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.