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Marine Growth Prevention & Corrosion Mitigation System Installation & Operation Manual
Wilson Walton International, Inc. 3349 Route 138, Bldg. B, Suite B, Wall, NJ 07719 Phone: 732-681-0707 y Fax: 732-681-6118 www.wilsonwalton.com
Table of Contents
1.0 Introduction 1.1 1.2 Purpose and Functions Types of Fouling 1.2.1 Slimes 1.2.2 Hard Fouling 1.2.3 Soft Fouling Effects of Fouling Effects of Corrosion
System Operation 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Background General Description Incrustation Protection (Marine Fouling) 2.3.1 Overview 2.3.2 In Detail Corrosion Protection 2.4.1 Overview 2.4.2 In Detail The Importance of Settings Safely Used with Evaporators Maritime Installations
3.0
Components 3.1 3.2 3.3 3.4 3.5 3.6 Controller Power Unit Remote Administration Display (RAD) Unit 3.2.1 Display Messages Antifouling Anodes Anticorrosion Anodes Cables Junction Boxes
4.0
Installation Instructions 4.1 4.2 4.3 Controller Power Unit Cable Connections Anode/Cofferdam/Flange
5.0
Commissioning
6.0
7.0
Shipyard Installation Specification 7.1 7.2 7.3 Drydock Engine Room Other
8.0
Parts Lists 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 Two-Way Power Supply Four-Way Power Supply Remote Administration Display (RAD) Unit Junction Box Cofferdam Aluminum Anode Copper Anode Iron Anode
9.0
Drawings CF-0001 AA-8002 AA-8004 AA-8000 CF-7000 CF-3003 CF-9000 CF-1000 Anode Installation Two-Way Power Supply Four-Way Power Supply Remote Administration Display (RAD) Unit Junction Box Cofferdam Cofferdam Arrangement Anode Detail
1.0 Introduction
Corrosion or deterioration of metals used in the construction of ships hulls and seawater circulation systems has posed a major problem to ship owners for many years. Of the various anticorrosion systems used by the shipbuilding industry, cathodic protection is one of the most efficient, providing an effective and economical solution to the multiple corrosion problems encountered on the underwater structures of ships. Another cause of major concern is biofouling or marine fouling of Seawater Cooling Systems because of the innumerable operating hours lost in cleaning marine growth. So far, all the systems used to combat biofouling have involved uneconomical maintenance costs and times. The Wilson Walton ClearFlo Corrosion and Fouling Protection System of seawater cooling lines eliminates all corrosion and marine fouling phenomena at a minimum of time and expense. This system incorporates the most up-to-date and advanced features in the field of corrosion and fouling engineering.
The growth of marine organisms in seawater pipes and heat exchangers has been a continuing problem. In situations when the seawater circuits are not in use or the flow velocity of the cooling water is relatively low, the marine organisms colonize in the seawater systems. Marine fouling can sometimes accumulate to such an extent that the use of the systems would be severely restricted or even completely prevented without water treatment. Even after marine organisms die, the shells frequently become detached, blocking pipes and pumps. Protection from marine growth is needed in the entire system (i.e., general engine room services, condenser and compressor cooling, circulating water in air conditioning systems, fire mains, evaporators, and other seawater piping throughout the ship). Corrosion similarly occurs on all surfaces, ferrous or non-ferrous, in contact with seawater, and usually the extent and rate of corrosion is increased by the presence of bacterial and hard fouling. Whereas corrosion of external surfaces of vessels is generally controlled by material selection, cathodic protection, and/or paint systems, the situation in seawater piping is far more complex and difficult to control. Variable factors influencing both fouling and corrosion in the seawater lines include water flow rates, temperature changes, salinity, areas of ferrous and non-ferrous surfaces, bimetallic contacts, local pH or oxygen variations, linings or coatings, etc. Considerable progress over historically favored methods of fouling and corrosion mitigation has been made by the introduction and proven performance of the ClearFlo system. ClearFlo is a single system of protection which combines modern developments in hardware with proven and established methods of corrosion and fouling prevention, based on sound scientific principles. This combination provides a cost effective automatic method of fouling protection with reduced corrosion rates in seawater circulating systems.
1.2.1 Slimes This type of fouling is in the form of aerobic bacteria, anaerobic bacteria and other seawater micro organisms, usually single cells or diatoms. It is present in coastal waters at high levels, and may enter a vessels seawater system and colonize, where ideal growth conditions exist. There is an ever-plentiful supply of nutrients available in seawater, and together with the warmer on-board environment, it is an
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ideal place for colonization. These slimes influence heat transfer in exchangers, condensers, and coolers, and similarly in anaerobic conditions will modify corrosion behavior. 1.2.2 Hard Fouling This type of fouling is the main concern in seawater circuits. It is usually composed of dense-shelled organisms such as barnacles, mussels, tube worms, crabs, oysters, chitons and limpets. Hard fouling characteristically occurs where the organisms become attached to a surface, from which point their rate of growth can be relatively fast, in the ideal ship environment, namely lower water flow rates, reduced amount of light, adequate supplies of food (protein), oxygen and higher temperatures. Shellfish in the form of mussels and barnacles cause the most problems. Although an effective screen will prevent entry of many of the larger or fully grown types, such as fish and crabs etc., their eggs, larvae and spats, along with those of mussels and barnacles, enter the system in seawater in high numbers during the spawning season, then remain and develop in the system to become fully grown adults. Most barnacles, of which 39,000 species are known, are 1 to 5cm long, whereas mussels in the order of 100,000 living species of mollusks, can be considerably larger. It follows that providing a toxic environment to the larvae and establishing conditions where the fouling organism cannot settle and grow will inhibit fouling in the system. The ability of hard fouling to attach to a surface is therefore an important factor. Mussels are held in place by strong byssal threads, so this bond must be prevented from occurring, or broken. 1.2.3 Soft Fouling This includes all plant species as well as certain animal organisms such as sponges and anemones with a specific gravity close to that of water. Plants are photo synthetic, their survival dependent on adequate light, whereas sponges and anemones are found mainly in deeper water. In both cases they are less prevalent in seawater cooling systems.
corrosion processes for ferrous and non-ferrous sections. Slime bacteria will lead to rapid localized corrosion as a result of the formation of sulfate-reducing bacteria (SRB) in anaerobic conditions. Corrosion rates are enhanced in two ways: By depolarization of the cathodic regions of local corrosion cells; and by production of hydrogen sulfide by reduction of naturally occurring sulfur compounds in seawater. Hydrogen sulfide rapidly attacks metals, and other types of bacteria oxidize sulfur compounds to produce areas of sulfuric acid, particularly beneath deposits. They may also be conducive to hydrogen embrittlement, which in turn enhances corrosion fatigue. The presence of adherent hard fouling will accelerate corrosion by giving rise to differential aeration cells and accelerated corrosion in the vicinity of the fouling, and turbulence which in turn can cause impingement erosion or cavitation of non-ferrous tubes. It also gives rise to localized pitting attack which is more detrimental than general oxidation and scaling over the entire surface, and destruction of paint films and associated local rapid attack where the metal is exposed. Since metabolic products of fouling promote acidic conditions, it follows that prevention of fouling will greatly reduce the susceptibility and incidence of corrosion in seawater circuits.
Each Wilson Walton ClearFlo system is custom designed for maximum performance, however, it should not be regarded as a panacea to all problems requiring no further attention. A small amount of supervision and maintenance is required and we therefore ask the user to strictly adhere to the instructions in this manual to ensure satisfactory operation.
2.1 Background
In the last few decades, marine fouling and seawater-induced corrosion have become major concerns to ship owners and industries in the maritime sector. ClearFlo is a single system that solves both problems. With ClearFlo, vessels and industrial facilities can substantially reduce their costs of operation, maintenance and periodic replacement of worn out parts. The system is fabricated from the most up-todate and sophisticated electronic components to guarantee precision, safety and robustness.
Pre-programming eliminates the need for adjustments by the user, simplifying system operation and avoiding erroneous modifications that would adversely affect performance. Should it be determined that a change in anode output is necessary, it can be made by simply exchanging
the TP/FT-10 control modules with modules pre-programmed by Wilson Walton to the new optimal settings. The microprocessor-based TP/FT-10 control modules ensure against the tendency of analog meters and digital control modules to drift, thus eliminating the need for calibration.
Owing to the large number of systems used in industrial seawater circulation circuits, each project must be studied individually to determine the most suitable design.
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3.0 Components
3.1 Controller Power Unit
The ClearFlo controller power unit is state-of-the-art switch-mode type, utilizing the same sophisticated computer-controlled, network-based intelligence as the acclaimed Aquamatic III ICCP system. Each unit is capable of controlling four (4) anodes. The continuous current capacity ranges from 0 amps to 2 amps output per channel (or anode), at 0-12 volts. AC input requirement is 85-264 VAC, 1-phase, 47-63Hz, 17 amps. The power supply is bulkhead-mounted, small (5 x 10 x 12), and lightweight (20 lbs). The internal power supply is fully conformal coated within a Type 316 stainless steel enclosure for enhanced corrosion resistance. All components are modular for simplified service. The controller regulates to 100th of an amp to each anode, and it provides continuous diagnostics for fault detection. The computer-controller monitors the anode consumption rate, and indicates the number of days life remaining for each anode, to eliminate user uncertainty. The controller automatically detects flow and no-flow conditions via auxiliary contacts on pumps. This significantly increases anode life, and relieves the crew of the responsibility of manually adjusting anode outputs at-sea and in-port.
The Service Anode reports detailed operational and programming data for diagnostic purposes, including the following, in addition to the above Log Display data: Anode program current regulation set point Controller D/A drive voltage Flow contact program usage
The Remote Administration Display (RAD) unit is the same physical size as the Power Unit cabinet, but
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weighs less (15 lbs), and it will monitor all of the systems readings in a single convenient location, such as the control room or bridge. Other features include a Version Display which reports the embedded software version number, and Global Reset which invokes an entire system re-initialization and self-test cycle. Also, more than one display can be connected to a system for identical readouts to be available at several locations. AC input requirement is the same as the power supply: 85-264 VAC, 1-phase, 47-63 Hz, 4 amps. 3.2.1 Display Messages The two-line display will always show the system name on the first line. In Normal Mode, the second line is reserved for the following status messages: Message System Stabilizing System Working OK Both Channels Conducting Desired Current Explanation Shown only at system power on / startup Indicates normal operation Current output equals the programmed current set point If Flow Contacts are used, the controller will reduce the anode output to minimum when the pumps are de-energized. If vessel is not in fresh or brackish water, check anode, anode cable, anode splice, and fuse Check anode, anode cofferdam, anode junction box, and anode cable Contact Wilson Walton International when this message appears
[Al/Fe/Cu] Anode Low Output [Al/Fe/Cu] Anode Possible Short Circuit [Al/Fe/Cu] Anode Limited Life Remaining Will Require Replacement Soon
From the default scrolling status messages above, Tap (short press) the Data Select button to view: [AL/FE] Anode [AL/FE] Anode CU Anode CU Anode [AL/FE] Anode CU Anode x.xx Amps x.xx Volts x.xx Amps x.xx Volts xxxx Days (remaining) xxxx Days (remaining)
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Press & Hold (long press) Data Select button to display: Service Mode Normal Mode Self Test Version Exit Menu
In Service Mode, the second line is reserved for the following status messages: Channel 1 Anode Type Channel 1 Set [AL/FE/CU] Anode [AL/FE/CU] Anode Channel 1 D2A [AL/FE/CU] x.xx Amp x.xx Amp x.xx Volt x.xx Volt
In addition to the anode, components supplied for installation are mounting ring, cofferdam, insulating sleeve, washers, nuts, terminals, etc. Anode stainless steel studs and cross-linked polyolefin shrink sleeves have been lengthened to reduce risk of metal chunks breaking off at the neck of the anode and becoming lodged in the strainers. Anode insulation has been improved with the addition of double neoprene O-rings in between rigid PVC washers, to prevent shorting out of anodes.
3.5 Cables
Anode cable tails are supplied by Wilson Walton (as an option) or the shipyard. They are type LSDSGU-4, two-conductor, low-smoke, cross-linked polyolefin insulated, non-halogenated thermoplastic jacketed, unarmored, and flame retardant. Size is AWG #14, nominal outer diameter is 0.29 inches, and weight is approximately 62 lbs. per 100 ft. Cable is USCG, ABS and DNV approved, and U.L. listed for Marine Shipboard Cable. Anodes are supplied complete with cable tails to enable electrical connection between the anode and the junction box. Anode feeder cables are supplied by Wilson Walton (as an option) or the shipyard, to enable electrical connection between the junction box and the power supply. This cable should be low smoke, 2conductor, unarmored and size AWG #14 to conform with junction box glands. AC input cables are supplied by Wilson Walton (as an option) or the shipyard, to enable electrical connection between the ships distribution panel and the power supplies. This cable should be low smoke, 3-conductor, unarmored, and size AWG #10. Power ground cables are supplied by Wilson Walton (as an option) or the shipyard, to provide a ground between each power supply and the hull. This cable should be low smoke, 1-conductor, unarmored, and size AWG #10. No ground is required at junction box or anode cofferdam. The Remote Administration Display (RAD) unit does not require separate ground cable. However, one core of the 3conductor AC input cable should be used as the ground. Data transmission cables are supplied by Wilson Walton (as an option) or the shipyard, to enable electrical connection between the Power Unit(s) and the Remote Administration Display (RAD) unit. This cable should be unshielded, bonded twisted pair, size AWG #16. Unshielded cable exhibits better capacitance than armored cable, which is especially important over longer distances. Bonded cable possesses better strength and signal integrity characteristics. Uniform conductor-to-conductor spacing is maintained, providing consistent electrical performance. The twisted pair configuration reduces Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI). Using cable with different properties may have an adverse effect on data performance, up to and including communication failure. Wilson Walton recommends Belden 8471 for optimal performance.
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Looking up from sea chest through aperture. Notice aperture diameter is slightly (5-10mm) larger than inside diameter of mounting ring (shown). This disparity allows room for a weld bead securing the underside of mounting ring to sea chest that does not interfere with the insertion of the anode through the aperture.
Looking down at mounting ring through aperture and into the sea chest.
The mating flange to receive the anode and cofferdam flange should be welded in position with welding on both inside and outside joints. All weld scale should be removed and any damaged paintwork reinstated. The anode cofferdam screw cap should be removed and the anode cable disconnected. Remove the compression gland and screw the anode cap back onto the cofferdam. Hand-tighten only. Carefully lift the anode/cofferdam/flange assembly by means of the eyebolts provided and lower the anode onto the sea chest or strainer mating flange, making sure that the rubber gasket is in position. Evenly tighten down the anode flange bolts. This process is repeated for all anodes. Note: All threaded sections of nuts, bolts and the cofferdam lid, including the anode connection, must be lightly coated with WWI Marine Guard.
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After installing the anode assembly, feed back the anode cable and compression gland. Reconnect the anode cable to the anode bolt. Replace the cofferdam cap, securing tightly onto the uppermost O-ring. Finally, tighten the cable compression gland and fit the gland shroud. Secure anode cables and take back for connection in the junction box. When vessel is afloat, carryout leakage tests by checking for ingress of water into the cofferdam.
Note: When anodes are installed in a treatment tank, a bleeder valve should be fitted to vent gases, water and back pressure.
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5.0 Commissioning
Note: Only to be carried out when the vessel is afloat. 1. 2. 3. 4. 5. Check all cable connections at power control unit, terminal box and anodes. Identify each positive output and relevant anode, and record the same. Switch on AC supply and then the panel on/off switch. Switch on all power supplies then switch on Remote Administration Display (RAD). Record all status messages and record all system readings.
6.0 Maintenance
Maintenance requirements are minimal. The system operates at constant current output and therefore does not require adjustment. A weekly recording of current outputs on each anode is recommended (a log sheet is provided). This provides a record of the systems operation, an indication of any changes in function, and a reminder when anode replacements are scheduled. A complete loss of current on any anode should be investigated by checking all cable connections and power panel fuses.
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7.3 Other
7.3.0 Yard to install 3-conductor AWG#10 AC-input cable from ships distribution panel to ClearFlo power unit. 7.3.1 Yard to install Belden data transmission cable from ClearFlo power unit to RAD unit. 7.3.2 Yard to install 5 ft. of power ground cable from ClearFlo power supply to deck.
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Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Description Auxiliary Power Supply Main Circuit Breaker (On/Off Switch) Control Board Drive Board Controller Node TP/FT-10 Input Terminal Block AC Input Terminal Block Graphic Overlay Control Board Standoff Control Board Mounting Screw TP/FT-10 Mounting Screw Driver Board Mounting Screw Steel Enclosure (Cabinet) Cable Gland
Qty 1 1 1 2 1 1 1 1 4 8 3 6 1 6
Part Number CF-CP3-1000 AQ-CP3-1201 CF-CCB-300 CF-CCB-301 AQ-CCB-302 CF-CP3-118 CF-CP3-103 CF-CP3-106 CF-CP3-136 AQ-CP3-137 AQ-CP3-108 AQ-CP3-138 CF-CP3-119 AQ-CP3-135
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8.5 Cofferdam
(Drawing #CF-3003 and #CF-9000) Item 1 2 3 4 5 6 7 8 Description Cofferdam Cofferdam Lid Cofferdam Neoprene Gasket Cofferdam Neoprene Mounting Ring M16 x 2.0 Stud M16 x 2.0 Nut M16 Washer Cable Gland Qty 1 1 1 1 8 8 8 1 Part Number CF-901 CF-902 CF-903 CF-904 CF-905 CF-906 CF-907 CF-908
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9.0 Drawings
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26
27
28
29
30
31
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10.2 Lloyds