ANTIFOULING SYSTEM

OPERATIONAL MANUAL
INSTALLATION / VESSEL: STOCZINA SZCZECINSKA NB B178/I/16

OPERATOR:

CONTENTS:- PAGE
SYSTEM SPECIFICATION 1
INTRODUCTION 2
ANODE OPERATION 3
ANODE MOUNTING SLEEVE TYPES 4
ELECTRONIC CONSTANT CONTROL UNIT 5
INSTRUCTIONS FOR MOUNTING CONTROL PANEL 6
INSTRUCTIONS FOR MOUNTING ANODES (FLANGED SLEEVES) 7
WIRING OF SYSTEM 8/9
SYSTEM COMPONENTS & NETT WEIGHTS 10
IN SERVICE INSTRUCTIONS & SETTINGS 11/12
INSTALLATION SPARES KIT 13

DRAWINGS DRAWING No.

ARRANGEMENT OF ANODE (FLANGED SLEEVES) A2545/A/10275
WIRING DIAGRAM FOR ANTI-FOULING SYSTEM A1204/E/10275
PLANNING DIMENSIONS FOR CONTROL PANEL A1229/E
ARRANGEMENT OF EL/DD/8 WAY CONTROL PANEL A1054/I/10275

Cathelco Limited Please Quote CA 10275/P

Marine House On All Correspondence
Hipper Street South
Chesterfield, United Kingdom S40 1SS
Tel: (44) (01246) 235916/232375
Telex: 547534 Mussel G.
Fax: (44) (01246) 206519
SIG DATE
24/06/03

ANTI-FOULING MANUAL
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SPECIFICATION

CLIENT STOCZINA SZCZECINSKA

VESSEL'S B178/I/16

CLIENTS INQ NO.

CATHELCO ORDER NO. CA10275/P

ANODE LOCATION 2 x WVR27 & 2 x WVR28 IN EACH OF 2 SEA CHESTS

ANODE MOUNTING TYPE FLANGED MOUNTING SLEEVES DN150 PN16

ANODE SPECIFICATION
No. OFF TYPE MATERIAL ANODE REF
4 MGS COPPER WVR27
4 TCS ALUMINIUM WVR28

ALL ANODES SUPPLIED WITH 2 M LG CABLE

CONTROL PANEL 1 OFF TYPE EL/DD/8W 220V 1 ph 60 Hz

POWER SOURCE 220V 1 ph 60 Hz

SPARES REQUIRED 1 SET INSTALLATION SPARES ONLY

ANODE LIFE 5 YEARS

CLIENT/YARD SUPPLY MATING FLANGES

CABLES FROM CONTROL PANEL TO JUNCTION BOX
POWER SUPPLY CABLE
JUNCTION BOXES

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INTRODUCTION
The Cathelco System is a patented method developed specifically for :-

a) The Control of marine growth (MG) in sea water systems

b) The reduction of corrosion of metal in contact with water.

It is difficult to generalise on the economics, but it is normally no exaggeration

to say that annual savings, taking in to consideration out of service time, are
sufficient to cover the capital cost of the System in two years or less.

Each Cathelco installation is designed for its particular task and should therefore
not be regarded as just another mass produced gadget which will cure all ills
with no further attention. Very little supervision is necessary, but we do ask for
your co-operation in following the simple instructions contained in this manual.

The Cathelco System, using our special anodes controls both marine growth
infestations and corrosion - the former being virtually eliminated, while the
latter will be reduced to a fraction of that normally to be expected.

The System is designed to give continuous and trouble free protection against
marine growth and corrosion with the minimum maintenance. It will only
operate for the full planned anode life and give complete protection, however, if
the anode currents are maintained at the correct settings.

Excessive anode current will result in an excessive rate of consumption of the

anodes, thus reducing their life and possibly leaving the water system
unprotected if the anode is prematurely consumed

Insufficient anode current will result in fouling of the water system.

Incorrect current setting either way can result in expensive cleaning operations
which should not be necessary if the system is operated correctly at all times.

Sea water that has been treated by a Cathelco system can be used as feed water
for evaporators or reverse osmosis plants for producing drinking water, as the
system will produce copper concentration well below that specified by the
Department of Trade.

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ANODE OPERATION

There are two types known as the Marine Growth (MG) Anodes and Trap
Corrosion Anodes (TC) or (FE) being used depending on the material of the
pipework/condenser system.

MG Anodes are manufactured from copper. They release ions during

electrolysis which combine with these released from the sea water to form an
environment which discourages spat and any other minute organisms entering,
and adhering in some area where they grow and start breeding. They are,
instead, carried straight through to discharge and, provided that no untreated
water is allowed to enter at some point subsequent to the anodes, freedom from
infestation is assured.

TC Anodes are manufactured from aluminium for use in a system with

predominantly steel pipes where the reaction of the aluminium anode with
seawater results in the formation of aluminium hydroxide. This disperses down
the pipework positively charged, forming anti-corrosive barrier on the pipework.

FE (Cast Iron) Anodes are used when the pipe work is mainly copper nickel or
aluminium brass. Here, the reaction of the cast iron anode with the seawater
releases Iron into the water flow for corrosion protection.

In order for the system to prevent marine growth it is imperative that where
there is more than one inlet, changeover of inlets occur.

There must be a period of at least 2 weeks if possible between changeover. Any

less than that may cause marine growth to appear. If in doubt, contact Cathelco.

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TYPES OF ANODE MOUNTING SLEEVES

These basically consist of three types:-

a) Weld-in sleeves for direct welding into the top plate of sea chests or strainers.

b) Flange mounted type for bolting either directly onto the top plate of the sea
chest or strainer, or bolting to pipe up stands.

Note : Both the above types of sleeve are supplied unpainted & covered with a
rust prevention coating. This coating MUST be removed using either White
Spirit/Turpentine before installation, welding in position or painting etc.

c) Nylon mounting sleeves, these are used for strainer use only, generally when
weld in sleeves cannot be used.

Irrespective of the type of anode sleeve, the top of the sleeve is fitted with a
safety cap which is pressure tested to 100 lbs per sq. inch. These are approved
by Lloyds and the department of trade and industry. The caps are supplied
complete with a water tight cable gland to ensure complete safety from the
ingress of seawater.

Instructions on fitting particular types of mounting sleeve are in later sections of

the manual.

NOTE:-

If the inside of the safety cap is filled with an electrical isolation grease (i.e.
silicon grease), it will help to prevent corrosion inside the cap and lid.

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ELECTRICAL CONSTANT CONTROL UNIT

SPECIFICATION EL/DD/ W TYPE

a) Enclosure

All steel construction with welded joints and flanges, finished in matt enamel
with locking perspex “window” door

Panel is in three sections as follows:-

Section 1 Mounting face with four 8mm holes for bulkhead mounting.
This section carries gland mounting plate in bottom face.

Section 2 Hinged at left hand face to section 1 carries all major electronic
workings i.e. rack system housing modules, mains input, anode
connections all accessible via open back.

Section 3 Safety glass panelled door hinged at left side fully sealed and
lockable. One key supplied.

b) Modules

As the name implies, all control systems in this unit are built up of ‘plug in’
components which are of brushed aluminium construction and require no
maintenance. Each module controls one pair of anodes via frontal mounted
amperage selector knobs. The current level for each anode is shown in the
digital display above each selector knob. Below which is an alarm L.E.D. this
will light when the current becomes too great or too low indicating either a
problem with the module or the anode.

c) Operation

When all connections have been made and anodes are fully immersed in
solution (seawater) the digital display should be set at the recommended levels
in the manual.

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INSTRUCTIONS FOR MOUNTING CONTROL PANELS EL/DD/ W TYPE

Fixing

Control panels EL/DD/2,4,6 and 8W planning dimensions shown on drawing

number A1229/E.
Control panels EL/DD/10,12,14 and 16W planning dimensions shown on
drawing number A1230/E.
Four holes are incorporated in each corner of the back plate of the panel, these
are for mounting. We recommend a bulkhead mounting in close proximity to
the sea chests/strainers to avoid voltage drop and cutting cable run costs.

MAINS SUPPLY UNIT

Run cable from available power source .... via gland to terminal marked
“MAINS IN”

SETTING UP

Once all the cables have been run and connected, the system is ready to be
switched on. NOTE - the following procedure can only be carried out with the
anodes in seawater.

a) Switch mains on at power switch on bottom left hand of front panel. A

red neon to right of switch will light up to register power on.

b) Set all anode currents as specified in Operation Manual by turning the

knobs to prescribed settings, confirmed by reading in the digital
display ammeter directly above each setting knob.

c) If the vessel is in fresh or brackish water the digital display may not
reach the recommended current settings which may cause the LED to
light up. This can be ignored & should correct it’s self when the vessel
is at sea in (salt water).

d) Switch off until Ship starts engine(s) up.

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INSTRUCTIONS FOR DN150 PN6 FLANGE MOUNTING ANODES

FITTED DIRECT TO SEA CHEST TOP PLATE OR STRAINER LID

It is important that anodes are mounted in the vertical position unless otherwise
stated on the Cathelco drawings for specific vessels.

DN150 PN6 MATING FLANGE

Drill and tap 8 holes M16 on 200 pitch circle diameter for 8 x M16 studs x 90
long complete with nuts and lock nuts.

FITTING

1a) If Cathelco have supplied drawings for your specific system, burn a hole in
the sea top plate 150mm diameter in position stated on drawing. Weld mating
flange in position (weld on both sides) and fit 8 studs to mating flange.

1b) If Cathelco have not supplied drawings Determine the position of the anode
mounting flange and burn hole in top plate of the sea chest 150mm in diameter.
The anodes must be positioned between the inlet grid and the main suction
outlet. Recommended centres of anodes 450mm minimum centres and 250mm
from nearest steel work.

1c) Weld mating flange in position on top of the top plate (weld on both sides) and
fit 8 studs to mating flange.

1d) Coat both pipe up stand and flanged mounting sleeve to same specification as
the sea chest/strainer lid.

2) Bolt flange mounting complete with anode to mating flange. Remember to fit
gasket between flanges. Remove lid from top of mounting flange and check
brass nut and lock nut are tight. Maximum torque - 70lbs (10 Kgs/m). Fill space
with an electrical isolating grease (silicon or similar).
Ensure ‘O’ ring is fitted to top of sleeve, replace lid and tighten gland.

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WIRING OF SYSTEM SOLID STUD ANODES

Client to supply all cables and connection boxes between:-

a) Power isolation switch and control panel

b) Control panel and anodes including earth return leads.

Minimum Recommended Cable Specification

Marine rubber double insulated. Use one core per anode and one core per earth
return. The minimum core size for all cables is as follows :-

0 - 25 Metre cable run Use 2.5sq mm core.

25 - 50 Metre cable run Use 4.0sq mm core.

50 - 100 Metre cable run Use 6.0sq mm core.

If the cable run is above 100 metres it is recommended to use separate control
panel.

For ease of identification, cables supplied as part of anode assemblies are

coloured as follows:-

MG (copper) Anode Cable - Grey Outer/Red Inner PVC covering.

or Red Outer/Red Inner PVC covering

TC (Aluminium) - Grey Outer/Black Inner or Black Outer

/Black Inner PVC covering

FE (Cast Iron) - Grey Outer/Black Inner or Black Outer

/Black Inner PVC covering

MG Anode stud has a 3mm long unscrewed section at the top of the stud

TC & FE Anodes studs are fully screwed to top.

Before tightening mounting sleeve lid & cable gland. Ensure that all anode
cables are securely fixed to the top of the anode mounting stud, with a cable
eyelet & M6 setscrew.

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WIRING UP SOLID STUD ANODES

An earth (-ve) return must be installed at each separate anode location i.e. if the
system supplied is designed for 2 sea chests/strainers then 2 earth returns must
be used. Use a min of 1 earth return for every 4 anodes Ensure that a separate
cable is used for this purpose. Use cable as specified above. Connect to the
terminals available in the rear of the control unit marked ‘earth returns’. We
suggest the cable connections are made by welding a bolt on to the strainer or
sea chest close to the anodes (but no nearer than 250mm).

Fit junction box close to the anodes and wire to control panel using
recommended cable as per attached wiring diagram and control box drawing.

It is recommended to fill junction box with a silicon grease or similar non-

hardening electrically isolating compound as a protection against corrosion.

After switching on, check the polarity of the anodes in relation to the hull. All
anodes are to be positive, relative to a negative hull.

TROUBLE SHOOTING

NO LIGHTS ON AT ALL

A) Check mains fuse in the front of the control panel (above on-off switch).

B) Check circuit breaker in distribution box.

ANY ONE DISPLAY WILL NOT SHOW A READING

A) Check anode fuse at the rear of the module.

B) Check if any cable has been severed.

C) Check anode lead joint at the sea chest.

D) Change over any two modules to check if fault is in module or rest of system.

ALARM L.E.D. LIGHTS UP

A) If digital display is showing zero treat as above

B) If digital display is not showing a reading but led is light, fault with module
Return For Repair.

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CATHELCO REF : CA 10275
SCOPE OF SUPPLY AND WEIGHTS PER HULL

No. Off ITEM / DESCRIPTION Wt. Each Total Weight

4 Anodes Ref : WVR27 77.8 kg 311.2 kg

4 Anodes Ref : WVR28 24.4 kg 97.6 kg
8 Anode Mounting (Flanged Sleeve) 27.2 kg 217.6 kg
1 Control Panel EL/DD/8 W 220V 25.0 kg 25.0 kg
1 Installation spares (see below)
1 Anode Installation / Removal tool ref TIM-9

Total nett weight of System 651.4 kg

NOTE: Installation Spares are for use if required during initial fitting
only. (see separate sheet for itemised detail)
ON BOARD SPARES
Only spares required for first 5 years operation are:

2 off 3.15 amp fuses for control panel modules and 2 off 2.5 amp fuses for control
panel power unit, spare fuses fixed to inside rear of control panel casting.
For replacement anodes required after 5 years, see list above (only anodes required)
Replacement anodes or guarantee work if required contact:
Cathelco Ltd (see first page)
SPARE PARTS LIST
NO. NAME SKETCH SUPPLY PART REMARK
PER HULL REF S
3.15 AMP SPARES
FUSES FUSES
1 FOR 2 F 3.15 A INSIDE
CONTROL L250V CONTROL
PANEL PANEL
MODULES
2.5 AMP SPARES
FUSES : FUSES
2 CONTROL 2 T2.5 A INSIDE
PANEL 250V CONTROL
POWER UNIT PANEL
SPARES

BOX
3 SPANNER 1 TIM-9

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CA 10275
IN SERVICE INSTRUCTIONS - SEA CHEST MOUNTED ANODES

DESCRIPTION

ONCE THE SYSTEM HAS BEEN INSTALLED IT WILL PERFORM TWO FUNCTIONS:-

A) Eliminate marine growth and reduce the corrosion rate in the seawater service
lines.

B) The system uses impressed current sacrificial anodes which are designed to
last 5 years approx. Once in service the anodes will require renewal every 5
years. Renewal can be carried out with the vessel in dry-dock. Please ensure a
reasonable despatch time when ordering replacement anodes.

You will require the following :-

4 Off Anodes Ref : WVR27

4 Off Anodes Ref : WVR28

WHEN RE-ORDERING PLEASE QUOTE DRAWING No. A2545/A/10275

The control panel is fully automatic and therefore does not require any
adjustment in service.

CHECKING

We suggest that as a matter of course the Control panel be checked every two
(2) weeks.

When checking, see that all the digital display ammeters are working, this will
determine all is correct. When the anodes have nearly wasted, the digital
display above the corresponding anode will start to fall. When this happens,
turn the anode current knob back to zero and leave it until the anode renewal.
Reset once again at sea after renewal to current settings given previously.

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IN SERVICE ADJUSTMENTS AND CURRENT SETTINGS

CA 10275

The effective working of the system can only be determined by inspection and
it is suggested that if after 6 months of operation the opportunity to examine a
strainer, length of pipe or heat exchanger, presents itself, this should be done.

In the event of there being signs of infestation, the current to each anode in
this section should be increased by a maximum of 0.2 amps, but if no fouling
is present the current to each anode within this section may be reduced by a
maximum of 0.2 amps.

This routine can be repeated at intervals, the current being adjusted

accordingly.

NOTE: The higher the current setting the shorter the anode life.
The lower the current setting the greater the anode life.

IN OPERATION NOT IN OPERATION

SEA CHEST ANODE CURRENT SETTINGS CURRENT SETTINGS
ANODE REF SIZE

MG 1 WVR27 0.8 amps 0.4 amps

TC 1 WVR28 1.0 amps 0.4 amps

MG 2 WVR27 0.8 amps 0.4 amps

TC 2 WVR28 1.0 amps 0.4 amps

MG 3 WVR27 0.8 amps 0.4 amps

TC 3 WVR28 1.0 amps 0.4 amps

MG 4 WVR27 0.8 amps 0.4 amps

TC 4 WVR28 1.0 amps 0.4 amps

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LIST OF INSTALLATION SPARES

USE WITH 120 DIAMETER ANODE M27 SOLID STUD SYSTEM

1 OFF Watertight cable gland type T & B 9521 (fit to sleeve lid)
1 OFF ‘O’ Ring 3mm sec x 110 mean diameter (fit between lid and mounting sleeve)
1 OFF Neoprene washer 120mm diameter x 1.6mm thick
The next two items connect anode power cable to anode stud
1 OFF Brass M6 hex head set screw x 10 lg
1 OFF Brass M6 flat washer
The next 4 items are used to bolt anode to mounting sleeve
1 OFF M27 brass full nut
1 OFF M27 brass half nut
1 OFF M27 plated steel washer
1 OFF UPVC Top Hat washer 55 o/d x 6 thk

ANODE MOUNTING TOOL

This tool to remain onboard to facilitate anode installation and removal.

1 OFF Box spanner
(Used to tighten/slacken M27 anode stud nuts)

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LOG SHEET FOR ANTI-FOULING AND CORROSION CONTROL SYSTEM
VESSEL NB B170/I/16 OWNER YEAR
SYSTEM FIRST INSTALLED 2005 ANODE CHANGE OVER PERIOD 5 YEARS CA 10275/P

Week MG–1 TC–1 MG–2 TC–2 MG–3 TC–3 MG–4 TC–4

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
Initial
Setting

OBSERVATIONS Strainer inspected on

(x) as observed Nil Light Medium Heavy
Fouling in Strainer
Fouling in Pipeline
Fouling in Heat Exch.
Corrosion in Stainer
Corrosion in Pipeline
Corrosion in Heat Exch.

Remarks______________________________________________________________________________

______________________________________________________________________________________

Submitted by____________________________ Chief Engineer_______________________________

Cathelco Limited Marine House, Hipper Street South, Chesterfield, S40 1SS. United Kingdom.
Tel: 01246 235916 or 207702 Fax: 01246 206519 Email [email protected].