Tensioned Impressed-Current Cathodic Protection and Monitoring
According to the appraisal conducted by the Chinese Society for Corrosion and Protection (Appraisal No. [2018] No. 8), this equipment set as a whole has reached an internationally leading level. ◆ Successful domestic localization and application of China’s first tensioned ICCP technology ◆ Innovative integration of a tensioned impressed-current system and a monitoring system ◆ First set of high-reliability integrated ICCP+CPMS equipment manufacturing technology ◆ First exploration and establishment of performance testing technology for tensioned ICCP equipment ◆ Development of the first installation technology for tensioned impressed-current equipment ◆ Innovative establishment of a comprehensive technical system
Category:
Corrosion Protection Solutions
Large ships
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Product Description
▍ Tensioned External Current Cathodic Protection and Monitoring Integrated Equipment (TAM)
Multiplex Controller: Adjust the protective current released by each auxiliary anode and monitor and evaluate the corrosion protection status of the platform.
Composite cable-electrode system: Integrates composite cable, auxiliary anode, and reference electrode into a single unit.
Tensioning and Limiting Structure: The structure, including top-mounted fixtures, gravity foundations, and limit devices, provides tension to the composite cable and restricts its swing amplitude.
» Technological innovation
As certified by the Chinese Society for Corrosion and Protection (Certificate No. [2018] No. 8), this set of equipment as a whole meets Internationally leading level 。
▶ Successful domestic application of China’s first tensioned ICCP technology
▶ Innovative integrated impressed-current cathodic protection system and monitoring system
▶ First-of-its-kind high-reliability integrated ICCP+CPMS equipment manufacturing technology
▶ For the first time, tension-based ICCP equipment performance testing technology has been developed.
▶ Developed the first installation technology for tensioned impressed-current cathodic protection equipment.
▶ Innovation has resulted in a comprehensive technological system.
▍ Multiplex Controller
» Technological innovation
| ▶ Innovatively adopting a distributed power supply scheme and modular design, independent control of the current for each auxiliary anode has been achieved. Fine-tuned regulation of control and protection potentials;
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▍ Composite Cable-Electrode System
» Technological innovation
▶ Pioneered a composite cable–electrode system that integrates load-bearing cables, auxiliary anodes, reference electrodes, power cables, and signal cables into a single unit, thereby achieving adaptability and reliability for long-term service in harsh marine environments.
▶ The auxiliary anode and reference electrode are integrated into a single unit, consolidating cathodic protection condition monitoring and ICCP control to form a closed-loop system.
The composite cable integrates multiple functions, including tensile load-bearing, protection of current transmission, and transmission of potential-monitoring signals, while also exhibiting excellent resistance to humid chlorine gas, aging, and fatigue.
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Auxiliary anode
This system employs auxiliary anodes to deliver protective current, offering advantages such as light weight, high strength, and resistance to hypochlorous acid. It utilizes either MMO anode rods or platinum-coated niobium anode rods for current delivery. At the connection points at the ends of the auxiliary anodes, a multi-layer sealing approach is adopted, incorporating sealing gaskets, sealant, and a custom-designed sealing structure, thereby ensuring the assembly’s watertight performance.
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Reference electrode
This system monitors the surface potential of the jacket structure using a reference electrode, offering advantages such as light weight, high strength, and resistance to hypochlorous acid. The dual-reference-electrode design enables mutual cross-checking of measurement data, thereby enhancing the reliability of the instrument. Furthermore, the internally designed, proprietary sealing structure improves the device’s water-tightness.
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▍ CPMCS Measurement and Control Software System
▍ Certification and Testing
Throughout all stages of this system—design, manufacturing, testing, installation, and commissioning—independent third-party review, witnessing, and testing are conducted, with certificates and reports issued accordingly.
● “BV Classification Society Product Certification, Type Approval, and Test Reports” ● “CCS Classification Society On-Site Inspection Report”
» Results Evaluation
On July 17, 2018, the scientific and technological achievement appraisal conference for the “Integrated Tension-Type Impressed-Current Cathodic Protection and Monitoring System for Offshore In-Service Platforms” was held in Dalian. The appraisal committee organized by the Chinese Society of Corrosion and Protection listened to a report on the research results, conducted an on-site inspection, reviewed the novelty search report, and, following a question-and-answer session and defense, unanimously concluded that the overall level of this achievement has reached the international leading standard.
» Receive honors
▶ Second Prize of the 2019 China National Offshore Oil Corporation Science and Technology Progress Award
▶ CNOOC’s “Three New, Three Transformations” Category I, Level 9 in 2019
▶ 2017 Demonstration and Application Project for the First (Set) of Key Technological Equipment in Dalian’s Priority Manufacturing Sectors
▶ Second Prize of the Dalian Science and Technology Invention Award, 2019
Related technologies
Offshore platforms are typically designed for a service life of 25 years or more. However, their pile-leg structures exhibit long natural vibration periods, significant dynamic effects, and pronounced issues related to structural fatigue and corrosion. Consequently, structural safety and corrosion protection are critical factors that determine the platform’s service life. Therefore, there is an urgent need to enhance risk management for structural safety and to improve lifecycle integrity management, thereby ensuring the safe operation and maintenance of these platforms.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
The system boasts numerous advantages, including excellent protection performance, high reliability, ease of installation and operation & maintenance, energy efficiency and environmental friendliness, and a high degree of digitalization. It can intelligently adjust the anode output current at different locations based on the cathodic protection status of underwater structures, ensuring that the structures are consistently maintained in optimal protective condition and providing long-term, effective safety assurance throughout the entire service life of offshore platforms.
Digital Twin–Based Structural Health Management System (HMS):
By collecting structural data from offshore platforms in real time or on a scheduled basis, operations and maintenance personnel can promptly identify potential structural issues, such as corrosion, fatigue, displacement, and abnormal vibration. Leveraging the accumulated big data from monitoring enables intelligent prediction, proactive early warning, and planned maintenance, thereby assessing the platform’s health condition, forecasting future risks, and guiding maintenance and repair activities.
In addition, the system can support the structural optimization design of offshore platforms to enhance their stability and durability, which is of great significance for ensuring the safe operation of these platforms and extending their service life.
The foundation structures of offshore wind farms are subjected to harsh marine environmental conditions over long periods, including wind loads, wave loads, tidal currents, and seawater corrosion. These factors can lead to structural damage or even failure, posing a serious threat to the safety and stability of wind energy facilities.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
It can significantly extend the service life of offshore wind power facilities, enable refined and intelligent control of cathodic protection, reduce the frequency of maintenance and component replacement, and lower maintenance costs. At the same time, it enhances the safety and stability of the facilities, thereby preventing accidents and losses caused by corrosion and erosion.
Digital Twin–Based Structural Health Management System (HMS):
It enables real-time monitoring of critical parameters such as the stress state, vibration characteristics, and corrosion condition of wind turbine structures. This allows for the timely detection of potential structural issues, prevention of failures, reduction of downtime, and ultimately enhanced operational efficiency and safety of the wind farm.
Meanwhile, by integrating IoT technologies with cloud-platform solutions, centralized data management and intelligent analytics can be achieved, further enhancing the accuracy and efficiency of monitoring. This supports structural health assessment and service-life prediction, providing a scientific basis for maintenance and repair activities, helping operators optimize their maintenance strategies, and reducing long-term operational costs.
Offshore photovoltaic systems are subject to a variety of environmental factors, including wind and waves, tidal forces, and corrosion, which can damage PV equipment or structures, thereby reducing power-generation efficiency and shortening service life.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
Impressed-current cathodic protection can significantly slow down or prevent the corrosion of steel piles, thereby extending their service life, reducing structural weakening and failures caused by corrosion, maintaining structural integrity, ensuring the stable operation and energy output of photovoltaic systems, enhancing overall economic benefits, and fostering the long-term development of the offshore photovoltaic industry.
Digital Twin–Based Structural Health Management System (HMS):
By monitoring the electrical performance, environmental conditions, structural loads, and other key parameters of photovoltaic (PV) modules, it is possible to assess the health and performance of the PV structure in real time. This enables the timely detection and resolution of potential issues caused by environmental changes—such as wind, waves, and water currents—thereby preventing structural damage, extending the service life of the PV system, and optimizing energy-harvesting efficiency. Such monitoring is essential for ensuring the stable operation of offshore PV installations and enhancing their energy-output efficiency.
Marine ranches may be exposed to extreme weather events such as typhoons and storm surges, which can damage aquaculture infrastructure. Moreover, the fixed structures of marine ranches—such as steel piles and net cages—are subject to prolonged immersion in the marine environment, making them susceptible to seawater corrosion. This corrosion can degrade the aquaculture environment and adversely affect the healthy growth of marine organisms.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
Impressed-current cathodic protection can slow the corrosion of metal structures in marine ranches, thereby maintaining their integrity and stability. Moreover, given that marine ranches may be located in diverse marine environments, intelligent ICCP systems can be optimized to suit specific environmental conditions—such as low temperatures and high salinity—enabling long-term, reliable cathodic protection. This significantly extends the service life of marine-ranch infrastructure, reduces maintenance and replacement costs associated with corrosion, and ultimately enhances economic efficiency.
Digital Twin–Based Structural Health Management System (HMS):
The system can collect real-time environmental data from marine ranches, including water temperature, salinity, dissolved oxygen, chlorophyll concentration, and pH, as well as monitor the growth status of underwater organisms. By leveraging real-time monitoring and intelligent analysis of this data, the system helps management personnel promptly identify and address potential issues—such as environmental changes, ecological disasters, and disease outbreaks—thereby enhancing aquaculture efficiency.
In addition, the system provides early-warning capabilities to promptly notify management personnel of detected anomalies, and supports remote control and digitalized management, thereby enhancing the efficiency and level of intelligence in the operation of marine ranches—crucial for ensuring their healthy, safe, and efficient functioning.
Subsea pipelines are critical infrastructure that connect offshore oilfields to onshore facilities, serving as the “green corridor” for offshore oil and gas transportation and playing a vital role in the petroleum and natural gas industries. However, due to their frequent exposure to harsh marine environments, these pipelines face severe structural health challenges, with high repair costs and significant technical difficulties.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
It can provide stable protection for subsea pipelines, particularly in areas with high soil resistivity. The system automatically adjusts the output current to maintain the pipeline surface at the designed protection potential, thereby delivering continuous and efficient cathodic protection. Effective cathodic protection reduces maintenance and repair activities caused by corrosion, lowers long-term operating costs, and ensures the safe transportation of oil and gas resources.
Digital Twin–Based Structural Health Management System (HMS):
The development and implementation of subsea pipeline structural monitoring systems are critical to ensuring the safe operation of these pipelines. By continuously monitoring pipeline integrity in real time, these systems can promptly detect potential structural issues—such as cracks, deformations, and corrosion—and enable the timely application of preventive maintenance measures, thereby reducing the risk of unplanned incidents.
During navigation, ships are subjected to a variety of dynamic loads and environmental factors. These factors can lead to stress concentrations, deformation, or damage in the hull structure. Meanwhile, corrosion weakens the structural integrity of the ship and increases maintenance costs. Effective corrosion protection measures and structural monitoring systems can extend the service life of ships and reduce operating expenses.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
The implementation of impressed-current cathodic protection can significantly extend the service life of ships, reduce corrosion-related damage, and lower maintenance costs, thereby helping to maintain the structural integrity of the vessel, ensure crew safety, and guarantee uninterrupted navigation.
Digital Twin–Based Structural Health Management System (HMS):
Sensors deployed at various structural locations enable real-time monitoring of critical parameters such as strain, stress, and vibration, thereby facilitating the timely detection of early damage or abnormal behavior in the structure. By continuously acquiring and analyzing diverse monitoring data, the system can provide a comprehensive assessment of the ship’s structural health, empowering crew members and management to make prompt decisions, evaluate the structure’s fatigue life, predict potential maintenance needs, optimize maintenance schedules, and reduce long-term operating costs. This is of great significance for ensuring the safe operation of ships and enhancing transportation efficiency.
The safe operation of a nuclear power plant depends on the integrity of its internal systems and equipment. For the metal structures within a nuclear power plant, particularly those exposed to the marine environment, corrosion protection and health monitoring are of paramount importance and must not be overlooked.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
The system enables real-time acquisition, automated analysis, and alarm notification of cathodic protection data in nuclear power plants. It ensures timely detection of faults and defects, triggers alarms, performs intelligent diagnostics, and provides recommendations for corrective actions, thereby enhancing management efficiency and reducing operation and maintenance costs.
Digital Twin–Based Structural Health Management System (HMS):
By continuously monitoring key structural components of nuclear power plants—such as the containment structure, reactor vessel, and cooling system—for parameters like displacement, strain, and crack propagation—this system can identify potential structural issues, prevent severe accidents, and safeguard both plant integrity and worker safety. In addition, the system provides data on the structural health condition, which can inform maintenance strategies and extend the design life of the nuclear power plant, thereby playing a critical role in ensuring the safe operation of nuclear facilities.
Port terminals are typically constructed from steel structures or reinforced concrete, both of which are susceptible to corrosion in marine environments—particularly in the fully immersed zone and the tidal zone—where corrosion rates are high. This can lead to pitting, reduction in structural strength, and even structural failure.
(2) Practical Significance
Impressed Current Cathodic Protection and Monitoring System (ICCP+CPMS):
The corrosion process can be slowed or halted by installing an impressed-current cathodic protection system. For port terminals, cathodic protection not only significantly extends the service life of structures and reduces maintenance costs, but also ensures the smooth operation of the port and the safe loading and unloading of cargo.
Digital Twin–Based Structural Health Management System (HMS):
By continuously monitoring key parameters such as displacement, strain, stress, and differential settlement of quay structures, it is possible to assess their structural health and performance. This enables the timely detection of structural aging, damage, or other potential issues, thereby preventing accidents and ensuring the safety of personnel and cargo. At the same time, the system provides data support for optimizing maintenance schedules and resource allocation, reducing unnecessary repair costs, and extending the service life of the quay. Furthermore, analysis of the monitoring data allows for the evaluation of the quay’s service capacity, reliability, and durability, providing a solid basis and guidance for decision-making related to structural repair, maintenance, and management—actions that are critical to ensuring the safety and functionality of port quays.
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Contact Information
Address: Company Headquarters:Building A, Overseas Students’ Entrepreneurship Park, No. 1 Huoju Road, High-tech Industrial Park, Dalian
Experiment–Manufacturing Base: Tangli Industrial Park, Hongqi Subdistrict, Ganjingzi District, Dalian City
Telephone: Corporate Headquarters: 0411-84660668
Experiment-Manufacturing Base: 0411-82646110
Email: info@kingmile.com
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