Impressed Current Cathodic Protection (ICCP) Systems

Complete Engineering, Material Supply, Field Installation & System Commissioning by GESIT

Impressed Current Cathodic Protection (ICCP) System Overview

Impressed Current Cathodic Protection (ICCP) is used when sacrificial anodes are not practical or cost-effective—especially when required protection currents are high, soil/water resistivity is elevated, or the asset traverses mixed environments.

ICCP Solution by GESIT

GESIT provides a complete ICCP solution, covering:

Engineering (design, calculation, drawings)
Material Supply (TR, anodes, cables, junction boxes, groundbed materials, test stations)
Field Installation (groundbed construction, TR setup, cable laying, wiring)
System Commissioning (energization, adjustment, verification, reporting)

Clients may also select:

Design Only
Material Only
Installation Only
Partial Supply / Retrofit of existing ICCP systems

When ICCP Is Required

ICCP is recommended when:

Required current is large, making galvanic anodes uneconomical
Soil or water resistivity is high (> 6,000 Ω·cm)
Pipelines or tanks pass through varying soil conditions
The system requires adjustability or remote monitoring
Long-term stable protection potential is needed

The system uses a Transformer Rectifier (TR) to deliver controlled DC current to inert anodes, maintaining structure-to-electrolyte potentials within safe ranges (target ≈ –850 mV vs Cu/CuSO₄, or as per standard).

ICCP Components Supplied by GESIT

1. Transformer Rectifier (TR) Unit

GESIT supplies industrial-grade TR Units in multiple configurations:

Manual Control TR — simple tap-switch operation
Automatic TR — constant current/voltage/potential
Solid-State TR — thyristor/MOSFET precision output
Remote Monitoring TR — SCADA / GSM / Modbus integrated

All TRs include weatherproof enclosures, metering, protections, and certification per project requirements.

2. ICCP Anodes & Groundbeds

Anode Types

MMO Titanium Anodes — long-lasting, efficient.
High-Silicon Cast Iron (HSCI) — cost-effective for soil.
Graphite Anodes — durable for moist soils.
Platinized Titanium Anodes — premium performance for marine & subsea

Groundbed Components

Pipe casing
Vent pipe
Anode centralizers
Carbonaceous backfill (coke breeze)

GESIT designs deep well, shallow horizontal, and hybrid groundbeds.

3. Junction Boxes (JB)

Available in FRP, stainless steel, or coated steel.

Types:

Positive Junction Box (PJB) — distributes current to anodes
Negative Junction Box (NJB) — return path to the structure
Monitoring/Test JB — potential measurement, shunts, selectors

All JBs can be customized with meters, resistors, fuses, and terminations.

4. ICCP Cables

Cable types supplied:

Anode (Positive) Cable — XLPE/PVC, XLPE/PVC/SWA, XLPE/PVC/AWA, HMWPE
Structure (Negative) Cable — burial-grade copper
Reference Electrode Cable — low-resistance for accurate measurement
Jumper Cables — corrosion-resistant stranded copper

Available in multiple AWG or metric sizes.

5. Test Stations / Test Points

Used for routine CP monitoring and potential measurements along pipelines, tanks, marine structures, and buried assets.

Supply Options by GESIT

GESIT offers flexible test station configurations to match project requirements:

Branded Test Stations: Supply of international brands such as Big Fink, Cott Manufacturing, or equivalent.

GESIT Fabricated Test Stations, Custom-made assemblies using: Casted aluminium head, Stainless steel box, FRP head.

Multiple support pole options: Galvanized steel pole, Coated steel pole, Concrete pole.

Optional features: Numbered terminal boards, Reference electrode access, Cable management and waterproof sealing

All test stations are supplied with internal wiring, terminals, and hardware as per project specifications.

Engineering, Material Supply, Field Installation & System Commissioning

Engineering

Design & Analysis

Current requirement calculation
Coating breakdown & structure exposure assessment
Selection of anode type and groundbed configuration
TR unit sizing (voltage, current, control mode)
Reference electrode placement strategy

System Configuration

Vertical or horizontal groundbed design
Anode output, spacing & consumption calculation
Cable routing with voltage drop analysis
Stray current & AC interference mitigation
Monitoring point layout (test stations & RMS)

Documentation & Deliverables

CP layout drawings (plan/profile)
Groundbed construction details
TR panel diagram & cable schedule
Bill of Materials (BOM)
Material & installation specifications
Commissioning procedure & method statement

Material Supply

GESIT supplies all ICCP system materials:

TR Units
Anodes (MMO, HSCI, Graphite, Pt-Ti)
Groundbed casing, vent pipes & backfill
Cables & joints
Junction boxes
Reference electrodes
Test stations
Accessories, fittings & connectors
All materials undergo QA/QC inspections before delivery.

Field Installation

Comprehensive on-site installation, including:

Groundbed construction (deep well or shallow)
Cable trenching, laying & termination
TR mounting & electrical works
JB installation & wiring
Test point installation
Earthworks and civil supports

System Commissioning

GESIT performs final commissioning involving:

Initial energization of the ICCP system
Output balancing and optimization
Structure-to-electrolyte potential measurements
“Instant-off” potential verification
Current distribution checks
Safety and functional tests
Submission of complete commissioning report and as-built drawings.

Ordering / Specification Guidance

To prepare an accurate ICCP solution, clients should provide:

Structure details (pipeline, tank, marine structure)
Soil resistivity / water conductivity data
Required design life
Drawings, alignment sheets, or coordinates
Preferred scope (full package, engineering only, material supply only, installation only, retrofit)

GESIT will submit a tailored ICCP proposal including system architecture, BOM, drawings, and commercial quotation.