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TANKGARD
Internal Cathodic Protection System
For Process Vessels and Tanks
Installation & Operation Manual

Phone: (713) 983-7117

Fax: (713) 983-8858

Deepwater Corrosion Services Inc.

www.stoprust.com

10851 Train Court

Houston, TX 77041

DEEPWATER CORROSION SERVICES, INC.

TANKGARD MANUAL

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Table of Contents
Section 1

System Description

Section 2

Anode Installation

Section 3

Reference Cell Installation

Section 4

Rectifier Installation

Section 5

Energizing & Commissioning

Section 6

Routine Maintenance

Section 7

Maintenance Forms

Section 8

Troubleshooting

Section 9

Reference Drawings

Section 10

Rectifier Schematic

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System Description
1.0

General
The TankGard system is an automatic, potentially controlled, impressed
current cathodic protection system which is designed to control internal
corrosion of the tank.
The system is comprised of the following main components:

2.0

Anodes
The anodes are the devices through which the cathodic protection current
is delivered to the internal tank surfaces. The anodes in this system are
through-wall mounted. XXXX (XX) 2 x 60 anodes are provided. These
anodes are cast from high silicon cast iron with a chromium addition
(SiFeCr).

3.0

Anode Mounts
The anode mount is the structure which supports the anode in the tank
while retaining electrical isolation between the anode and the tank shell.
The mounts used on the vessel are FlangeMatetype 6 sch. 150.

4.0

Reference Electrodes
The reference electrodes provides a means to measure the electrical
potential between the tank wall and the fluid within the tank, this is a
measure of the degree of cathodic protection being afforded to the vessel.
The electrodes used in this vessel are two POLATRAK HP-1Z zinc
electrodes for potential monitoring, and one POLATRAK RT-1Z which is
deployed through the wall on a retractor and will be used as the control
electrode.

5.0

Power Unit
The power unit or rectifier delivers D.C. electrical current through the
anodes, the type of unit installed as part of this system is as follows:
Manufacturer
Rating:

Universal Rectifiers Inc.

AC 120 Volt 60 Hz 1 Phase
DC XX Ampere @ XX Volts

Controller

CD-11 IR Free

Cooling

Natural Air

Serial Number(s)

XXXXXX
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Anode Installation Procedure

Thru Wall Mount (Ref. Fig. 1.0)
CAUTION: The cast silicon iron anodes used in TankGard Systems are quite
brittle, they should not be dropped or otherwise mishandled. Always leave them
in the packaging provided until needed for installation.
1.0
Ensure that the anode head is screwed tightly into the FlangeMate anode
mount. If loose, use a pipe wrench to tighten until the rubber sealing washer
between the anode head and the mount compresses.
2.0
Slip the steel gasket provided over the anode and introduce the anode into
the nozzle.
3.0
Have somebody support the end of the anode inside the tank as the
cantilever load will be quite large.
4.0
Install the fasteners and tighten nuts to the desired torque in the
appropriate sequence.
NOTE: When installed the anode may appear to droop a little
inside the vessel; this is normal.

Anode Installation Procedure

Roof Suspension Mount (Ref. Fig. 2.0)
CAUTION: The cast silicon iron anodes used in TankGard Systems are quite
brittle, they should not be dropped or otherwise mishandled. Always leave them
in the packaging provided until needed for installation.
1.0
Ensure that both upper and lower blue head connections are tight and the
sealing washers are compressed.
2.0

Ensure that there are no kinks or loops in the suspension cable.

3.0
Place the steel gasket provided on the flange nozzle, and install spacer
blocks as shown on the diagram.
4.0
Introduce the anode into the nozzle and slowly lower it by the suspension
cable into the tank. This can be achieved manually, the entire weight of an
average assembly is between 120 lbs. and 150 lbs. If a crane is available to
assist, the anode may be rigged from the handles on the outside of the flange.
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5.0
Set the assembly down onto the spacers. Always use the handles on the
flange to lift and maneuver the assembly. Do not use the electrical condulet
box.
6.0
Align the gasket and two or three bolts then remove spacers and gently
lower the assembly onto the flange face.
DO NOT GET FINGERS BETWEEN FLANGE FACES!
7.0
Install the blue Xylan coated fasteners and tighten nuts to the desired
torque in the appropriate sequence.

Reference Electrode Installation

Retractable Electrode (Ref. Fig. 3.0)
NOTE: If a retractable electrode is required it is necessary to
have a pre-installed 2 ball valve at the desired location on the
tank. Ensure that the location of the valve provides sufficient
clearance for the probe to be fully retracted (approx.36).
1.0
Loosen the packing gland nut enough to allow the probe body to slide
easily in the housing.
2.0

Retract the reference electrode fully into the housing of the retractor.

4.0
Tighten the packing gland nut until the electrode is held tight in the fully
retracted position.
5.0
Ensure that the ball valve on the vessel is closed, then remove the blind
flange or bull plug from the valve. Exercise caution here as there may be
pressure trapped between the blind flange or bull plug.
6.0
Install the new tapped blind flange to the valve and screw the retractor into
the flange, a thread lubricant is recommended as stainless steel threads tend to
gall.
7.0
Double check that the bleed valve is closed and that the safety chain is
secure.
8.0
Slowly open the process valve and allow the system pressure to equalize.
The packing gland may leak slightly, tighten it just enough to stop the leak.
9.0
Push the probe in far enough so that the electrode is just clear of the
nozzle inside the vessel.
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10.0

Tighten the packing gland to 55 - 60 ft./lbs.

11.0

Tag the valve Do Not Operate.

12.0

Remove cover of condulet and make wiring connection.

Fixed Electrode (Thru Wall Mount) Polatrak HP-1Z (Ref. Fig. 4.0)
NOTE: If fixed thru wall mount electrodes are used, a pre-installed NPT
thread-o-let or tapped NPT blind flange is required.
HP-1Z
1.0
The HP-1Z is designed for monitoring at the vessel only, it requires no
cabling. See attached instruction sheet.

Fig. 4.0 HP-1Z Electrode

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POLATRAK HP-1Z HIGH PRESSURE REFERENCE CELL

INSTALLATION & OPERATION

Back Plug

Isolating Union

Installation Nipple Extension Shaft

Zinc Element

WARNING - DO NOT ATTEMPT TO DISASSEMBLE REFERENCE ELECTRODE

INSTALLATION:
1
2
3

Select appropriate NPT fitting which will locate the electrode element in the
water phase of the vessel.
Apply teflon thread tape to the installation nipple.
Using the hex installation nipple only, screw the electrode into the vessel.

INTERROGATION:
1
2
3

Using a standard digital voltmeter, set meter to 2 or 3 Volts DC range.

Using probe type leads, hold the red (positive) lead on the nipple and the
black (negative lead) on the plug.
Record the value - less than (+)0.250 Volts is protected more is unprotected.

BLACK (-) LEAD TO PLUG

RED (+) LEAD TO NIPPLE

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Fixed Electrode (Deck Mount) Polatrak WB-1Z-E (Ref. Fig. 5.0)

NOTE: If fixed deck (roof) mount electrodes are used, a pre-installed NPT
thread-o-let or tapped NPT blind flange is required.
1.0
The fixed electrode is supplied ready to screw in. The condulet is already
attached. Simply wrap some Teflon thread tape around the NPT thread and
screw into the thread-o-let or tapped blind flange. Tighten at nipple, not at the
condulet.

Fig. 5.0 WB-1Z-E (Extended Deck Mount Electrode)

Rectifier Installation
1.0
The rectifier is to be located in a non-hazardous location, the case is rated
NEMA 4X. Select a site and mount the cabinet to a panel such that the status
indication lamps on top of cabinet protrudes above the panel and are visible
through 360 (If Fitted). The center of the cabinet should ideally be about 56
from ground level.
2.0
No knockouts are provided in the cabinet. They will have to be field
determined, in most cases it should be sufficient to provide 3 (three) knockouts,
one for AC power in, one for DC power out and one for the reference electrode.

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3.0

AC Connection
Run a two wire 115 Volt supply and connect at the AC input block on the
lower left hand corner of the panel.
4.0

DC Connection
Run a single #2 AWG cable from the positive terminal on the rectifier to
the common bus in the junction box. (See schematic system diagram). From
there run a # 6 or 8 AWG wire to each anode one on each shunt leg.
5.0

Reference Electrode Connection

A #12 AWG wire should be routed in its own conduit from the retractable
electrode to the terminal marked electrode on the rectifier panel.
6.0

Low Level Shutdown (Optional)

A separate contactor is provided to facilitate low level shutdown. This
requires an interface to the level control system computer. The normally closed
contactor requires 115 Volts AC to open.

Energization & Commissioning (Bell Controlled Units - Ref. Fig. 7.0)

Follow the next steps to commission the system:
ENSURE THAT THE VESSEL CONTAINS FLUID
1.0
Before energization, using a multimeter, check and note the following
readings: electrode to structure potential, this will be a DC voltage approximately
(-)0.30 V to (-)0.45V. Read from the electrode and structure posts. The reading
should agree with the reading on the analog potential meter on the panel. If the
reading varies significantly from these values, check the wiring and ensure that
the electrode is wet. If there is still a problem, call Deepwater at 713 983 7117.
2.0
Check the potential between anodes and the tank. This value should be
approximately (+)50 mVDC with the positive test lead to the anode and the meter
set on the lowest DC range. If the reading is zero, the anode may be shorted to
the vessel, call Deepwater Corrosion.
3.0

Set the Auto/Manual switch to Auto.

4.0

Set the voltage taps to C1 F1.

5.0
Switch on the unit at the main breaker. The red power on the lamp should
illuminate.

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6.0
Depress the potential read/set toggle to the set position. Use a small
screwdriver to adjust the potential screw on the auto controller panel. Adjust
the screw until the potential meter reads (-)0.1 Volts, this should require several
clockwise rotations. Note: the toggle switch must be held down when making
this adjustment.
7.0

Release the toggle and switch the power off at the main breaker.

8.0

Adjust the voltage taps to C1 F6.

9.0

Switch the power back on.

Voltage and current should register on the main meters, the green LED on
the auto controller should blink and the potential on the meter should move
toward the set value. After several minutes the current should begin to drop off
slightly as the set potential is approached. If this does not happen the taps may
need to be increased to allow more current to flow. If this is the case switch the
unit off and adjust the taps to C2 F3.
10.0

Set the current limit:

When the unit has been running for about 1 hour, adjust the screw in the
current section of the controller counter-clockwise until the red LED begins to
blink. Then rotate the screw slowly clockwise until the light goes out, then add
one half turn clockwise.
11.0

Set the status lamps: (If fitted)

Turn the light adjust screw fully clockwise, then turn slowly counterclockwise until the red light goes out and the green comes on. If the current
drops below the limit just set the red light will come on. Several minor
adjustments may be required over the first week or two until the system
stabilizes, if the red light comes on simply turn the screw counter-clockwise until
it goes out.

Routine Maintenance
1.0
Monthly Readings
Once every month, readings should be measured and logged on the enclosed
maintenance form, the form is self-explanatory as to how the readings are
recorded. It should be expected that the current and voltage readings may vary,
however, the desired potential level should be maintained. The completed forms
can be faxed to InterResources and any problems will be reported back to the
customer.

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2.0. Adjustments
If the rectifier is unable to supply sufficient current to achieve the desired
potential level, it will be necessary to make an adjustment. Follow these steps:
1)

Switch the unit off.

2)

Adjust the link bars to the next fine tap.

3)

Switch the unit on, if the desired potential is not achieved

within 5 minutes of re-energization, repeat steps 1 and 2 until it
is.
If the rectifier is not responding as expected, call
Deepwater Corrosion.

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TANKGARD Cathodic Protection System Monthly Maintenance Report

Vessel Location:

Tech:

Vessel Type:

Date

Vessel ID:

Rect. #:

Rectifier Tap Settings As

Coarse __________
Found
Fine
__________
Rectifier Tap Settings As
Coarse __________
Left
Fine
__________
DC Output
As Found _______________ Amperes
(Read From Meters)
As Left
_______________ Amperes

Of _______________
Of _______________
Of _______________
Of _______________
_______________ Volts
_______________ Volts

LED Status on Controller: (Check Appropriate Box)

On

Off

Blinking

Green
Yellow
Red

Potentials and Anode Currents

Parameter
Red Lead (+)
IR Free
Read from meter on panel
Potential

Black Lead (-)

Scale

Value

Scale
200mVdc
200mVdc

Value

Potential Set Read from Potential Meter (Hold

Point
Read-Set Switch to Set)

Parameter
Anode 1
Anode 2

Individual Anode Currents

Red Lead (+)
Black Lead (-)
Shunt #1 Top
Shunt #1 Bottom
Shunt #2 Top
Shunt #2 Bottom

Additional Notes on Adjustments, Malfunctions, Suggestions:

Fax completed to: Deepwater Corrosion Services, Inc. 713 983-8858 Attn: Engineering

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Reference Electrode Replacement-Retractable Electrode(Fig 3.0)

1.0

Disconnect the wire inside the condulet.

2.0
Slowly loosen the packing gland allowing the system pressure to push the
probe out. If there is insufficient pressure to push the probe out, gently pull the
probe until it is fully retracted into the body. NEVER STAND DIRECTLY IN THE
PATH OF A RETRACTOR ASSEMBLY. ALWAYS STAND TO ONE SIDE.
3.0

Tighten the packing gland nut to hold the probe securely.

4.0
Close the process ball valve slowly, any interference means that the probe
is not fully retracted, do not force the valve closed or the valve and the probe will
be damaged.
5.0

Unscrew the probe and remove it from the blind flange.

6.0

Plug the flange thread.

7.0
Clean the probe rod to remove any debris, this will prolong the life of the
packing material and ensure a good seal.

Basic Troubleshooting
1.0

Wiring Diagram

A wiring diagram is available for use by experienced personnel. Only

experienced electrical personnel should attempt to locate and repair electrical
problems, should they occur.
Some of the more common problems are listed below:
Symptom: No D.C. Current or Voltage Output
Check A. C. overload protection for blown fuses or tripped breaker. Check A.C.
power supply into unit. Check reference potential versus set point, if desired
potential is being held, the unit will shut down automatically.
Symptom: D.C. Voltage but no Current Output
Check D.C. Ammeter, read with external meter across total current shunt. Check
external D.C. connections, anodes may have failed or D.C. fuses may have
blown.

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Symptom: D.C. Current Output but no Voltage Reading

Check C.C. Voltmeter, use external meter across positive and negative
terminals.
Symptom: Maximum Rated D.C. Voltage Cannot be Attained
Check: Load resistance of external D.C. circuit, some anodes may have failed or
tank may not be full. Check that unit is not operating against a preset voltage or
current limit.
If the problem cannot be easily fixed, call either of the following (have the unit
model and serial number available):
2.0

Spare Parts

Spare parts may be ordered directly from Universal Rectifiers Inc. at the above
number. The serial and model numbers will be required from the unit name
plate.
Telephone

Fax

Deepwater Corrosion Services

(713) 983-7117

(713) 983-8858

Universal Rectifiers Inc.

(281) 342-8471

(281) 342-0292

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Reference Drawings

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Rectifier Schematic

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