Pipework Fouling Protection

Anti-fouling systems help avoid problems of blockages in water intakes. The main cause of the problem
are barnacles and mussels which are drawn into the intake of vessels as larvae and then attach
themselves to the surfaces of pipes where they grow and multiply.

There is also considerable evidence that marine growth accelerates corrosion. Previously the
only remedy has been mechanical removal and the replacement of damaged parts. Preventive measures
have been used such as chlorination, chemical dosage or an electrolytic system.

Electrolytic system

The electrolytic system consists of pairs of copper and aluminium or iron anodes which are
mounted in the ship's sea chest or strainer, and a control panel, either an LED panel or an analogue
digital meter showing the output of each anode.

In operation a dc current is applied to the copper anode which produces ions which are then
carried throughout the pipework system by the seawater flow. Although the concentration of copper in
solution are said to be extremely small- less than two parts per billion- they create an environment where
marine organisms cannot settle or multiply. This also gives continuous protection to valves, condensers
engine cooling systems and ancillary equipment.

A second anode is employed to combat corrosion. All metals have layers of protective oxide
films which are prone to breakdown by natural means. Seawater which is carrying corrosive agents such
as sulphur, can break down these protective films on all metal surfaces. Soft iron anodes are used for
protection of alloyed pipework such as yorcalbro ( an aluminium brass).

Chemical dosing

This involves metering in quantities of an anti- foulant into the sea water boxes. A typical chemical is
Ferrous chloride which as a by product coats the pipework with a protective ferrous layer.

Ultrasonics

Ultrasonics are said to have a two fold effect on anti-fouling: a disturbance action, caused by the high
frequency waves, which renders the habitat unacceptable and a mechanical action, which operates on
organisms trying to deposit adhesive, by preventing it from solidifying and on already anchored organisms
of 4-5mm. A reduction in fouling of as much as 80% is claimed.

A generator produces and then sends electrical impulses at high frequency via a coaxial cable
to transducers mounted externally to the sea chests or strainers. Each transducer contains a piezoelectric
ceramic crystals, which when excited by the electrical impulses generate the ultrasonic beam. Power
levels are said to be low, with an input of around 300-600w for each generator, which can supply four
transducers. The main advantages of this system is that it is non-invasive, no parts are in contact with
sea water so require replacing, and that no toxic substances are produced.

Electro-Chlorination

Chlorine is used as an effective pollution control. However, its application raises difficulties in
the form that it is used

Chlorine gas is highly toxic and attacks the mucous membranes in the repiratory tract

Anhydrous liquid chlorine has a very high thermal coefficient of expansion and places high
hydrostatic loading on container. Also, it is a vigoorous oxidising agent and can cause instant auto-
oxidation of metal surfaces when ignited by a spark. Water in trace amounts can lead to rapid corrosion of
the container. The release of a 50 ton tank requires evacuation of a 5 mile radius.

Sodium Hypochlorite is available as a 15% high concentration liquid manufactureed by

chemical industry
It is odourless and requires no special handling. However the economics of use is poor. A sewage plant
requireing 6 ton of chlorine per day would require 83 tonnes of sodium hypochlorite (13-15% solution).

Bulk storage is impractical due to the 100 day half life. On site production removes the costs
of transportation.

Method of operation

Titanium is used as the cathode material as it is Electrochemically inert at postive voltages less than
9volts. For the anode the titanium is coated with 100micro inches of platinum. This layer is consumed at a
rate of 6 mg/ampere per year giving a life expectancy of 3 years.(Note this layer degrades much more
rapidly if the unit voltages and currents are not set correctly)

The Anode/Cathode voltage is 7v

Chlorine is generated a the anode along with other elements to form NaOCl ( sodium
hyperchlorite). Large quantites of hydrogen are produced which must be safely evacuated.

10pp chlorine in sea water will kill all marine life quickly, 1 PPM will prevent fouling. This may
be tested on board.

The total output of chlorine is a function of current rather than flow through the unit,
adequate flow is required to ensure cooling and to prevent calcerous deposits.

A typical 1 Kg unit requires a minimum flow of 100 litres per minute. Less than this will mean
regualr acide cleaning is required, less than 50Litres per minute will lead to overheating and heavy
fouling. Cell damage occurrs at greater than 9v, high voltage alarm/shutdown occurrs at 8 v.

This system is designed to be used in sea water only and not in fresh water.

Troubleshoot:
 I have sailed with all these methods and each has proved to be very effective in the
control of fouling. The easiest to use by far was the electrolytical unit although the cost of
replacement copper anodes ( which are quite some size) is prohibitive.

Like all equipment careful monitoring is essential. I joined one vessel and on walkround
with my relief noted that the output from the Chlorinator unit was incorrect. After getting the unit
operational, which involved the replacement of cells which has been damaged due to incorrect
voltage being applied across them, there followed several weeks of cooler cleaning as the growth in
the pipework died off.