MARINE MACRO FOULING: A REVIEW OF CONTROL TECHNOLOGY IN THE CONTEXT OF AN ON-LINE EXPERIMENT IN THE TURBINE CONDENSER WATER BOX

OF AL-JUBAIL PHASE-I POWER/MSF PLANTS1

P. K. Abdul Azis, Ibrahim Al-Tisan, Mohammed Al-Daili, Troy N. Green and Khalid Ba-Mardouf
Saline Water Conversion Corporation P.O.Box 8328, Al-Jubail -31951, Saudi Arabia Tel: + 966-3-343 0012, Fax: + 966-3-343 1615 Email: rdc@swcc.gov.sa &

Saeed Ali-Al-Qahtani & Khalid Al-Sabai

Desalination and Power plants, Al-Jubail 31951 Kingdom of Saudi Arabia.

ABSTRACT The problem of macrofouling has serious implications in the performance of desalination and power plants. Intake structures, screens, seawater piping systems and heat exchanger tubes are the sites worst affected in the plants causing overall decline in plant efficiency at great economic cost. The last half a century has witnessed significant advancements in the development of macrofouling control technologies. Materials of inherent antifouling properties are widely used in the construction sector. Control technologies available include antifouling paints and coatings, injection of biocides, marine bio-active compounds materials of inherent antifouling properties, heat treatment, pulse-power devices, UV and nuclear radiation, scrubbing devices, biological control, etc. Literature search carried out during the last few years has yielded about 450 references. The paper presents, in a very concise manner, state-ofthe- art macrofouling control technologies pertinent to desalination and power plants in the Kingdom. The paper also discusses the issues of biofouling control in the AlJubail plants based on the results of an on-line macrofouling experiment conducted in one of the turbine condensers of Al-Jubail Phase-I MSF/ Power plants.

Presented at the 3rd Acquired Experience Symposium, Al-Jubail, Saudi Arabia, 4-6 Feb. 2002. and also published in Desalination 154 (2003) 277-290.

1.

INTRODUCTION AND REVIEW

Man has been aware of the problem of biofouling ever since he ventured into the sea. In the 4th century B.C. Aristotle, the Greek Philosopher, had referred to the slowing down of ships due to their hulls being covered by barnacles. Macrofouling has been defined as the attachment and subsequent growth of a community of visible plants and animals on structures and vessels exposed to water [1]. A precursor to macrofouling is the microfouling caused by bacteria, fungi and other microscopic organisms. Because of the proximity of desalination plants to the marine environment, marine macrofouling has become a serious problem of concern to utility managers everywhere. There has been a significantly laudable effort in the world to understand the phenomenon of biofouling and evolve strategies for its prevention and control [2,3]. About 5000 biological species have been listed as involved in the fouling of structures exposed to or immersed in water, the composition and community assemblages showing wide variations from site to site. An earlier study in the intake bay of the Jubail Desalination and power plants showed the involvement of 31 genera of organisms in the biofouling settlement on glass coupons [4]. Two of the most significant groups associated with fouling are bacteria and diatoms. Once attached to a surface, they rapidly divide and form a slime film of great importance to the emerging fouling community. Mold and fungi also occur besides a variety of algae of which some live as single cells, and others, such as seaweeds live as large filamentous or branching plants. Representatives of the animal kingdom range from protozoans to chordates. Animals involved in macrofouling consists largely of barnacles, mussels, bryozoans, hydroids, tunicates and serpulid worms. Corals, sea anemones, sponges, echinoderms, amphipods, isopods, nemerteans and platyhelminthes also occur. Problems of biofouling are most common on ship hulls, navigational buoys, underwater equipment, seawater piping systems, beach well structures, industrial intakes, Ocean Thermal Energy Conversion Plants (OTEC), offshore platforms, moored oceanographic instruments and submarines. Water lines lose their carrying capacity and speed of flow due to biofouling growth along pipelines. Due to attachment of fouling organisms, the performance of heat exchanger tubes declines. Biofouling also causes corrosion of materials. The marine industry in the world incurs an estimated expenditure of 10 billion sterling pounds a year to combat the problems associated with biofouling. About 450 papers on the subject of biofouling have been reviewed for the purpose of this presentation. The literature collected under

this project through the database available at the National Institute of Oceanography, Goa, India has been deposited at the Library of the SWCC Research and Development Center, Jubail [5]. These publications deal with the fundamental aspects of biofouling [6-19] as well as the large number of control technologies developed around the world [20-26]. The readers are advised to refer the bibliography compiled by Abdul Azis [5] for details of references listed in Table 1.

The R&D Center had undertaken a study of macrofouling caused by marine shells in response to such a request from the Jubail Plant Manager. The project started in September 1999 would end in March 2002. This paper is based on the online biofouling experiments conducted in the Jubail MSF/ Power plants. The technology for biofouling control has been discussed on the basis of an extensive literature survey carried out during the period. The purpose of this study was to understand the nature and magnitude of macrofuling inside the water box and the degree and extent of condenser tube choking due to growth of marine life, scale deposits and accumulation of debris. Other aspects such as plankton ecology, water quality and environmental biofouling would be dealt in subsequent publications.

2. 2.1

EXPERIMENTAL DESIGN AND METHODOLOGY Site of experiment

The online study of biofouling was carried out in the turbine condenser water box of Al-Jubail Phase-I MSF /Power plants Unit 2, for a period of one year covering all the seasons. The unit that was shut down for overhauling was inspected by the research team on 10-7-1999 to assess the status of biofouling in the unit. Digital photographs 1-3 indicate the status of biofouling in the unit at the time of shut down. The experiment was started after cleaning and overhauling. Material specification of the condenser is given below: 1. 2. 3. 4. 5. 6. 7. Type of Condenser Construction Cooling water Capacity of Condenser Number of tubes Condenser tube length Condenser tube diameter : : : : : : : Radial flow Rectangular Seawater 25 tons 2629 8104 mm 20.96 mm

8. 9. 10.

Pressure drop No. of water pass Flow rate of cooling water

: : :

11. Condenser tube metal 12. Tube Plates 13. Cooling surface Area 14. Water Box metal 15. Shell metal 16. Internal Supports metal 2.2

: : : : : :

0.15 bar (minimal); 0.23 bar (normal) One Max.: 14 202 ton/hr; Min.: 10 090 ton/hr Normal : 12 935 ton/hr Titanium ASTM B338 Gr-2 Aluminium Bronze ASTM B171 Alloy 614 2951 m2 Aluminium Bronze ASTM B 171 alloy 630 ASTM A 285 Gr-C ASTM A 285 Gr-C

Experimental coupons and coupon holders

Titanium Gr-2 Plate sheet coupons (100 x 100 x 1.5 mm) with 180 grit finish conforming to ASTM B 265, procured from M/S Metal Samplers (USA), with a certified Material Test Report were used in the study for all the experiments. The coupons were holed at the Pilot Plant workshop. Coupon holders that could be fixed to Anodes were designed and fabricated by the Pilot Plant staff. Coupon fixing device was designed in such a way that the individual coupons remain away from each other and each could be retrieved with out disturbing the other (Photograph - 4). 2.3 Methodology

Titanium coupons were cleaned, sterilized and weighed before use. The anodes on the Left and the Right sides of the Inlet and Outlet sides were selected as the site for fixing the coupons. Four coupon holders each were fixed to the anodes at the Inlet and Outlet sides. Each holder carried 2 coupons each. The experiment started in September 1999, was completed in September 2000. Two coupons each were retrieved at intervals of three months. Accordingly, the first set of coupons remained exposed to the cooling water for three months, the second set for six months, the third set for nine months and the last set for 12 months representing the winter, spring, summer and fall seasons respectively. This design enabled the research team to evaluate the situation of biofouling during the different seasons of the year. An inspection of the Phase I Intake Screens was made on 25-11-2000. The purpose of the visit was to locate the source of the huge quantities of polyethylene bags, wire ropes, cans, weeds, wood etc., noticed in the Turbine Condenser Water Box. Operating Data on Residual chlorine for Power

Plant Phase I Unit- 2 received from the plant have been used to discuss the chlorine availability in the process stream.

The retrieved coupons were examined for fouling film formation and biofouling. Weight gain method was used for estimating the degree and extent of fouling materials getting settled on the surface of coupons. One of the coupons removed from the Inlet and Outlet sides was dried in an oven for overnight at a temperature of 60oC. The coupon is taken out, allowed to return to room temperature and re-weighed. Biofilm thickness of the slime could not be measured, as the film observed was very thin. Visual inspection of the Water Box and Condenser tubes were made once in three months when the Water Box was opened for coupon retrieval. Members of the Research Team carried out inspection of the Water Box once in a quarter, photographed the situation and prepared notes on the same.

3. 3.1

RESULTS Weight Gain by Coupons

Data on the weight gain/loss displayed by the coupons are presented in Figure-1. The weight of settled material ranged from 0.05 to 0.19 gm per coupon on the Inlet side and from 0.03 to 0.15 gm on the Outlet side. The weight gained was lower in the coupons kept at the Outlet side indicating meager settlement on coupon surfaces. The weight loss displayed by certain coupons indicated a certain degree of corrosion taking place in the water box. 3.2 Visual Examination

Visual examinations were carried out on the Inlet and Outlet sides of the water box and condenser tubes four times during 1999-2000 covering the winter, spring, summer and fall seasons to document the status of film formation. At no time was the film thick enough to take any measurement. 3.2.1 Condition of the coupons

The three month exposed coupon on the Inlet side carried black and reddish deposits on one corner. It also showed the presence of a slime film on both sides, but with out any biofouling settlement. The six month exposed coupon also showed the presence of a

slimy film on both sides. The coupon was covered with a strip of polyethylene bag. This was also covered by a brown film (Photograph-5). The nine month old coupon taken out in Summer, showed the presence of gelatinous slime in some areas and a brown slimy film in the remaining areas. The coupon was devoid of any macrofouling settlement. The 12 month old coupon was deep brown with patches of white and black deposits. One piece of an algal filament was seen along with a patch of debris. No other settlement was seen on the coupons. The three months old coupon on the outlet side showed a greenish slimy film with hard particles stuck to the surface. Red deposits increased with the duration of exposure. The 12 months exposed coupons showed the presence of diatoms and protozoans. No macrofouling settlement was observed. 3.2.2 Condition of the Water box and turbine Condenser Tubes

The inlet side of the water box was free from any settlement during the first three months (inspection in winter). Several tubes were partially blocked by white, slime deposits (Photographs: 6-7). Strips of polyethylene bags were found covering the inlets of tubes impeding the flow of water. About 5 kg of debris consisting of dead and broken shells of Balanus sp., mutilated parts of crabs, remains of sea grass, pieces of polyethylene bags, nylon ropes and stones were removed from the water box. Both the anodes showed signs of corrosion. Inspection after six months (spring season) showed that the debris and pieces of polyethylene bags that were found clogging the tubes during the winter season were no longer present. But more tubes than observed previously were choked now by white deposits. No marine growth was seen either inside the tubes or on the walls of the water box. Inspection after nine months (summer season) showed a recurrence of polyethylene bags, nylon ropes, algal litter and other debris (Photographs 8&9) covering the inlets of numerous tubes. This was more than that seen during the spring season observation. A matter of great concern was the presence of macrofouling organisms, some embedded in tar balls and sediments (Photographs 10-13).Both the anodes were greatly corroded. During the inspection in the twelfth month, about 50-60% of the tubes were found to be affected by deposits and garbage settling (Photograph 14). No organism was seen inside the tubes. The tubes were largely free from any macrofouling. The walls of the water box showed some settlement of barnacles that was negligible. However, it was quiet insignificant as to cause any problem for the smooth operation of the unit under study. On the outlet side, both the anodes were heavily damaged due to corrosion. None of the debris and

garbage seen on the inlet side was seen on the outlet side of the water box and condenser tubes during any of these inspections. However, many tubes were seen choked due to deposits seen on the inlet side (Photograph 15). Barnacles were found settled on the roof side of the water box. They were all small and black. 3.3 Chlorine Residual

Chlorination is continuously dosed at the Intake itself. The Intake is provided with 6 sets of Sodium Hypochlorite (NaOCl) generators producing about 45.5 kg/h of chlorine per generator. On a day of full production, about 7200 kg of chlorine is produced and injected in the Intake Pit. The normal dosing rate is 2ppm where as the shock dosing rate is 8 ppm. The aim is to get an optimum Residual Chlorine level of 0.20 to 0.50 ppm, considered adequate enough to kill marine life and prevent organisms from attaching to surfaces. The Residual Chlorine in the seawater intake ranged from 0.24 to 0.35 ppm and that at the Turbine Condenser inlet and outlet ranged from 0.05 to 0.33 ppm. During the period of April to August 2000, Residual Chlorine in the Turbine Condenser was less than 0.20 ppm. 3.4 Inspection of Phase-I Intake Screens

The entry of trash and garbage was found to be a menacing problem, choking the tube inlets on many occasions during the year. The following points were checked. 3.4.1 Bar Screen Zone The Rubber Boom fixed in front of the Intake pit has many gaps in between allowing floating materials to reach the Bar Screen and enter the intake pump house. Although this boom was meant for preventing oil from entering the pump house, it prevents the floating trash and garbage from entering the pumping location. 3.4.2 The Bar Screen The bars were found to be heavily fouled by barnacles and bivalves. The wall of the intake was also found to be fouled by large Molluscs. These settled organisms make the spot a location for breeding. 3.4.3 Travelling Screen There are 16 sets of single flow type Travelling Screens designed to filter the feed seawater before it enters the seawater pumps and the screen wash pumps. The Power 7

Plant side is catered by 8 sets of travelling Screens with a maximum screening capacity of 22,800 kg/h at a maximum design seawater flow rate of 11,556 m3/h/screen/NLWL (Normal Low Water Level, the elevation of which is - 700 mm). The seawater velocity through the screen is 0.3 m/s (about 1 km/h). Eight sets of Screens fixed on the desalination side of the Intake carry a maximum screening capacity of 20,000 kg/h at a maximum design flow rate of 9,265 m3/h/screen/NLWL. The seawater velocity is slightly less on this side. The mesh size of the wire cloth fixed to the screen is 9.5 mm in square.

Each set of the Travelling Screen is installed in the pump pit in front of the seawater pump through a specially designed concrete slit. When operated, the screen travels in such a way that the feed water to the pump always flows through it before it reaches the pump. The moving screen lifts the trash collected by the screen, and when it reaches the ground level, the trash gets automatically left on a trash collection rack. There was heavy fouling on the travelling screen. Photographs 16-17 depicts the conditions observed on one of the screens.

The inspection of the site showed that there is gap left between the screen and the trash receiving rack as part of the safety margin allowed for the movement of the screen. Many of the screen blade tips were found corroded creating more space between the screen and the trash receiving rack. The trash filtered by the screen falls back in to the bay in front of the seawater pump (Photograph 18). Naturally, these items also get pumped into the feed stream of the Power and Desalination units.

One part of the screen was found to be heavily biofouled due to settlement of barnacles and bivalve shells, where as the other part of the screen was free from any settlement. It is presumed that the Travelling Screen was not operated continuously. Leaving the screens bathed in the incoming seawater permits biogrowth. Prolonged exposure means more biofouling. Such massive settlements of organisms eventually create a breeding ground for these organisms with in the Intake Pit. This is likely to expose the plant structures to greater biofouling.

4.

DISCUSSION

The rationale for the present study has been the problem of fouling caused by molluscan and crustacean organisms in the Turbine condenser Water Box of the Jubail Phase I MSF/Power plants, in spite of standard chlorination used as the disinfection regime at the Intake Pumping bay. The online experiment did not show any macrofouling settlement during the period of this study except certain occasional presence of Barnacles during the summer season when the residual chlorine levels were less than 0.20ppm. Chlorination is widely used to prevent settlement of fouling organisms in cooling conduits of power stations with varying degrees of results [27]. Macrofouling has been reported when there is only intermittent chlorination or when residual chlorine levels are very low [28]. Mussels and barnacles, once settled during no chlorination periods were found to be able to resist the subsequent exposure to chlorine and during the breaks in chlorination they can actively feed and carry on their normal life [29]. Flow velocities of less than 1.2 m/second are known to allow larval settlement. Once established, shell communities can withstand velocities ranging from 1.5 to 2.5 m/second and flow velocities below 0.1 m/second may not provide adequate food and oxygen for their growth [30]. In the present study, macrofouling has been noticed on the bar screens and the traveling screen. This has the potential of turning this area in to a breeding zone for barnacles and mussels with potential release of larvae of biofouling organisms in the feed stream. 4.1 Control Technology

While presenting this overview, we would like to underline the fact that there is no silver bullet offering a universal solution to biofouling problems. In the following section, control measures have been categorized and briefly discussed with the modes of their delivery to the fouling zones. These methods have to be carefully selected for specific applications. Major references in this regard are summarized in Table 1. 4.1.1 Antifouling (AF) paints and coatings

They provide, probably, the most cost-effective method to prevent fouling. These are mixtures that contain sufficient water-soluble resins, pigments, metal salts and inert fillers. AF coatings remain the most favored delivery system to control biofouling on most marine structures (other than cooling water systems). The advantages of coatings

are ease of manufacture, high speed, low cost application, reasonable duration and relatively low coast. The disadvantages are limited life, the lack of ways to apply coatings to submerged or wetted surfaces and toxicity of control agents. Copper oxide coatings remain the most widely used AF coatings, and the basic insoluble-matrix rosin-copper (I)- oxide coatings (using vinyl, chlorinated rubber, and polyisobutyl resins) developed in the 1950s remain the same. These coatings are capable of delivering static barnacle resistance of over 90% for as much as four years. A major development in AF coatings has been the organotin toxics that became available in the early 1960s. There are two basic types of organotin coatings: coatings that icorporate organotin compounds and coatings based on film forming resins that contain a chemically bound organotin. Antifouling Elastomeres offer an intriguing approach to long lasting fouling control, with a toxicant reservoir that is much larger than in paints. 4.1.2 Injectable biocides

Flowing systems provide marine organisms with a salutary environment for the settlement of organisms because the moving water stream replenishes nutrients and oxygen. Injectable biocides with biocidal or biostatic properties have made it possible to take anitfoulants to areas where coating cannot be provided. They are most often used in geometrically constrained locations existing in the interior of pipes, heat exchanger systems or other enclosed and/or remote areas in flowing water systems. Chlorine, first used as a disinfectant in 1800, was first used on a plant scale in 1879 and it became the widely used disinfectant since the 1970s. Low-level chlorination is still the most commonly used method for the prevention and control of biofouling. The desalination industry is well aware of the benefits of this biocide. Because of the hazards involved in the transport and storage of this gas, in situ electro-chlorination is the technique being followed at seawater intakes of power and desalination plants. At the doses injected now, with a residual chlorine level of 0.20 to 0.50ppm, plants do, at times, experience macrofouling problems. Long-term exposure of organisms to a particular toxicant develops in them a certain degree of immunity and the same dose may not necessarily have the previously known toxicity on a prolonged application regime. According to experimental studies reported from India, high concentrations of chlorine (8 mg/l) as sodium hypochlorite was found needed to achieve 100% kill of marine larvae. Continuous chlorination was found necessary to arrest the growth of shell in the case of molluscan biofoulers (Mytilus edulis). At 1ppm residual chlorine, 12 10

mm size mussels showed 100% mortality only in 504 hours (21 days) whereas at 10ppm residual chlorine they died in 30 hours. 95 mm size mussels died in 48 hours at 10ppm residual chlorine. Assessments are available on the merits of low dose continuous chlorination, intermittent chlorination (2ppm residual for 1 hour in 8 hours), targeted chlorination and application of bromine chloride, copper-chlorine mixture, iron and hydrogen peroxide mixture. The chlorine demand of seawater changes with water quality variations. In an effort to develop an environment friendly biocide regime the synergistic effect of chlorine and copper has been put to a combination method that reduced the required chlorine to about one-tenth and copper to one-sixth. Basically, bromine chloride and chlorine dioxide were found to be more effective than chlorine but they were also more expensive. Ozone has been found feasible as an alternative to chlorination for control of biofouling in once through cooling systems. The use of small amounts of cationic flocculants (Acrylate additives) at the rate of 2 to 4mg/l with chlorination has been found to remove biomass from heat exchanger surfaces. Acrylic films and plastic films have been investigated as potential covering for surfaces. Except for chlorine, bromine and bromine chloride, little is known about the effects of these materials, and in the case of halogens, recent works has suggested that their harmful impacts is significantly greater than previously reported. Marine creosote, alone or together with copper salts, remains the mainstay for the bio-protection of wooden structures in the marine environment. In a recent study [30], 47 chemicals having potential for preventing attachment of zebra mussel were identified and tested. 4.1.3 Marine bioactive compounds

The search for environmentally benign antifouling agents has resulted in the isolation of a large number of marine natural, non toxic compounds that demonstrated significant antifouling activity with out any side effects. About 200 species of marine organisms were tested for their antifouling activities with their extracts with many species exhibiting encouraging results. The antifouling activity of several secondary metabolites was tested in bioassays using barnacles, algae and bacteria. The polyhydroxysterols isolated from octocorals has been cited as a breakthrough. It was found as a more effective substitute for the highly toxic organotin compounds.

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4.1.4

Materials of inherent AF properties

There has been a continuous endeavor to develop structural materials that are inherently fouling resistant. Copper and some of its alloys are the earliest recognized and most widely used antifouling structural materials. By applying an electric current, its rate of leaching is increased thereby enhancing the antifouling potential. Leaching of copper results in improper shell growth and in some cases interfere with various enzymatic processes. Copper-Nickel alloys are well known for their range of application and reliable performance because of their inherent resistance to biofouling and corrosion. The search for cost effective marine alloys that are inherently antifouling and are also insoluble has produced a new marine alloy, based on copper, manganese, cerium and gallium with greatly promising results. Conventional concrete structures have been given antifouling property by incorporating toxic compounds with proven resistance for biofouling. Monomers and polymers with chemically attached biocides constitute one of the latest classes of materials, called controlled release biocides that give inherent protection to marine structures. 4.1.5 Heat treatment Heat treatment is considered a viable alternative and is being practiced by several utilities in different countries. Marine organisms are significantly more temperature sensitive than their terrestrial cousins. Warm waters having temperatures between 5070C can kill nearly all organisms and it has found successful as a localized fouling control technique if flushed for 1-2hrs in cooling water systems. This technique is extremely energy intensive and can be considered for small, extremely critical surfaces. 4.1.6 Pulse-Power technology Pulse power technology, the technology of short, high electrical power pulse generation has made tremendous progress in the past decade. Powerful, long-time, pulse-power devices are now available to generate electrical pulses of duration shorter than one nanosecond [32]. Based on experimental studies, it is stated that pulses on the order of one microsecond are sufficient for preventing biofouling.

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4.1.7

Ultra-violet and Nuclear radiation

Effect of UV and nuclear radiation in preventing the primary settlement of biofilm has been investigated with encouraging results. UV-B radiation has been found to kill mussel larvae before they get settled on a surface. It is also stated as having an ability to control zooplankton communities. Nuclear radiation has been attempted in India for

preventing microfouling in the cooling conduits of a Nuclear Power Plant. Paints are available incorporating a radioactive material. Although many isotopes with stable properties have been identified and tried with remarkable antifouling effectiveness, it has not become popular because of extreme concerns on their fallout impact on human beings and ecosystems. 4.1.8 Scrubbing

This is probably the oldest fouling control technology known to man. Here, mechanical energy is used to keep fouling surfaces clean. The development of diving technology since the 1950s has made it possible for marine structures and ship hulls to be scrubbed by divers. Rotating brush devices used for cleaning microbial fouling from the heat exchanger surfaces of Ocean Thermal Energy Conversion Plants have worked successfully. Scrubbing technology has become very commercialized and the US Navy gives worldwide contract for cleaning ship hulls on a routine basis. The use of rods and brushes to remove highly developed fouling communities in the interior pipes and tubes is at time the only method possible. Two commercial approaches, namely the spongerubber balls and flow driven brushes, focus on cleaning heat exchanger tubes. While the ball cleaning system has been found to be useful indeed, it has also been implicated in tube corrosion and erosion. 4.1.9 Biological control

Studies carried out in the USA have brought out encouraging results in this regard. The captive reared, common map turtle (Graptemys geographixca) was found to feed heavily on Zebra mussel, one of the most prolific macrofoulers in American waters opening the prospects of biological control of macrofouling. The fish bull chub (Nocomia raneyi) has been tested positive for crushing and ingesting hard- shelled molluscan foulers. In other instances, blue crabs, hermit crabs and stone crabs were found to prey significantly on oysters (mollusca).

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4.1.10 Other techniques Pressure washing, water jetting, magnetic fields, sonic devices, robotics, Reproductive control and cathodic protection are the other techniques found feasible by many investigators and recommended to the industry.

5.

CONCLUSION

The Turbine Condenser Water Box did not show the previously experienced menace of biofouling caused by marine shells. Neither the heat exchanger tubes nor the experimental titanium coupons showed any tendency of macrofouling. The marine organisms observed were very negligible. Heat exchanger tubes were seen choked by white deposits and their inlets were seen covered with polyethylene bags and other debris. Although residual chlorine levels were below the desired 0.20ppm concentration on certain occasions, it appeared that the intake chlorination was effective in controlling the ingress of biofouling organisms. An inspection of one of the traveling screens, carried out independently of the online experiment showed that the gap that exists between the screen and the trash receiving rack facing the pump, is the source of polyethylene bags and other trash that were seen inside the Water Box from time to time. This is a problem that needs to be tackled on a priority basis.

6.

RECOMMENDATIONS 1. It is always prudent to maintain a residual chlorine level of 0.20ppm inside the Water Box. This regime should be carefully managed to avoid the chance of biofouling settlement. 2. Fouling on the traveling screen needs to be prevented, as the organisms getting settled and growing thereafter, could breed and release their larvae in large numbers right in front of the pump which could be sucked into the feed water line of the plant. Further, idling of the screen should be avoided. Macrofouling on the screen further enhances the chance of corrosion of the screens.

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3. Some of the methods mentioned above may be examined by the plant personnel for application in the Condenser Water Boxes and other locations in the plants, where macrofouling is experienced.

7.

RFERENCES

1. Fischer,E.C., Cstelli,V.J., Rodgers,S.D. and Bleile,H.R., (1981), Technology for control of Biofouling, Technology for Control of Marine Biofouling, 261-299. 2. Woods Hole Oceanographic Institute, (1952), Marine fouling and its prevention. Annapolis, MD: US Patent No.4,123,338, 31 October 78. 3. Crisp, D.J., (1973), The role of the biologist in antifouling research, In Proc. 3rd International Congress on Marine Corrosion and Fouling, Evanston,IL: North Western Univ. Press, 88-93. 4. Abdul Azis, P.K., Al-Tisan, I. And Sasikumar, N., (2001), Biofouling potential and environmental factors of seawater at a desalination plant intake, Desalination, 135, 69-82. 5. Abdul Azis, P.K., (1999), Bibliography on Biofouling Studies, ecology and Marine Biology Department, SWCC R&D Center, Jubail, Kingdom of Saudi Arabia. 6. Page, T.L., Neitzel, D.A., Simmons, M.A. and Hayes, P.F., (1986), Biofouling of power plant service systems by Corbicula, Proceedings of the second International Corbicula Symposium, Little Rock (USA), 41-45. 7. Isom, B.G., (1986), Historical review of Asiatic clam (Corbicula) invasion and biofouling of waters and industries in the Americas, Proceedings of the Second International Corbicula Symposium, Little Rock (USA), 1-5. 8. Li, C., (1989), Biofouling and filter blocking algae in Daya Bay, Collection of Papers on marine ecology in the Daya Bay-1, 3rd Institute of Oceanography, Xiamen, Peoples Rep. China, 53-58. 9. Satpathy, K.K., (1989), Biofouling control measures in power plant cooling systems: A brief overview, Pro. Specialists meeting on marine biodeterioration with reference to power plants, IGCAR, Kalpakam (India), 153-166. 10. Jones, J.M. and Little, B.J., (1990), USS Princeton: Impact of marine macrofouling (mussels and hydroids) on failure/corrosion problems in seawater piping systems, Naval Oceanographic and Atmospheric Research Laboratory, Stennie Space Cent., MS(USA),19. 11. Huang, Z., Zheng, C., Li, C., Wang, J, Lin, S., Yan, S., Zheng, d. and Lin, N. (1990), Biofouling at water inlet of nuclear power station in Daya bay, Collection of papers on Marine Ecology in Daya Bay-2, 3rd Inst. Ocean., Xiamen, P.R.China, pp.478-488.

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12. Challinor, C.J., (1991), The monitoring and control of biofouling in industrial cooling water systems, Biofouling, 4(4), 253-263. 13. Turpenny, A.W.H. and Coughlan, J., (1992), Power generation on the British coast: Thirty years of Marine Research, Hydroecol., 4(1), 1-11. 14. Al-Ahmad, M. and Aleem, F.A., (1994), Scale formation and fouling problems and their predicted reflection on the performance of desalination plants in Saudi Arabia, Desalination, 96(1-3), 409-419. 15. Sasikumar, N., Azariah, J. and Nair, K.V.K., (1993), Changes in the composition of tropical fouling community at a power plant discharge, Biofouling, 6(3), 221-234. 16. Poulton, W.I.J., Cloet, T.E. and von Holy, A., (1995), Microbiological survey of open circulating cooling water system and their raw water supplies at twelve fossil fired power stations, Water Sc. As. 21(4), 357-364. 17. ONeill, C.R. Jr., (1996), The Zebra Mussel, impacts and control, Cornell Coop. Ext. Inf. Bull. No. 238, 62. 18. Venugopalan, V.P., Thyagarajan, V. and Nair, K.V.K., (1997), Marine growth in large seawater intake systems: Problems and their control, Proc. 2nd Indian Nat. Conf. Harb. and Ocean eng., Thiruvananthapuram (India), Vol.1, 640-647. 19. Thyagarajan, V., Venugopalan, V.P., Subramoniam, T. and Nair, V.K., (1997), Macrofouling in the cooling water conduits of a coastal power station, Indian J. Mar. Sci., 26(3), 305-308. 20. Lawrence, C.F., (1997), Chemicals for Zebra Mussel control, Proc. 7 Intl. Zebra Mussel and Aquatic Nuisance Species Conf., New Orleans, LA (USA), 28-31. 21. Singh, I.P., Takahashi, K. and Etoh.H., (1996), Potent attachment inhibiting and promoting substance for the blue mussel, Mytilus edulis galloprovincialis, from two species of Eucalyptus, Biosci-Biotechn.-Biochem., 60(9), 1522-1528. 22. Ten Hallers, C.C., (1997), Tributyltin and policies for antifouling, Environ. Technol., 18(12), 1265-1268. 23. Lockheed, (1977), Ways to control Biofouling, Sea Technology, 18(11), 30-31. 24. Rajagopal, S., Nair, K.V.K. and Azaria, A., (1995), Response of brown mussel, Perna indica, to elevated temperature in relation to power plant biofouling control, J. thermal Biol.,20(6), 461-467. 25. Neuhauser, E.F., Rhode, M.A., Knowlton, J.J., Wahanik, R.J., Borden, M., Lewis, D.P. and Mackie, g., (1992), Thermal back-flushing to control Zebra Mussels at steam station, J. shellfish Res., 11(1), 234-235. 26. Pickles, S.B., (1997), Medium pressure Ultra-Violet light to control Zebra Mussels, Proc. 7 Intl. Zebra Mussel and Aquatic Nuisance Species conf., New Orleans, LA(USA), 28-31.

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27. Rajagopal, S., Nair, K.V.K., Azaria, A., van der Velde, G and Jenner, H.A., (1996), chlorination and Mussel control in the cooling conduits of tropical coastal Power Station, Mar. Env. Research, 41,201-221. 28. Anderson, D.B. and Richards, B.R., (1966), Chlorination of seawater: effects on fouling and corrosion, Trans ASME, 203-208. 29. Holmes, N.J., 1967), Mussel settlement in the cooling water Intake screens at Power Stations, Central Electricity Research Laboratories, Report No.RD/L/N 1 Leatherhead, Surrey, 6. 30. Jenner,, H.A., (1980), The biology of the mussel Mytilus edulis in relation to fouling problem in industrial cooling water systems La tribune du CEBEDEAU, 33, 13-19. 31. Cope, W.G., Bartech, M.R. and marking,L.L., (1997), the efficacy of candidate chemicals for preventing attachment of Zebra mussel (Dreissena polymorpha), Environ.Toxicol.Chem., 16(9), 1930-1934. 32. Schoenbach, K.H., Abou, G.A., Alden, R.W., Turner, R. and Fox, T.J., (1997), Biofouling prevention with pulsed electric fields, Proc. 7 Int. Zebra Mussel and Aquatic Nuisance species conf., New Orleans, LA (USA), 28-31.

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Table 1: Anti-fouling Technology: available literature sources Anti fouling agents Sources Copper compounds and Cresco, 1996; Rao&balaji, 1994; Mukherjee et al., 1993; metal Marshall, 1980; Marine engineering, 1980; Chandler, 1979; Mc Naught, 1978; Gibson, 1972. Ten Hallera, 1997; Fargasova& Kizlink, 1996;Price et Organotin compounds al.,1994; linders, 1994;Fonalik et al., 1983; Kronstein,1980; and organometallic Talbptt et al., 1980;Drisko et al., 1977; Bennet & Zedler, polymers 1966 Organolead Kronstein, 1977; Henry and Paul, 1969 Elastomers Carderelli, 1963; cuthrell, 1967; Hohman, 1976 Biocides Chlorine Allonies and Khalanaki, 1997; Venogopal et al., 1997; Menia and DeBruyn, 1997; Thompson et al., 1995; Rajagopal et al., 1995; Satpathy et al., 1994; Fisher, et al., 1994;de Beer et al.,1993; Nayar, 1989; William and Knox, 1989; finger, 1985; Kinelaki, 1985 and Wilde et al., 1983. Chlorine dioxide Holte and Ryan, 1997. Copper-chlorine Knox-Holmes, 1993. Hydrogen peroxide Characklis, 1980; Nishimura et al., 1988. Bromine& Iodine Bidwell et al., 1992; Koening et al., 1995. Potassium and Dekan, 1995; Matissof, 1992. Chloramine Ozone Meldrim et al., 1981; Nakayama et al., 1980; Paller, 1979. Creosote Anderson, 1981. Marine organisms used Eel grass Zimmerman, 1993. Ascidians e Teo&Ryland, 1995. Haltori et al., 1996; Tsukamoto et al., 1996; Mokashe et Marine sponge, al.,1994; Henrikson&Pawlik, 1995. Nudibranch, Holothurians Corals Mary et al., 1997;Mizobatchi et al.,1993, 1996; Alizobuchi et al., 1994. AF Materials Copper Castelli, 1979; Spears and Stone, 1969; Karande, 1977; Copper-Nickel Ansuini et al.,1978; Gaffoglio, 1987 Copper-ManganeseMukherjee, 1997 Cerium-Gallium Titanium Maruthamuthu et al., 1995. Controlled release Parks et al., 1981; Talbot et al., 1980. materials Payne, 1997; Rajagopal et al.,1994&1995; Neuhauser et al. Heat treatment 1992; Jones et al., 1990; Somerville, 1986. Shoenbach et al.,1997; Fear & Macko, 1997; Okochi et al., Pulse-power 1994; Useami et al., 1994; Nakasone et al., 1993. Pickles, 1997; Chalker, 1992; Seki et al., 1985; Nair, 1990. UV & Nuclear

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Radiation Scrubbing Biological control Others Pressure washing Water jetting Magnetic devices Sonic devices Robnotics Reproductive control Cathodic protection

Burnett, 1980; Mitchell&Bensen, 1980; Leventhal, 1978; Sato et al., 1972; Santhakumaran, 1970. Richards et al., 1997; Rickard et al., 1997; Serrouyu et al., 1985; Cloe et al., 1995. Rickard et al., 1997. Bain, 1981. Smythe et al., 1997. Menezes, 1992; Zipts et al., 1990; Murphy&Latour, 1979; Suzuki&Konno, 1970; Iskra, 1960. Martin&Landsberger, 1992. Fingerman et al., 1994; Ram et al., 1992. Easwar et al., 1995; Perez et al., 1994; sawant&Wag,1994; Little&Wagner, 1993.

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0.4 0.2 Weight (gm) 0 -0.2 -0.4 -0.6 Fall Winter

Weigh Gained Quarterly increase/decrease

Spring
Fig. a

Summer

0.4 Weight (gm) 0.2 0 -0.2 -0.4 -0.6 Fall

Weight Gained Quarterly increase/decrease

Winter

Spring

Summer

Fig. b
Figure I: Fouling in Heat Exchanger/Water Box at the Al-Jubail Desalination/ Power Plant(19992000).
(a): Inlet side (b) Outlet

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Digital Photograph: Different stages of fouling in the turbine condenser Water Box. 1-3: Visual Inspection at the time of shut down in July 1999; 4-: Coupon holder fixed on the anode. After 3 months: 5-: titanium coupons with polyethylene pieces on it; 6-7- Condenser tubes clogged with deposits. After 6 months: 8-: Polyethylene bags, ropes & debris. After 9 months: 9-:Balanus settled on a bag. 1 2 3

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Digital Photographs: Materials observed in the Condenser Water Box inlet side. Inspection after 9 months: 10 -: Tar ball with a Serpulid worm; 11- Bivalve Molluscs; 12Balanus clusters with tar balls; 13-Crabs. Inspection in September 2000: 14- Polyethylene bags and other debris on Turbine Condenser Tubes; 15-Tubes getting clogged; 16&17
macrofouling settlement on the Travelling Screen; 18- Travelling Screen (Pump front) showing polyethylene bags, seaweeds & other debris that could fall in the bay and carried into the feed stream.

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