Anti-fouling systems for offshore and coastal applications

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Electrochlorination Copper Ion Generation

Cathelco Offshore

Cathelco effective solutions to bio-fouling problems

Cathelco are technological leaders in antifouling systems for marine applications with a record of over 10,000 installations on ships, offshore platforms and onshore locations all over the world. Customers are supported through an international network of agents in over 40 countries. Cathelco specialise in electrochlorination and copper ion generation and thus offer clients the best solution to their particular requirements. With our strong background and knowledge of bio-fouling, we can analyze fouling problems and design the most effective system for protection. Our equipment is also engineered to the highest standards of quality. Beyond this, Cathelco can provide further support for customers on corrosion suppression and cathodic protection through Corrintec, a division specialising in sub sea pipeline cathodic protection surveys, and in the Asia Pacific region by IEV Ltd, the market leader in ocean powered marine growth control technology. By combining technical innovation with practical experience, Cathelco offer custom designed solutions which provide reliable performance and cost effectiveness. applications are:q Production Platforms & FPSOs q Drilling Platforms q Marine Vessels For onshore installations, Cathelco exercise the same degree of skill in design, engineering and project management, ensuring that anti-fouling systems are supplied on schedule and operate with maximum efficiency. Typical onshore applications are:q Petrochemical Refineries q Desalination/Reverse Osmosis Plants q Power Stations q Onshore Cement Plants q Onshore Smelters

Macro & micro-fouling

Bio-fouling comes in two forms: Macro-fouling: Barnacles and mussels can gradually restrict seawater flow and reduce the efficiency of cooling systems. In more extreme cases, pipes and valves can become completely blocked, resulting in shut-down of systems and consequent loss of production time. This can result in damage to equipment and may compromise standards of safety. Micro-fouling: Comes in the form of a layer of slime over the surface of heat exchanger plates and tubes and can reduce heat transfer efficiency by as much as 25%. It can also accelerate corrosion and result in a situation where maintenance is required more often than usual with subsequent increases in running costs. In water injection systems, the problem is two-fold: firstly, the problem associated with fouling and secondly, the need for a chlorine residual in the seawater to allow for efficient operation of the dual media fine filters.

A complete service for anti-fouling ECS and CIG systems: q Budgetary estimations q Detailed design q Fabrication q Installation q Commissioning q Maintenance q New or retrofit

Systems for offshore and onshore applications

Where seawater is used for cooling purposes, down-hole injection for the maintenance of oil reservoir pressure or for fire-fighting systems, bio-fouling can jeopardise the safe and efficient operation of equipment and processes. With the option of electrochlorination or copper ion generation, Cathelco can provide the most appropriate form of protection. Cathelco design and engineer systems for all types of anti-fouling applications, material specifications and site conditions. Factors taken into consideration include space restrictions, outdoor or indoor installations, safe or hazardous areas and high or low ambient temperatures. For offshore applications, anti-fouling systems are built as complete skidmounted units with each component stringently tested prior to assembly, ready for immediate shipment, installation and commissioning. Typical offshore

With fire fighting systems, which are mainly in a "standby/no flow" condition, anti-fouling at the intake caissons is essential for protection against macrofouling to avoid blockages.

Electrochlorination
Seawater is electrolysed into sodium hypochlorite (hypo, also known as "bleach"). It is the preferred chlorine alternative to replace conventional hazardous chlorine products. Hypo is used to prevent the growth of slime, barnacles, mussels and to destroy bacteria (disinfection). Continuous and shock dosing can be administered intermittently for more effective control. Benefits q Effective protection against macro and micro-fouling (continuous and shock dosing). q Safe and reliable, also eliminating the handling and storing of hazardous chlorine based chemicals. q Ideal to be used as an anti-bacterial agent (disinfection). q Suitable for offshore installations where chlorine is required for fine filter (dual media) water injection packages. q Essential to protect seawater intakes on desalination plants as well as providing chlorine for drinking water disinfection. q Minimum environmental impact (chlorine decomposes back into common salt again).

Copper Ion Generation

Copper ions are generated by means of electrolysis. Only very small concentrations are required to prevent the growth of slime, barnacles and mussels. Continuous and shock dosing can be administered intermittently for more effective control. Benefits q Effective protection against macro and micro-fouling. q Safe and reliable. q Intermittent dosing provides effective control against fouling. q Low impact on the environment is assured by controlled dosing. q Large caisson mounted units can be supplied to meet specific client requirements. q Small basket mounted units for fire pump and other applications.

Electrochlorination Systems (ECS)

Cathelco specialise in the design and manufacturing of electrochlorinators to offer clients the best solution to their particular anti-fouling and disinfection needs. Our electrochlorinators are designed to generate hypo with the highest chlorine concentration that is economically possible, for example: 2,000 PPM in seawater systems and 8,000 PPM in fresh water + salt systems. This ensures all hypo generation equipment (piping/fittings, hypo storage tanks and hypo dosing pumps) is of a minimum size, thus saving running and maintenance costs as well as requiring the minimum installation space. Electrochlorinators are also designed for either safe or hazardous areas, and to meet all the requirements of the client.

No need for commercial chlorine products

The purpose of electrochlorination is to offer a safe, economical and independent chlorine alternative to hazardous commercial chlorine products. Electrochlorination is the only 100% safe chlorine technology and is generated:q on-site - at the point of application. q on demand - only when required and always "fresh", also eliminating bulk storage. q using only basic inputs - seawater + electricity, or, fresh water + salt + electricity.

Consumables and consumption

The generation of sodium hypochlorite requires only: seawater + electricity, or, fresh water + salt + electricity. Consumption, when generating a sodium hypochlorite solution containing 1kg available chlorine is shown in the table below. SEA WATER SYSTEMS: - 4.2 kWh (AC) - 500 litres sea water (Where hypo @ 2,000 PPM) FRESH WATER + SALT SYSTEMS: - 5.5 kWh (AC) - 125 litres fresh water - 3.5 kg salt (Where hypo @ 8,000 PPM)

Principles of electrolysis
Salt is composed of sodium and chloride. When direct current is passed through

The electrolyser
The electrolyser consists of anodes and cathodes of solid titanium sheets that are arranged to form multiple cells inside a horizontal PVC tube/casing. This design is called a "plate electrolyser" and is the most popular and most efficient design, representing approx. 95% of all electrochlorinators world wide. Cathelco is only offering plate electrolysers. Anodes are coated with Mixed Metal Oxides (MMO) of the platinum group of metals, which is essential for the generation of chlorine.

Hydrogen and hypo de-gassing tank

Hydrogen is generated during electrochlorination. It is an inert byproduct and does not participate in the overall chemical reaction. It is discharged along with the hypo into the de-gassing tank where it is safely diluted and removed using blower fans.

Applications of hypo (chlorine)

Chlorine in the form of hypo, also called "bleach", is a powerful oxidant and is mainly used for: q anti-fouling to prevent sliming and mussel/barnacle growth. q disinfection and anti-bacterial purposes. q water treatment to oxidise and remove iron and manganese.

titanium electrodes in seawater or a salt water solution, the chlorides will disassociate to form chlorine. The process is basically as follows: q At the anode - oxidation of chloride ions to produce chlorine. q At the cathode - reduction of water to produce caustic soda and hydrogen. q In the cell - chlorine reacts with the caustic soda to produce sodium hypochlorite instantly.

In order to ensure a fail safe operation, dilution air is measured with an air flow meter and only after the set flow rate is achieved, is a signal sent to the control panel to enable the electrochlorination process. Any dilution air low flow condition will activate the emergency shut down system. The purpose of the hypo de-gassing tank is to:q enable the safe dilution and removal of hydrogen. q act as a hypo retention tank.

The Flow Process

Continuous and shock dosing
Continuous and shock dosing are usually considered for the effective control of micro and macro-fouling in sea water applications. During continuous dosing, a low chlorine dosing is maintained at all times. It provides protection against the majority of bio-fouling. Unfortunately macro organisms can become resistant to this low chlorine dosing and require a much higher chlorine dosing. During shock dosing, a much higher chlorine dosing is applied only for a short time and repeated at certain fixed intervals. This ensures complete protection against all micro and macro-fouling Cathelco offers a complete range of dosing strategies to ensure optimum antifouling protection at the lowest chlorine usage.
DC POWER SUPPLY Transformer & Rectifier HYPO + H2 100X DILUTED H2

BLOWER AIR (2x FANS)

OUT

ELECTROLYSER IN
FILTER ACID WASHING SYSTEM

HYPO DEGASSING TANK HYPO to DOSING PUMP(s)

SEAWATER or FRESH WATER + SALT

Scaling and de-scaling

All water contains dissolved calcium and magnesium. Calcium carbonate and magnesium hydroxide will always deposit on the cathode, a process commonly referred to as "scaling". It is a universal phenomenon with all electrochlorinators, without exception. Scale is easily removed by flushing the electrolyser with 5% diluted hydrochloric acid. The process takes approximately 1 hour and is required after every 10 days of continuous electrochlorination. The average down-time is therefore only 0.4%. The consumption of hydrochloric acid is very low and is re-used several times before additional acid is required to restore the acid concentration. Cathelco is offering manual and automatic acid washing systems.

Copper Ion Generation (CIG)

As the result of experience gained over the last 25 years as technological leaders in copper based anti-fouling systems, Cathelco has developed the Copper Ion Generator for controlling bio-fouling in offshore oil and gas installations. Unlike other copper based applications, the key principle of the offshore Copper Ion Generator is to produce a relatively high dose of copper ions. This is injected into the sea-water lift and fire-fighting caissons via dedicated dosing lines. To maximise the anti-biofouling effect and minimise the environmental impact of the treatment, the copper dose is applied on a discontinuous basis. This provides a level of copper sufficient to prevent the settlement of micro and macro-fouling, whilst at the same time, due to the dilution effect, minimises the level of copper ions which eventually pass to the environment. A further advantage of applying a discontinuous dose, is to prevent marine organisms getting resistant to the applied dose. It also results in the most costeffective way of controlling bio-fouling and minimises the operational costs of the Copper Ion Generation system. Seawater feed to the skid mounted Copper Ion Generation package is regulated by way of pressure control and emergency shut-down valves with flow control meters. All these systems are designed to operate in a "fail safe" mode. The ion generator operates at atmospheric pressure and the hydrogen produced as a natural part of the electrolysis process, is vented to a safe area by way of a "fail safe" hydrogen dilution and venting system. The Copper Ion Generation package can be designed to operate under "safe" or "hazardous" area conditions, and the control panel unit can be skid mounted or remotely located to suit client requirements. The control of the package can be by local PLC or via the clients main control network.

Hydrogen Dilution Fans 2 x 100% hydrogen dilution fans arranged to work in series, ensuring fail safe hydrogen dilution at all times.

Thermal Flow Switches Two thermal flow switches monitor the flow of air in the venting duct to provide a fail safe system.

Terminal Box To EExe/EExd specification suitable for hazardous area classification.

Electrolysis Chamber

Electrolysis Chamber

ESD & PRV Responsible for emergency shut down and pressure control. All systems designed to operate in fail safe mode

Flow Meter Continuously monitors flow through package. The electrolysis vessels can be used either individually or operating in parallel.

International Service Network

Our international network of sales and service centres can provide immediate advice and assistance on the complete range of Cathelco products.

Argentina Australia Brazil Brunei Canada

(East & West Coast)

China
(Dalian, Guangzhou, Shanghai, Hong Kong)

Korea Malaysia Mexico Norway Philippines Poland

(Gdansk & Szczecin)

Croatia Cyprus Denmark Egypt Finland France

(Atlantic & Mediterranean Coasts)

Portugal Romania Russia Saudia Arabia Singapore South Africa

(Durban & Cape Town)

Germany Greece Holland Iceland India Indonesia Iran Ireland Italy Japan

Spain Sri Lanka Sweden Taiwan

(Kaohsiung & Tapei)

Turkey United Arab Emirates USA

(East, West & Gulf Coasts)

Vietnam Venezuela

Cathelco Ltd, Marine House, 18 Hipper Street South Chesterfield S40 1SS United Kingdom Telephone +44 1246 207702 Fax +44 1246 206519 E-mail: sales@cathelco.co.uk Web site: www.cathelco.co.uk