ANTIFOULING SYSTEM FOR

2,824TEU CONTAINER CARRIER HMD H.0369/0370

CLASS:GL

Cathelco Limited Marine House, Hipper Street, Chesterfield S40 1SS, United Kingdom

Tel: (44) (0126)235916/232375 Fax: (44) (0216) 206519 Web: www.cathelco.co.uk

Cathelco

ANTI-FOULING MANUAL

ANTIFOULING SYSTEM OPERATIONAL MANUAL

INSTALLATION / VESSEL: HMD H0369 & H0370 OPERATOR: CONTENTS:- PAGE SCOPE OF SUPPLY AND NET WEIGHTS 2

INTRODUCTION 3

ANODE OPERATION 4

ANODE MOUNTING SLEEVE TYPES 5

ELECTRONIC CONSTANT CONTROL UNIT 6

INSTRUCTIONS FOR MOUNTING CONTROL PANEL 7

INSTRUCTIONS FOR MOUNTING ANODES (FLANGED SLEEVES) 8

WIRING OF SYSTEM 9/10/11

SYSTEM COMPONENTS & NETT WEIGHTS 12

IN SERVICE INSTRUCTIONS & SETTINGS 13/14

INSTALLATION SPARES KIT 15

DRAWINGS DRAWING Nos.

ARRANGEMENT OF ANODE (FLANGED SLEEVE) A3312/19042

SYSTEM LAYOUT FOR ANTI-FOULING SYSTEM A3484

JUNCTION BOX DETAILS A3294/19042

ARRANGEMENT OF 300A/4D/ 4 WAY CONTROL PANEL C2114

TERMINAL LAYOUT FOR 300A/4D/ 4 WAY CONTROL PANEL C2115

Cathelco Limited Please Quote CA 19042 Marine House On All Correspondence Hipper Street South Chesterfield, United Kingdom S40 1SS Tel: (44) (01246) 207702/246701 Fax: (44) (01246) 206519

SIG DATE 14/07/04

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CATHELCO

ANTI-FOULING MANUAL

SYSTEM SPECIFICATION SHEET

CLIENT HMD

VESSEL'S H0369/H0370

CLIENTS ORDER No.

CATHELCO ORDER No. CA 19042

SEA WATER TO BE TREATED 2 STRAINERS FLOW RATE = 2500m/Hr (max)

ANODE LOCATION 1 MG & TC ANODE IN EACH OF 2 STRAINERS

ANODE MOUNTING TYPE JIS 10K-150A FLANGED MOUNTING SLEEVES

ANODE SPECIFICATION

No. OFF TYPE MATERIAL ANODE REF 2 MG/KB COPPER YZZ27/KB 2 TC/KB ALUMINIUM YZZ28/KB

ALL ANODES SUPPLIED WITH 15 M LG CABLE CONTROL PANEL 1 OFF TYPE 300A//4D/ 4 W 400V 3 ph 60 HZ

PAINTED : RAL 7032

JUNCTION BOX 2 OFF JUNCTION BOXES SUPPLIED BY CATHELCO

POWER SOURCE 400V 3 ph 60 HZ

SPARES 1 SET INSTALLATION ANODE LIFE 2 YEAR

YARD SUPPLY MATING FLANGES / PIPE UPSTANDS

CABLES FROM CONTROL PANEL TO JUNCTION BOX & VESSELS ALARM SYSTEM POWER SUPPLY CABLE EARTH RETURN CABLES

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CATHELCO

ANTI-FOULING MANUAL

REV B

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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CATHELCO

ANTI-FOULING MANUAL

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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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CATHELCO

ANTI-FOULING MANUAL

REV C

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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CATHELCO

ANTI-FOULING MANUAL

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ELECTRICAL CONSTANT CONTROL UNIT 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 Back section with Mounting Bars with four 22mm holes for bulkhead mounting. This section carries gland mounting plate in bottom face, Isolator switch box mounted on the left hand face & cable connectors, mounted on the inside of the back plate.

Section 2 Safety glass panelled door hinged at left side fully sealed and

lockable. One tee bar key supplied. b) Modules As the name implies, all control systems in the MPGS system 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 selector knob should be set at the recommended levels in the manual.

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CATHELCO

ANTI-FOULING MANUAL

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INSTRUCTIONS FOR MOUNTING CONTROL PANELS Fixing Control panels planning dimensions shown on drawing number C2114 Two holes are incorporated in each of the back mounting bars 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

WIRING UP Connect Anti-fouling system anodes & earth returns as per wiring instructions

later in manual. SETTING UP Once 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

green 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 the digital display ammeter directly above each 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 its self when the vessel is at sea in (salt water).

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

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CATHELCO

ANTI-FOULING MANUAL

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INSTRUCTIONS FOR JIS 10K - 150A FLANGE MOUNTED 120 DIA ANODES FITTED TO PIPE UPSTAND

1) Pipe upstand to be supplied and fitted by client. Pipe to have minimum bore of

136mm to ensure clearance of anode mounting assembly. Flange to be JIS 10K - 150A unless otherwise agreed with Cathelco

If Cathelco have supplied drawings for specific system: Burn a hole in the sea

chest top plate to suite outside diameter of pipe in position stated on drawing. Weld pipe upstand in position, ensuring: a) Pipe is welded to sea chest on both top and bottom surfaces. b) Flange top surfaces must be horizontal unless otherwise stated. If Cathelco have not supplied drawings : Determine the position of the pipe

upstand and burn a hole in the top plate of the sea chest to suit pipe outside diameter. The anodes must be positioned between the sea inlet grid and main suction outlet. Recommended centres of the anodes 400mm minimum centres at 200mm from the nearest steel work.

Weld pipe upstand in position, ensuring:- a) Pipe is welded to sea chest on both top and bottom surfaces. b) Flange top surfaces must be horizontal unless otherwise stated. c) Coat both pipe upstand and flanged mounting sleeve to same specification as

the sea chest/strainer. 2) Bolt flange mounting complete with anode to mating flange on pipe upstand.

Remember to fit gasket between flanges. Remove lid from top of mounting flange and check brass nut and lock are tight. Maximum torque 70 lbs/ft (10kg metres).

Fill space with an electrical isolating grease (silicon or similar). Ensure that O ring is fitted to top of sleeve. Replace lid and tighten cable

gland.

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CATHELCO

ANTI-FOULING MANUAL

REV B

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 4.0sq mm core. 25 - 50 Metre cable run Use 6.0sq mm core. 50 - 100 Metre cable run Use 4.0sq 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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CATHELCO

ANTI-FOULING MANUAL

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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.

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CATHELCO

ANTI-FOULING MANUAL

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CONTROL PANEL MALFUNCTION ALARM RELAY

If specified by the client each control panel can be supplied as original

equipment (at extra cost) with a flashing warning beacon and/or zero voltage relay to indicate a malfunction when any of the following occur:-

1) No electrical supply to the panel i.e. power module fuse blown 2) Current supply to one or more anodes being less than approx. 0.2 amps 3) Current supply to one or more anodes being greater than approx. 4.0 amps ALARM RELAY A relay with zero voltage contacts is fitted to the control panel module with 2

wiring points being clearly marked on the wiring connection block inside the control panel

NOTE:- The relay can be supplied with either normally open contacts or

normally closed contacts (Client to specify) Cathelco recommend normally closed relay contacts.

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CATHELCO

ANTI-FOULING MANUAL

CATHELCO Ref CA 19042 SCOPE OF SUPPLY AND WEIGHTS PER HULL

No. Off ITEM / DESCRIPTION Wt. Each Total Weight

2 Anodes Ref : YZZ27/KB 90.9 kg 181.8 kg 2 Anodes Ref : YZZ28/KB 28.8 kg 57.6 kg 4 Anode Mounting (Flanged Sleeve) 27.6 kg 110.4 kg 1 Control Panel 300A/4D/ 4 W 400V 229 kg 229 kg 2 K4 Junction Boxes 1 Installation spares (see below) 1 Anode Installation / Removal tool ref TA25

Total nett weight of System 578.8 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 2 years operation are: 2 off 3 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 2 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

PER HULL PART REF

REMARKS

1

3 AMP FUSES FOR

CONTROL PANEL

MODULES

2

F 3.1 A L250V

SPARES FUSES INSIDE

REAR OF CONTROL

PANEL

2

2.5 AMP FUSES :

CONTROL PANEL

POWER UNIT SPARES

2

T2.5 A 250V

SPARES FUSES INSIDE

REAR OF CONTROL

PANEL

3

BOX

SPANNER

1

TA25

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CATHELCO

ANTI-FOULING MANUAL

CA 19042 IN SERVICE INSTRUCTIONS - STRAINER 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 2 years approx. Once in service the anodes will require renewal every 2 years. Renewal can be carried out with the vessel afloat. Please ensure a reasonable despatch time when ordering replacement anodes.

You will require the following :- 2 Off Only Anodes Ref. YZZ27KB 2 Off Only Anodes Ref. YZZ28KB WHEN RE-ORDERING PLEASE QUOTE DRG No. A3312/19042 ADJUSTMENTS 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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CATHELCO

ANTI-FOULING MANUAL

IN SERVICE ADJUSTMENTS AND CURRENT SETTINGS

CA 19042

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.

SEA CHEST ANODE REF

ANODE SIZE

IN OPERATION CURRENT SETTINGS

NOT IN OPERATIONCURRENT SETTINGS

MG 1 YZZ27KB 3.8 amps 0.2 amps TC 1 YZZ28KB 3.8 amps 0.2 amps

MG 2 YZZ27KB 3.8 amps 0.2 amps TC 2 YZZ28KB 3.8 amps 0.2 amps

NOTE: When vessel is in blue water anode life may be extended by turning current settings down to 0.4 amps. for 408 anodes & below turn current down to 0.2 amps on both MG & TC.

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CATHELCO

ANTI-FOULING MANUAL

REV - LIST OF INSTALLATION SPARES

USE WITH 120 DIAMETER KB ANODE M30 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

2 OFF Brass M6 hex head set screw x 10 lg

2 OFF Brass M6 flat washer

The next 4 items are used to bolt anode to mounting sleeve

1 OFF M30 brass full nut

1 OFF M30 brass half nut

1 OFF M30 plated steel washer

1 OFF M30 Tab Locking 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 TA25

(Used to tighten/slacken M30 anode stud nuts)

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