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Companies
Europe Limited
"A Commitment to Excellence"
Adam Street, Bowesfield Lane
Slockton-on-Tees
Cleveland TS18 3HQ. England
Tel: (01642)614106 Telex: 587388
Fax:(01642)614100
;:^.-
^M^:
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ANFOMATIC MANUAL
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05
ANFOMATIC
ANTI-FOULING AND CORROSION
RPEVENTION SYSTEM
FINNAL DRAWING
11 OOTEU CONTAINER VESSEL AT JINGLING S/Y
HULL NO.JLZ040409/10/11/12
CONTRAL NO.ECTEC-P04212/213/214/215-034
.f^'-
APR.2006
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ANFOMATIC
INSTRUCTION MANUAL
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8
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INDEX
1.0
INTRODUCTION
1.1
General System Description
1.2
Safety Precautions
2.0
3.0
INSTALLATION INSTRUCTIONS
3.1
Power Control Unit
3.2
Connecting Cables/Junction Boxes
3.3
Anode/Cofferdam/Flange
3.4
Anode Replacement Procedure
4.0
COMMISSIONING
5.0
6.0
MAINTENANCE
7.0
8.0
DRAWING SCHEDULE
9.0
10.0
NOTES
IDIXl.
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1.0
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INTRODUCTION
1.1 General System Description
Principle of Operation.
Marine fouling and biological fouling commonly occur in seawater circulation
systems. This involves the establishment of marine plants and animals, and bacterial
growths. These fouling organisms enter the system in microscopic and macroscopic
form, e.g. larvae and spats, settle and develop into adult forms wherever favourable
environmental conditions exist.
Hard fouling by mussels, barnacles etc. most commonly occurs in seawater circuits
and can result in interference in flow conditions, blockage and increased corrosion.
Traditional chemical methods of water treatment to prevent fouling are now less
favoured particularly, for example, chlorination. Chlorine accelerates corrosion rates,
usually by causing pitting attack on steel, is environmentally unacceptable and
treatment requires continuous monitoring and control.
The Anfomatic System.
The Anfomatic system employs a variation of the well-established impressed current
cathodic protection principle. Direct current applied to the copper anode(s) releases a
controlled quantity of copper ions into the system to create an environment in which
primary forms of marine life do not grow.
Current applied to the aluminium anodes releases a 'floe', a precipitate of aluminium
hydroxide which can help reduce corrosion rates on ferrous components in the
seawater system by modifying the ferrous oxides formed and film deposition. Ferrous
anodes in the system are designed to help with corrosion reduction in non-ferrous
materials.
The Anfomatic system is automatic, requires minimal maintenance and is
environmentally friendly. Mussels and similar marine life which are the primary
cause of blockage in marine sea water cooling systems are not killed by the Cupric
ions given off by the Anfomatic anodes. The environment created is hostile without
being fatal and prevents the microscopic embryos from attaching to pipeline walls,
settling or developing. A further benefit of the Anfomatic system is that potable water
distillation plants can be operated without interruption.
Anode functions are as follows:
WW - Cuproline:
WW - Aloline:
WW - Ferroline:
Anti-fouling
Reduction in corrosion of steel materials.
Reduction in corrosion of copper based materials.
1.2
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8
Isolate the supply, carry out the "Tag Out" system drill or equivalent as
specified by the operators own safety procedures.
2.
3.
Ensure that any capacitors associated with the equipment are fully
discharged, fitting shorting straps if necessary.
Energised Equipment
Work on 'live' equipment is only to be carried out if there is no alternative.
Personnel involved must be briefed on the precautions.
1.
2.
3.
Use insulated tools if practicable taking particular care that tools do not
cause short circuits.
4.
5.
6.
7.
8.
Do not work alone. Make sure your assistant knows the electric shock
procedure, also where and how to isolate the power supply in an
emergency.
contain
2.0
2.1
Electrical
2.1.1
2.1.1
2.1.2
Electric Cable
2.1.3
Junction Box
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2.1.2
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Cable
(a)
Input
All input cables and shrouds are of shipyard supply. Fittings, terminations,
glands, etc are also usually of shipyard supply. The AC supply cable size is
rated according to the maximum DC output of the power unit. Usually, a very
small conductor size is adequate but for physical and electrical reasons, it is
preferable to use a larger cable conductor size than the nominal current
capacity needed. Cable insulation, armouring and sleeving is dictated by ship
classification requirements.
Input cable size of minimum cross-section 4 sq. mm per conductor is
recommended.
e.g. 3 X 4 sq. mm PVC/PVC/SWA/PVC
(b)
P.C. Output
The positive DC output from each channel is connected to a corresponding
anode (positive output) and the common negative to each sea chest, strainer or
reaction vessel in which the anodes are installed respectively (negative return)
via an intermediate junction box.
Single core, 6mm cable is generally adequate for DC distribution to the
anodes without any significant voltage drop or alternatively multi-core cables
may be used. For convenience many systems utilise 3 core cable per module
output with two positive to anti-fouling and corrosion mitigation anodes
respectively and one negative to the sea chest (see Drawing No. AM 1164).
An armoured ship wiring cable for DC supply is recommended (e.g.
EPR/CSP/GSW/CSP) unless cable tray or conduit is used for distribution. In
such cases cables with acceptable insulation and sleeving alone can be
adequate (e.g. EPR/CSP or XLPE/PVC/PVC). Cable voltage rating is not
significant since units operate well below 18 volts DC with the maximum
output of the power unit rated at 12 volts except in specialist applications.
(c)
Earthing
An insulated earthing cable with a recommended minimum 6 mm , single
core should be connected from the earth connection on the power unit housing
to a suitable external earth point.
2.1.3
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2.2
Alloy Anodes
A typical anode assembly, complete with cofferdam and mounting flange is shown in
drawing No. AMI500. The anode can be separated from the cofferdam and flange as
shown in drawing AMI503
Anode size and material type is indicated by an alphanumeric code identifying the
model, material & dimensions of each anode.
Typical examples of minimum anode material required for anti-fouling are given
below for various flow rates at 2, 3 and 5 year dry docking cycles.
Flow Rate (m^/Hr)
100
200
300
400
500
600
700
800
900
1000
2 years
6.6 Kg
13.2 Kg
19.7 Kg
26.3 Kg
32.9 Kg
39.5 Kg
46.0 Kg
52.6 Kg
59.2 Kg
65.8 Kg
3 years
9.9 Kg
19.8 Kg
29.6 Kg
39.5 Kg
49.3 Kg
59.2 Kg
69.0 Kg
78.9 Kg
88.8 Kg
98.6 Kg
5 years
16.4 Kg
32.9 Kg
49.3 Kg
65.8 Kg
82.2 Kg
98.6 Kg
115.1 Kg
131.5 Kg
147.9 Kg
164.4 Kg
3.0
3.1
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INSTALLATION INSTRUCTIONS
3.1
3.2
3.3
3.2
(a)
(b)
(c)
(d)
Be easily accessible.
(e)
(f)
3.3
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The agreed positions for the apertures for the cofferdam entry points should be
clearly marked and burnt or cut out taking precautions to protect surrounding
equipment with heat resistant blankets etc. A stand-by fire extinguisher and
fire sentry should be provided.
(b)
The mating flange to receive the anode and cofferdam flange should be welded
in position with continuous welds on both inside and outside joints and
inspected by the relevant certifying authority at the time of installation.
(c)
(d)
All weld scales should be removed and any damaged paint work reinstated.
(e)
(f)
(g)
Make the negative cable connection onto the welded flange. AFTER making
this connection, the stud and nut assembly should be completely covered with
a light coating of Marine Lubricant.
(h)
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Secure anode cables and negative single cable together and take back for
connection in the junction box.
Anode Type
Cofferdam Colour
Cable Colour
WW Cuproline
WW Aloline
WW Ferroline
Blue
Silver Grey
Black
Red
Black
Black
Note: Cable colour scheme is indicative only and refers only to Corrpro
Companies (Europe) Ltd. standard supply cable. Where client
specified cable is supplied it may not be possible to match this colour
scheme.
(i)
3.4
When vessel is afloat, carry out leakage tests by checking for ingress of water
into the cofferdam.
(b)
Unscrew cofferdam lid and slide along the cable until the lid is clear of the
cofferdam.
(c)
Discoimect the cable from the anode support stud. Secure cable and lid safely.
(d)
(e)
(f)
(g)
Remove the lock nut and main securing nut from the support stud. Carefully
remove all accompanying washers.
(h)
(i)
Ensure that the cofferdam is clean and then fit to the new replacement
assembly.
(j)
Replace washers in correct sequence and secure cofferdam with nuts supplied.
The main securing nut should set to a minimum torque of 100 Ibs./ft.
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(k)
Using a suitable test meter ensure that the anode is electrically isolated from
the cofferdam mounting.
(1)
Locate complete assembly in the sea chest and secure with the eight (8)
cofferdam flange nuts. Ensure gasket is in position and tighten down evenly.
(m)
Connect anode positive cable, re-fit lid and tighten cable gland.
A specific data sheet for each vessel stating anode sizes, locations and operating conditions is
provided (Section 7.0). This data sheet is for completion on board by the vessel's engineers
after installation and testing of the equipment has been carried out. All anodes are designed
with a +20% margin allowing for overrun and higher current settings if required.
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4.0
4.1
Commissioning
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Fault Finding
FAULT
LCD display on one module
fails to illuminate.
PROBABLE CAUSE
Faulty module.
REMEDIAL ACTION
Exchange module with
another that is known to be
working. If fault remains on
original module, retum to
manufacturer for replacement
2. Anode Consumed
Replace as necessary
5.0
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Symbol
<-
"OK" or "Enter"
i
J
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6.0
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MAINTENANCE
The maintenance requirement for the Anfomatic system is minimal. The system
operates at constant current output and does not therefore require adjustment unless
the operational requirements specifically require regular adjustments to be made.
A weekly recording of current outputs on each anode is recommended for which a log
sheet is provided as enclosed.
This provides a record of the system's operation, an indication of any changes in
fiinction and a reminder when anode replacements are scheduled.
A complete loss of current on any anode should be investigated by checking all cable
connections, power panel fiises or by interchanging modules.
Regular electrical maintenance should be carried out according to the operators own
procedures and planned maintenance system.
Anodes should be replaced at the end of their designed life span or during each dry
docking of the vessel according the procedure laid down in the manual.
7.0
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INSTALLATION DETAILS
AC INPUT CABLE
JUNCTION BOX
NEGATIVE CABLE
CURRENT SETTINGS
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7.0
Cont.
INSTALLATION DETAILS
INSTALLATION DATE/LOCATION
OPERATION PERIOD
ORDER DATE FOR REPLACEMENT ANODES
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8.0
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DRAWING SCHEDULE
1. AM 1164
2. AM 1158/14
3. AM 1167
4. AM 1500
5. AM 1501
6. AM 1514
9.0
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08
Corrpro
Companies
Europe Limited
"A Commitment to Excellence"
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08
Vessel
Anode
Ship Owner
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Anode Location
Amperage Reading
Weekl
Month
Week 2
Weeks
Week 4
Week 5
10.0
NOTES
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08
10.0
NOTES
Cent.
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08
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APPENDIX 1.
SPARE PARTS LIST
ITEM:
Part. No.
Power Unit:
Power Unit Complete
AN-CPU(TRl)
AN-CPU(TR2)
AN-CPU(M)
AN-CPU(PFA)
AN-CPU(K)
AN-CPU(F3)
AN-CPU(F5)
AN-CPU(IL)
AN/CD-I 500
AN/CD(L)-STD
AN/CD(MB)-STD
AN/G-MB
AN/G-OX
AN/ST(MB)-M16
AN/NF-M16
AN/WF-M16
AN/CG-M16
AN/CD-SB
AN/CD(L)-SB
AN/CD(MB)-SB
AN/G-MB(SB)
AN/G-OX
AN/ST(MB)-M12
AN/NF-M12
AN/WF-M12
AN/CG-M16
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CXP006R
CXP006B
AM1500/4
AM 1500/6
AMI500/7
AM1500/8
AMI 500/9
AMI 500/11
AM1500/12
AM 1500/13
AM1500/14
AM 1500/23
AMI500/24
AM1500/25
Replacement Anodes:
State either three letter identifier code (e.g. AM1501-SJT) or anode dimensions & material.
D.C. OUTPUT
JUNCTION BOX
ORG. No. AMI 178
A.C. INPUT
POWER CONTROL
UNIT
3 CORE CABLE
EPR/CSP/GSWB/CSP
3 CORE
JUNCTION BOX
ORG. No. AM1178
ANTI-CORROSION
ANTI-FOULING
REDRAWN IN CAD
\IW
SEA CHEST 2
DCR
No.
DESCRIPTION
I W
DATE
company
WILSON WALTON
Information shown on this drawing is confidential and must not be copied or conveyed to third parties
without the express permission of Wilson Walton International (UK)Ltd.
Certain Items shown on this drawing are subject to worldwide patent applications.
ANTI-FOULING
ANTI-CORROSION
25/2/98
AMI 164
AH
'25/2/98
00
NOTES
PANEL ENCLOSURE TO BE IP54
UNIT TO BE MOUNTED ON HULL WITHOUT
REMOVING ANY INTERNAL EQUIPMENT
ALL DIMENSIONS IN mm.
^
MOC MODUU
*-
Oo
st
0 t C'08
MODULE ASSEMBLY
(VARIABLE - 10 WAY CONTROL SHOWN).
CABLE ENTRY GLAND PLATE ON BOTTOM OF UNIT
FIXING HOLE CTRS.
TYPE
2 TO 10 WAY CONTROL 2 1 2
h-
'A'lL-
(L
W
600
W1
Wt. - CASE ONLY
18kq.
560
D
402
HI
134
-JTA'
120
60
(TYP)
Wl
18
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Corrpro
Companies
Europe Limited
"A CommitmsDJt to isolenc^
Adam Street, Bowesfield Lane.
_08HOLE
A==^fr^
Fax: 614100
Telex: 587388
ANFOMATIC SYSTEM
'13/6/03
AH
AM1158/14
13/6/03
01
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25/3/97
DCR
No.
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1/10/98
CHECK
company
WILSON WALTON
Information shown on this drawng is confidential and must not be copied or conveyed to third parties
without the express permission of Wilson Walton International (UK)Ltd.
Certain items shown on this drawing are subject to worldwide patent applications.
ANFOMATIC SYSTEM
MODULAR
Drawn
DPS
NTS
C.P.U.-
ANODE
24/6/92
AMI 167
CONNECTIONS
PFR
25/6/92
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ITEM
1
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7
8
9
10
1 1
DESCRIPTION
COFFERDAM
COFFERDAM LID
HEAT SHRINK SLEEVE
NITRILE GASKET
RIGID P.V.C. WASHER
ELECTRODE
NITRILE GASKET
M,16 WASHER
M.16 NUT
M.I 6 STUD X 60 LG.
MOUNTING BOSS (SEE DETAIL)
NOTES
1) YARD TO CUT HOLE 130 DIA. IN TOP PLATE
AND WELD ON MOUNTING BOSS AS SHOWN.
2) REMOVE ALL BURRS & SHARP EDGES
No. HOLES
Ml 6 x 2 0 DEEP
OCR
No.
ff
Corrpro
Companies
Europe Limited
"for Every Comer of Your World"
NOTE.
SPECIAL ATTENTION TO BE
PAID DURING OUTFiniNG
TO ENSURE THAT THE CABLE
GLAND IN THE GOFFERDAM LID
Fax; 614100
Telex: 587388
IS NOT DAMAGED
ANFOMATIC ANODE
GENERAL ARRANGEMENT
RO
1:2
15/11/01
AM1501
AH
15/11/01
01
148 CRS.
TERMINALS BLOCK
DCR
No.
ff
Corrpro
Companies
Europe Limited
For Every Comer of Your forW
CHECK
ANFOMATIC SYSTEM
RO
NTS
4/11/02
AM1514
AH
11/11/02