verify that the appropriate zone of the ICCP system has been de-energized and tagged out. The rest of the ICCP system should remain energized, ionizing the hull. The energized zone must remain tagged out until the epoxy has cured. CAUTION Particular care must be exercised to protect the anode from damage during sandblasting. 19-4.5.4 Prepare the dielectric shield for application of the aquatic epoxy paint by removing all loose and damaged Capastic. Areas of bare metal shall be prepared to as near-white metal finish (SSPC-SP-10) as possible using an Oceanclean Sandblaster. Use the sandblaster to fair the edges of sound Capastic to a 20-30 degree angle. For minor repairs and to repair cracks at the anode/Capastic shield interface, a rightangled grinder may be used. NOTE The supervisor must ensure that the time between surface preparation and epoxy paint application is kept to a minimum. If a prepared surface is left for a lengthy period without paint, it will begin to rust and the surface wil l have to b e sandblasted again before paint application. Similarly, an oily film can form in a very short time and prevent successful

    paint application. Wiping the prepared surface with a concentrated detergent (e.g. Joy) immediately before paint application can help the paint to adhere. 19-4.5.5 Follow the manufacturers instructions for mixing the epoxy paint system. NOTE Two-part epoxies generally begin curing as soon as the components are mixed. The minimum amount of paint required should be mixed at any one time. 19-4.5.6 Apply the epoxy paint by hand, trowel, paint brush, or for large areas, by a paint application machine. NOTE Painting underwater requires patience. Divers must avoid the temptation to try to paint too much surface at one time. Too much paint applied at one time often results in the paint peeling away from the prepared surface before it has time to adhere. Best results are obtained from working the paint in t o th e p r e pa r e d su r fa c e, especially in areas of pitting. In these areas it is important to work the paint into the surface to expel as much water and air as possible. 19-4.5.7 Fair the epoxy up to the edge of the anode and flush with the sound epoxy. Refer to paragraph 19-1.4.6.d for required thickness. Do not paint the surface of the anode except when fairing in the anode securing bolts. NOTE Experience with epoxy paints has shown that application in temperatures lower than 50

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    degrees F is not advisable. In general, the lower the seawater temperature, the longer the cure time. 19-4.5.8 Calculate the required cure time using the graph in Appendix A. 19-4.5.9 Upon completion of the required cure time, visually inspect the epoxy application. Confirm that the epoxy is cured and appears properly bonded to the existing dielectric shield. 19-4.5.10 When the epoxy cure has been confirmed, energize the ICCP system and test in accordance with Naval Ships Technical Manual, Chapter 633, Section 6. 19-4.6 POST-REPAIR PROCEDURES 19-4.6.1 Upon completion of the repair, a written report should be provided to the ships Engineer officer for the ships records. The report shall contain all information pertaining to the repair including the completed work package with all Quality Assurance (QA) documents, documentation of the damage

    assessment (NAVSEA Form 4730/7), photographs, any problems encountered together with their solution, and any post repair action required (e.g., periodic inspections, rework during next dry docking, etc.). A copy of the report should be retained by the repairing activity. A copy of the report should be forwarded to NAVSEA 00C5 when requested. 19-4.6.2 Whenever possible photographic and videotape records of dielectric shield repairs should be taken to provide a reference for the next underwater hull inspection. Copies of these photographic records along with the hull survey report forms should be forwarded, if requested, to NAVSEA (SEA 00C5).

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    APPENDIX A APPROVED UNDERWATER EPOXY PAINTS


    A-1. APPROVED MATERIALS Evaluation of underwater epoxy paint systems is an ongoing project. The current approved epoxy paint for dielectric shield repair and the source of supply is shown in Table A-1. A-1.1. Curing Times for Hycote 461. For curing times for Hycote 461 refer to Figure A-1.

    Table A-1. Approved Epoxy Paint.


    Material Hycote 461 Source East Coast: Seaward Marine Services Inc. 5409 Beamon Road Norfolk, VA 23513 (757) 853-7683 West Coast: Seaward Marine Services Inc. 424 W. 8th St. National City, CA 92050 (619) 474-8163

    A-1

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    Figure A-1. Curing Times for Hycote 461.

    A-2

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    APPENDIX B SETUP AND OPERATION OF THE SANDBLASTER


    B-1 SETUP WARNING b. With the 1/8-inch drilled holes in the couplings aligned, insert the safety clip. B-1.6 Connect additional lengths of blast hose following steps a. and b. above until the required length is obtained. This should include the final length with a threaded hose fitting for the blast nozzle. B-1.7 Install the blast nozzle: WARNING a. Coat the nozzle threads with anti-seize compound. Do not use grease. CAUTION Do not overtighten the blast nozzle when installing it on the hose end threaded fitting. Do not use a wrench to tighten. b. Install the blast nozzle with a gasket. Tighten to contact then add 1/4 turn hand tight. B-1.8 Connect the remote control system with the deadman switch: a. Connect the required lengths of extension section twin control hose (each 50 feet long) to the starting section hoses connected to the air inlet piping and the air inlet control valve. b. Connect the required lengths of extension section control hose (each 50 feet long) to the starting section hose connected to the abrasive regulator. c. Connect the deadman control switch with hoses to the proper color-coded extension hoses. d. Ensure that all hose fittings are tight.

    Im p r o p e r u s e o f t h e s a n d blaster can be extremely hazardous.

    Always depressurize the blast tank whenever the unit is left unattended. NOTE Figure B-1 provides information concerning the correct method of connecting the hoses for the sandblaster. B-1.1 Place blast tank on a solid surface near the work site. B-1.2 Inspect the blast tank and components for damage and missing parts. Repair or replace as necessary. Ensure that there is no grease on the O-rings and gaskets. B-1.3 Check ancillary equipment against the inventory list. B-1.4 Check blast hose end fittings to ensure that the gaskets are in place. B-1.5 Connect the blast hose with quick disconnect couplings to the outlet of the blast regulator: a. Push the coupling faces firmly together and rotate in a clockwise direction until the locking lugs are engaged.

    B-1

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    Figure B-1. Hose Connections for the Sandblaster

    e. Ensure that the petcock on the deadman control switch is shut. WARNING For safe operation the deadman control switch should be located not more than 6 inches from the blast nozzle coupling.

    B-1.9 Using tie-wraps, attach the deadman control switch to the blast hose at a comfortable point near the nozzle, but not more than 6 inches from the blast nozzle coupling. B-1.10 Using tie-wraps, attach the twin control hoses and abrasive regulator control hose to the blast hose. Strap loosely to prevent the control hoses from being crushed when the blast hose is turned.

    B-2

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    WARNING To prevent the operator from receiving static electricity generated by the abrasive flow, the blast tank must be grounded. B-1.11 Connect the grounding cable to the unit grounding connection and to a known ground point. B-1.12 Shut the manual exhaust valve. B-1.13 Shut the manual air inlet valve. B-1.14 Open the choke valve located in the vertical air line piping on the blast tank. (The choke valve handle is in line with the piping when the valve is open). B-1.15 Set the abrasive regulator by turning the handle three to four turns counterclockwise from the fully shut position. Do not turn more than five turns. B-1.16 Connect the air supply to the air inlet connection. Install the safety clip, if applicable. WARNING

    B-1.18 Inspect all fittings for leaks. Repair all leaks before proceeding. B-1.19 Test operate the deadman control switch: a. Activate the switch by pressing the safety button into the side of the switch. b. Depress the switch operating handle. Pressurized air should discharge from the nozzle. c. Check the air inlet valve next to the abrasive regulator for proper operation and for leaks. d. Release the switch operating handle. Pressurized air flow should stop. WARNING

    To prevent serious personnel injury, exercise extreme caution when working around the sandblaster when the tank is pressurized. B-1.20 Pressurize the blast tank: a. Open the manual air inlet valve. WARNING

    Topside personnel must wear ear and eye protection when operating the sandblaster. WARNING

    Do not exceed 120 psi inlet air pressure. B-1.17 Pressurize up to the manual air inlet valve and the deadman switch with 85-120 psi low pressure air.

    To prevent serious personnel i n j u r y, c h e c k t h e s e a l i n g plunger and sealing O-ring from a safe distance. b. Check to ensure that the sealing plunger has moved upward and is seated against the sealing O-ring.

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    c. Check for leaks. Repair all leaks before proceeding. WARNING

    (1) (2)

    Shut the manual air inlet valve. Press the safety button, depress the operating handle to activate the deadman control switch, and open the toggle valve to remove excess air from the blast tank and reduce noise. Slowly open the manual exhaust valve. Shut the toggle valve and release the operating handle of the deadman control switch when the blast tank is depressurized. Verify that the sealing plunger has moved downward on the support pipe. CAUTION

    To prevent serious personnel injury and equipment damage, do not point the blast nozzle at personnel or equipment. CAUTION The carbide nozzle is very fragile and shatters easily. Do not drop or mishandle it. B-1.21 Hold the blast hose securely at the nozzle end and point it away from personnel and equipment. B-1.22 Fully open the petcock on the deadman control switch. B-1.23 Press the safety button and depress the operating handle to activate the deadman control switch. Pressurized air will be discharged from the blast nozzle. B-1.24 Check the operation of the abrasive regulator: a. Open the toggle valve to start air flow from the abrasive regulator and tank. b. Stop the pressurized air flow from the abrasive regulator and tank by shutting the toggle valve. c. Release the operating handle of the deadman control switch. B-1.25 Fill the blast tank with abrasive: a. Depressurize the blast tank.

    (3)

    (4)

    (5)

    To prevent accelerated wear on the plunger face and O-ring, do not overfill the blast tank with abrasive. The recommended level is no higher than the bottom edge of the sealing plunger. NOTE The recommended abrasive material is Silica Sand #2. b. Fill the blast tank with abrasive. WARNING

    To prevent serious personnel injury, exercise extreme caution when working around the sandblaster when the tank is pressurized.

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    WARNING Th e topsi de o per ator mu st wear ear and eye protection when operating the sandblaster. c. Pressurize the blast tank: (1) (2) Shut the manual exhaust valve. Slowly open the manual air inlet valve. WARNING

    WARNING I m p r o p e r u se o f t h e s a n d blaster can be extremely hazardous. WARNING

    To prevent the operator from receiving static electricity generated by abrasive flow, ensure that the blast tank is properly grounded. WARNING

    To prevent serious personnel i n j u r y, c h e c k t h e s e a l i n g plunger and sealing O-ring from a safe distance. d. Check to ensure that the sealing plunger has moved upward against the sealing O-ring. B-1.26 The sandblaster is now fully operational. B-2 OPERATION WARNING

    Do not exceed 120 psi inlet air pressure. WARNING

    Topside personnel must wear ear and eye protection when operating the sandblaster. WARNING

    Wearing a Mark 21 helmet, the maximum allowable time for a d i ve r to o p e r a te th e sa n d blaster is 5 hours. WARNING

    Always depressurize the blast tank whenever the unit is to be left unattended. B-2.1 Before the diver enters the water, ensure that the following steps have been accomplished: a. All steps in B-1, with special attention being given to the following: (1) The blast tank has been pressurized with the sealing plunger against the sealing O-ring.

    To prevent serious personnel injury, exercise extreme caution when working around the sandblaster when the tank is pressurized.

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    (2)

    The safety button on the deadman control switch has been pulled out to prevent activation. The petcock on the deadman control switch has been shut. The toggle handle on the deadman control switch has been shut (handle is pointed toward the hose). The abrasive regulator has been adjusted by turning three to four turns counterclockwise from the fully shut position. No more than five turns have been used.

    B-2.4 Press the safety button and depress the operating handle to activate the deadman control switch. Pressurized air will be discharged from the blast nozzle. NOTE The diver controls the starting and stopping of abrasive flow from the blast nozzle by opening and shutting the toggle valve. The amount of abrasive discharged is manually controlled by turning the crank handle on the abrasive regulator; clockwise to decrease flow, counterclockwise to increase flow. NOTE For efficient blasting, air must be supplied for 30 seconds before the toggle valve is opened to supply sand. B-2.5 With the operating handle depressed, start the flow of abrasive by opening the toggle valve (handle is pointed away from the hose). NOTE Practice in the use of the sandblaster is required in order to clean only the pre-determined area. Overly long bursts of sandblasting can obscure the work area and lead to the diver wandering from the pre-determined area thus creating additional work and increasing the risk of damage to anodes and rference cells. Overly short duration bursts will reduce the ability to obtain proper sand velocity which will reduce the

    (3)

    (4)

    (5)

    b. Any discrepancies noted have been corrected. c. Additional bags/containers of abrasive are available for refilling the blast tank. WARNING

    To prevent serious personnel injury and equipment damage, do not point the blast nozzle at personnel or equipment. CAUTION The carbide nozzle is very fragile and shatters easily. Do not drop or mishandle it. B-2.2 Hold the blast hose securely at the nozzle end and point it away from personnel and equipment. B-2.3 Fully open the petcock on the deadman switch.

    B-6

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    effectivness of the sandblasting. NOTE

    (5)

    Verify that the sealing plunger has moved downward on the support pipe. CAUTION

    Even though abrasive flow will be stopped when the toggle valve is shut, pressurized air will continue to be discharged from the nozzle as long as the operating handle is depressed. B-2.6 Stop the flow of abrasive by shutting the toggle valve. B-2.7 Release the operating handle of the deadman control switch to stop air flow from the nozzle. B-2.8 Restart blasting by following steps B-2.2 through B-2.5. B-2.9 Refill the blast tank with abrasive: a. Release the operating handle of the deadman control switch to stop blasting. Do not shut the toggle valve. b. Depressurize the blast tank:

    To prevent accelerated wear on the sealing plunger face and O-ring, do not overfill the blast tank with abrasive. The recommended level is no higher than the bottom edge of the sealing plunger. c. Fill the blast tank with abrasive material. d. Pressurize the blast tank: (1) (2) Shut the manual exhaust valve. Slowly open the manual air inlet valve. Verify that the sealing plunger moves upward against the sealing O-ring.

    (3)

    B-2.10 Restart blasting in accordance with steps B-2.2 through B-2.5. B-2.11 Secure from blasting:

    (1) (2)

    Shut the manual air inlet valve. Press the safety button and depress the operating handle to activate the deadman control switch to remove excess air from the blast tank and reduce topside noise. Slowly open the manual exhaust valve. Shut the toggle valve and release the operating handle of the deadman control switch when the blast tank is depressurized.

    a. Shut the toggle valve. CAUTION To prevent the hose from becoming clogged with abrasive, do not release the operating handle on the deadman switch until all abrasive has been discharged from the nozzle. b. Release the operating handle. Ensure that the safety button is pulled out to prevent depressing the handle. Shut the petcock.

    (3)

    (4)

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    S0600-AA-PRO-190

    c. Pull the blast hose to the surface. B-2.12. Blow out water and abrasive residue from the blast hose: a. Lay out the blast hose with as few bends as possible. b. Hold the blast hose and nozzle securely at the nozzle end and pointed away from personnel and equipment. c. Check to ensure that the petcock and toggle valve are shut. d. Press the safety button and depress the operating handle to activate the deadman control switch. Pressurized air will be discharged from the nozzle along with any water and abrasive residue. e. Release the handle of the deadman control switch when all water and abrasive residue have been discharged from the nozzle. B-2.13 Depressurize the blast tank in accordance with step B-2.9b. WARNING WARNING To prevent serious personnel injury, ensure that the main air supply valve is shut and the air supply hose is depressurized before disconnecting. B-2.14. Shut the main air supply valve to the blast tank. B-2.15. Disconnect the depressurized air supply hose from the air inlet line if blasting has been completed. B-2.16. Perform post-dive maintenance in accordance with MRC UW2160 R-1. NOTE Setup and operating procedures as well as maintenance procedures for the sandblaster will be provided with the equipment. Operators must adhere to these procedures to ensure proper operation and maintenance of the equipment.

    Never shut off the main air supply to the blast tank until the tank is completely depressurized.

    B-8

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