Cathelco BWT system gains IMO Type Approval

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1 Cathelco BWT system gains IMO Type Approval After 5 years of research and development followed by rigorous testing on land and sea, Cathelco received IMO Type Approval for their ballast water treatment (BWT) system in April. The approval was granted by the Federal Maritime & Hydrographic Agency of Germany (BSH) as most of the research work was carried out at the Cathelco R&D facility in Kiel. This is what we have been waiting for in order to start marketing the BWT system internationally, said Justin Salisbury, managing director of Cathelco. I would like to congratulate Matthias Voigt and the team in Kiel for the hard work and dedication that they have applied to the project over a number of years. My congratulations also go to Robert Field and his team who were involved in many of the design and mechanical engineering aspects of the project including installation on the MV Eddystone, Mr Salisbury added. As the BWT system incorporates a number of technical innovations, Cathelco have applied for a patent under the application number Commenting on the installation on board the M.V. Eddystone, ship managers, Andrew Weir Shipping said:- We have trialled a number of BWT systems on our fleet. In terms of initial technical discussions, installation planning, system performance and ease of operation Cathelco s system has exceeded our expectations. Justin Salisbury, holding the BWT Type Approval certificate, with Peter Smith (left) and Robert Field (right). Although Cathelco have entered the BWT market later than some manufacturers they have turned this to their advantage by producing a system which meets the ever more stringent IMO standards with the most advanced technology. The key feature that differentiates Cathelco is the relationship between the UV transmittance (UVT) sensor and the UV intensity (UVI) meters. The UVT sensor measures UV light transmittance through a sea water sample taken before it reaches the chamber. The sensor operates in conjunction with UV intensity meters, mounted on the edge of the chambers, to create a feedback loop providing empirical evidence that the correct dosage has been applied. Based on a combination of filtration and UV technology, the guiding principle has been to keep the BWT system completely chemical free so that there are no active substances which need to be neutralised before discharge. This also applies to the cleaning-in-place (CIP) system which uses cleaning balls to polish the quartz tubes and interior surfaces of the UV chambers without the use of chemicals. Another advantage of the cleaning system is that it mitigates corrosion. AMS approval Having gained IMO Type Approval, the next step for Cathelco is to submit the BWT system for approval under the Alternate Management System (AMS). This will enable it to be used on ships entering American waters. Contents: 2 Cathelco BWT system gains IMO Type Approval 3 Cathelco systems protect cruise ships of the future 4-5 A Quantum leap in control panel design 6-7 Cathelco protecting offshore assets worldwide 8 Cathelco Seafresh sees major increase in desalinator sales Continues over... May 2014

2 One of the likely requirements of USCG approval is that BWT systems are capable of working in all levels of salinity including salt, brackish and fresh water. Our system was designed to exceed the IMO regulations as we included fresh water testing within the programme at the NIOZ facility in Holland. Relatively few systems are approved for both sea water and fresh water operation and we are hoping to be amongst the first in the market to gain approval, said Peter Smith, Cathelco s sales director. Marketing the system When the IMO Convention is ratified over 74,000 vessels will have to be fitted with BWT systems with the greatest numbers estimated between 2017, 2018 and Cathelco have taken the decision to focus on a key section of the market covering ships with ballasting capacities up to 2,400m3/hr. There are more than 40,000 of these vessels including container ships, cruise ships, offshore vessels and mid-range tankers and bulkers. Our system will be attractive to owners because it is compact and has a number of unique features. The UVT sensor is an extremely accurate way of measuring the required UV Matthias Voigt handing over documents dosage. This accuracy means that the power usage of the UV lamps can be optimized saving energy when the conditions allow. This goes together with stepless power supply, another feature which economises on the power requirement, Peter Smith explained. In the market place, Cathelco will be competing against some well established manufacturers of BWT systems, but also new entrants who have seen a short term opportunity. Because of the size of the capital investment in BWT systems, customers will be looking very closely at the companies that are invited to tender. Cathelco have been serving the shipping industry for more than 50 years, we are financially sound and have a strong reputation for quality and service. All of these factors put us at an advantage. said Mr Smith. Another important factor is that Cathelco have an experienced network of agents who have attended technical and commercial BWT courses in order to provide the necessary sales and service support. New BWT production facility Expanding production facilities Now that Type Approval has been received, Cathelco are pressing ahead with plans to increase their production facilities. Our existing facilities do not have the capacity to cope with the anticipated demand for BWT systems. Plans have already been submitted to construct a 13,000 square foot extension to the factory as the first phase of the development programme, Mr Smith explained. In addition to production and assembly facilities, the factory extension will have a test bed area where systems can be rigorously checked before delivery. Another aspect of the expansion will be increasing the size of the technical and production teams. The company currently employs around 100 people, a figure which could rise significantly over the coming years. Cathelco has always had a strong technical team and we will be building on this to provide the necessary expertise to support and service the demand from the BWT market, particularly in the retrofit sector, Mr Smith concluded. 2

3 Cathelco systems protect cruise ships of the future When the first of Royal Caribbean s new generation of Quantum class cruise ships is launched this year, Cathelco equipment will be protecting the hull and sea water pipework systems. The Quantum of the Seas and Anthem of the Seas can each accommodate more than 4,000 guests in RCCL s largest and most advanced staterooms, some with actual balconies and others with virtual balconies where realtime views of the ocean and exciting destinations are projected on the walls. At 348 metres in length and with 16 passenger decks, the new ships will offer the very latest in entertainment and recreational facilities. Among the firsts at sea is a new sky diving experience which allows everyone to enjoy the thrill of skydiving in a safe environment. There is also a capsule which lifts passengers almost 100 metres above the sea and over the sides of the ship to provide 360 degree views. Both vessels are being built at the Meyer Werft yard in Papenburg where the Quantum of the Seas is currently under construction in the building dock. The first ship is due for delivery in the autumn of 2014 with the Anthem of the Seas to follow in the spring of The Cathelco pipework anti-fouling systems will protect a total of 20 seachests on each vessel serving extensive shipboard equipment including freshwater evaporators, reverse osmosis systems, air conditioning chillers and sea water cooling pumps. The AF system will also protect a number of fire fighting pumps and their associated pipework. The flow rates through the seachests serving the air conditioning system are up to 4,730 cubic metres per hour. For these seachests we are supplying pairs of our largest copper and aluminium anodes measuring 1100mm in length and 140mm in diameter, said Carlo Soddu who has been closely involved in the project at Cathelco. Both of the sister ships will have forward and aft ICCP systems supplied by Cathelco. The 250 amp forward system will have an arrangement of two 125 amp C-Max disc anodes and reference electrodes wired to a thyristor control panel and mounted port and starboard. The more powerful 350 amp aft system will have two 175 amp C-Max disc anodes and reference electrodes. C-Max anodes are compact, lightweight and have the advantage of being diver changeable for easy replacement without drydocking. Cathelco are also supplying ICCP systems for two cruise ships for Carnival and Holland America Line which are being constructed by the Italian shipbuilder Fincantieri. The 99,000 grt Holland America Line vessel will be capable of accommodating 2,660 passengers, while the 135,000 grt Carnival Cruise Lines ship will have a capacity of 4,000 people. The Holland America ship is scheduled for delivery in late 2015, whilst the new Carnival Cruise ship will enter service in the winter of Anthem of the Seas under construction Both ships will have 200amp forward ICCP systems and 400 amp aft systems using arrangements of C-Max diver changeable disc anodes and reference electrodes. It is likely that these vessels will be the first cruise ships to be installed with the latest Cathelco Quantum ICCP control panels which have the advantages of easy control/ monitoring and comprehensive data logging. They also provide greater connectivity enabling data to be display remotely or integrated with the ship s computer systems. In the French-speaking cruise market, Compagnie Du Ponant have built a reputation for super luxury cruises using small vessels to reach the Arctic, Antarctic and tropical destinations. Their latest ship, due for delivery in 2015, is being built by Fincantieri Ancona to accommodate 264 passengers and 140 crew members. Cathelco are supplying an ICCP system for the 142m vessel which will become the sister ship to the Le Soleal. 3

4 A Quantum leap in control panel design The introduction of the Quantum series of AF and ICCP control panels during the coming months will provide customers with useful new features and greater connectivity giving Cathelco a competitive edge in the market place. From the customer s perspective, these improvements have the advantage of being available at no increased cost. This is the first major development in control panel design for more than a decade and takes Cathelco into the 21st century, said Peter Lindley, who has brought the project to fruition over a period of 3 years. The new panels provide numerous benefits, but the most significant breakthrough is the ease with which systems can be controlled and monitored. This is combined with much more comprehensive information about system performance. The project has been driven by the fact that manning levels on ships have decreased in recent years which means that there is less time for crew members to walk around the vessels on a daily basis checking on individual items of equipment. We have responded with control panels which record more data and make it instantly available, Mr Lindley explained. One of the main principles behind the design of the new panels is greater connectivity. The new AF panels produce an RS485 signal which allows remote control and monitoring, enabling Quantum touch screen anti-fouling control panel Peter Lindley the system to be governed from a more convenient location on the ship such as a control room. Alternatively, the data can be fed to ships bridge computer systems. The other important innovation is that where ships have Cathelco AF and ICCP systems, the AF system can be controlled from the ICCP control panel in a master and slave relationship. There are strong practical advantages in controlling both systems from a single location in the aft of the vessel. Otherwise it could take an engineer 15 minutes or more to get from one end of the ship to the other, said Mr Lindley. A key aspect of the new control designs is that all of the data can be downloaded to a USB stick and then ed to Cathelco for analysis, eliminating the time spent on filling in log sheets. For customers using the new control panels, log sheets will become a thing of the past. Furthermore, the data is much more detailed which gives a clearer picture of the performance of the system. If problems arise we are in a position to investigate them more thoroughly, Mr Lindley commented. Main menu on Quantum anti-fouling touch screen control panel Quantum touch screen AF panels With its compact design and up to the minute appearance, the Quantum touch screen AF panel is a good example of the advances that have been made. With the wider use of tablet technology, touch screen interfaces are now being produced more economically and that means that we have been able to incorporate them into the control panel design at a competitive cost, said Mr Lindley. The other important feature is that at 10.3 kilos the new panel is less than half the weight of its predecessor an important factor when ship designers are keen to make weight savings wherever possible. 4

5 Although the dimensions of the 4 way panel (320 high x 300wide x 180mm deep) are not significantly smaller than previously, there is a tremendous difference in the weight. This has been achieved by using the latest switchmode technology with smaller, lighter components, Mr Lindley explained. The touch screen interface enables users to view seven different screens beginning with the Anode Outputs. This is followed by the main Menu screen The next screen shows the Alarm Set Point which is now configurable, whereas in the past it had a fixed value. Crew members can now set the high and low alarm values for themselves which is convenient if changes are made to the system or extra anodes are added, Mr Lindley explained. Moving on through the screens there is Alarm Info which displays the date of the event and the relevant alarm channel together with additional data. In the event of a problem this information can be downloaded to a USB and then transmitted to Cathelco for detailed investigation. The Trend Graph screen provides a snap shot of the performance of the system at any particular time in a graphical form. The information behind the Data History screen will be particularly useful to the crew. Data covering all the parameters of the system is recorded twice a day and can be downloaded as a daily log, eliminating the need for paper log sheets. Next is the Language Setting which will enable data to be displayed in English, Chinese, French, German, Japanese and Spanish, although there are plans to extend the number of languages Finally, we come to Current Reduction which is now a standard feature on touch screen panels instead of an optional extra. This enables the current to be adjusted in relation to the flows through high and low seachests. The current reduction facility is configurable on four levels per channel and automatically changes the current setting according to the pumps which are in use at any particular time. This extends the life of the anodes and enables the ship owner to benefit from decreased running costs. Quantum AF modular panels The Quantum touch screen AF panel can control a maximum of 16 anodes. For systems larger than this, Cathelco will continue to manufacture modular panels without touch screen features. This will also provide continuity where replacement panels are required for existing installations. Quantum ICCP control panels Here the emphasis has been on upgrading the features of the thyristor panel. The next stage of development will focus on the modular panel with the aim of reducing its size and weight. Although the amount of information displayed locally on the new Quantum ICCP thyristor control panels has not greatly increased, there has been a tremendous advance in the ability to control the system and monitor data remotely. The amount of data which is automatically logged has also increased significantly. However, the Quantum AF modular panel will include some of the features of the touch screen version including RS485 connectivity for remote control/ monitoring and fully configurable alarms. It has always been possible to view data on the control panel, but the ability to actually control the system from a different part of the ship is completely new for our standard ICCP systems, Mr Lindley explained. As mentioned above, the ICCP panel also has a vital role in enabling the AF system to be controlled and monitored remotely. The key thing about the Quantum ICCP panel is that it can be used in a master and slave configuration. It means that the forward ICCP system can be controlled by the aft panel and that information about the whole system can be viewed in one location. As I have already mentioned, this has considerable time saving advantages for ships engineers. Furthermore, it eliminates the need to install a separate remote monitor as we did in the past, Mr Lindley commented. The Quantum ICCP master panel will store comprehensive data about the configuration of the system which can be monitored through a series of displays. These include the size of the system in terms of current output, voltages, electrode types, numbers of electrodes, set points and the alarm configuration. The master panel also logs data concerning the performance of the system covering output voltage, output current, potential readings, percentage output and the alarms. Quantum anti-fouling modular control panel All of the configuration and performance data can be uploaded to a USB memory stick and viewed in a standard PC. The information can then be ed to Cathelco, replacing the tedious task of filling out ICCP log sheets. The automatic data logging feature will give us access to far more information than was generally available from ICCP log sheets. For instance, if an alarm condition is shown, we will be able to see if a set point has been inadvertently changed by the crew. In the past, it was often a case of having to re-contact the engineer in order to ask for extra information, Mr Lindley explained. The panels can communicate via an RS485 link which enables them to be remotely monitored and controlled. It also allows them to be connected to the ship s control systems or integrated with bridge monitoring and control. In common with the AF Quantum panels, text can be displayed in different languages. We are delighted to be able to provide customers with all of these valuable features at no extra cost. It also means that commissioning is greatly simplified and if issues arise at any time in the future, the ability to access data from a USB stick means there is a much stronger likelihood of resolving problems without the customer incurring the cost of sending a Cathelco engineer, concluded Peter Smith, sales director Quantum ICCP thyristor control panel 5

6 Cathelco protecting offshore assets worldwide From the booming Brazilian market to projects in the Middle East and Europe, Cathelco are working alongside some of the biggest names in offshore design and construction to provide solutions in hull corrosion protection and pipework anti-fouling. ICCP systems for Brazil The world s largest oil discoveries in recent years have come from Brazil s offshore reserves. As a result, the country now contributes 22% of the globe s deep sea oil production. However, there are formidable challenges in reaching the offshore pre-salt oil reserves which are situated exceptionally deep under thick layers of rock and salt which are difficult to penetrate. In the Lula field, for example, the ocean floor is 2,150 metres beneath the surface of the sea. Then it is necessary to drill through 3,000 metres of rock before reaching a layer of salt that is 2,140 metres thick. Only then do you reach the oil 6.5 billion barrels in this field alone. The race to exploit Brazil s offshore oil has led to a surge in the construction of FPSOs used for the processing and storage of oil and gas before it is either piped or shipped to the shore. In its business plan Petrobras, the country s government controlled oil firm, laid out plans to invest $147.5 billion in exploration and production. Over the last decade, Cathelco has supplied ICCP hull corrosion protection systems for 17 FPSOs, most of the orders coming via Workship do Brazil, Cathelco s agent located in Rio de Janeiro. These generally involve collaborations between companies such as SBM Offshore (world leaders in the design and operation of FPSOs), and shipyards in Singapore or China which have the resources to convert the vessels. As a result of the collaboration, Cathelco has developed considerable experience in the design of ICCP systems for these applications and has maintained an ongoing relationship with SBM Offshore. The first FPSO project for Brazil was for the FPSO Capixaba which was converted in Singapore and delivered in Since then the demand for FPSOs has accelerated and during 2013 we received orders for 14 ICCP systems, said Andrew Gamble, large projects manager at Cathelco. Two of the latest orders involve the supply of ICCP equipment for the FPSOs Cidade de Maricá and Cidade de Saquarema which will operate in Brazil s Lula pre-salt field. They will be converted from double hulled 308,491 dwt VLCCs, which will be modified and upgraded at the Chengxi Shipyard in Guangzhou, China. Delivery of the vessels is planned for the end of 2015 and early 2016, respectively. Each vessel will have 600amp forward and aft systems consisting of an arrangement of hull mounted anodes and reference electrodes which are connected to a control panel. In operation, the anodes emit a current which flows over the surface of the hull and neutralises corrosive activity. The reference electrodes constantly measure the electrical potential at the hull/seawater interface and send a signal to the control panel which raises or lowers the electrical output. In this way, the optimum level of corrosion protection is achieved at all times. The installations will use the latest Cathelco C-Max linear anodes which are diver changeable, an essential feature for FPSOs which are operational for 15 to 20 years, remaining on station for prolonged periods of time. With linear anodes, current is emitted from one or more tubular elements, depending on output, which are made from titanium with a mixed metal oxide coating. The elements are mounted on an integral backing shield made from strong, but lightweight ABS plastic which helps to distribute the current over the widest hull area. This works in conjunction with the di-electric shield, a sprayable epoxy coating which surrounds the anode. Working with SBM Offshore, Cathelco supplied an ICCP system for the FPSO Cidade de Paraty, the first of the company s Generation 3 FPSOs to start production in the pre-salt basin off Brazil. More recently, a system has been provided for the Cidade de lihabela, a vessel which is similar in design to the two latest FPSOs, Andrew Gamble concluded. 6

7 AF systems for Abu Dhabi Last year, Cathelco won a series of orders to supply seawater pipework anti-fouling systems for jackup rigs built by Lamprell Energy Ltd, the UAE based provider of diversified engineering services for the offshore oil and gas industry. The anti-fouling equipment was supplied for four jackup rigs constructed at the Hamriyah yard for the National Drilling Company (NDC) of Abu Dhabi. The rigs which were completely outfitted and equipped by Lamprell are LeTourneau designed, self elevating mobile offshore drilling platforms of the Super 116E (Enhanced) Class Design. It is the sixth time that Cathelco has supplied this particular type of pipework anti-fouling equipment to Lamprell for jackup rig applications. The first occasion was in 2009 when a system was installed on the Offshore Freedom, the first newbuild jackup to be constructed by the company. All of the orders have been secured by Nico International Dubai, Cathelco s well established agent in the United Arab Emirates. On each of the NDC rigs, the Cathelco system will protect the lines from 3 pumps using anodes which are mounted directly into 10 inch diameter pipes using pipe upstands. There are a number of ways of mounting anodes on jackup rigs including the options of putting them below the pump inside the caisson, on deck within an electrolysis tank or by using pipe upstands, said Carlo Soddu, who has been closely involved in the project at Cathelco. The advantage of using the pipe upstand method is that the copper ions are drawn directly in the flow of seawater which maximises their effectiveness. In addition, it is easy to change the anodes when replacement is necessary, a procedure which can be completed in less than 30 minutes. AF electrolysis tank system for Adriatic platform Cathelco have supplied an anti-fouling electrolysis tank for the Ivana K, an offshore platform operated in the Adriatic Sea by INAgip, a joint venture between the Croatian oil company INA and the Italian Eni organisation. The Ivana K is a receiving, processing and compressing platform which serves 17 production platforms in the North Adriatic and Marcia fields located midway between the Italian and Croatian mainland. The order for the equipment was won through Elsenia, Cathelco s long standing Croatian agent based in Rijeka. The Cathelco anti-fouling system will protect sea water lines connected to four lift pumps eliminating the risk of blockages caused by barnacles and mussels which can impair the efficiency of vital gas processing operations. The electrolysis tank houses three copper anodes and one aluminium anode connected to a control panel. In operation, the copper anode produces ions which are carried throughout the pipework system by the flow of seawater and prevent barnacle and mussel larvae from settling and growing. At the same time, the aluminium anode produces ions which help to form an anti-corrosive layer on the internal surfaces of the pipes. The dosed water is fed to the bottom of each sea water lift pump for maximum effectiveness. One of the most important requirements of the system was that it should operate safely in an ATEX Zone 2 explosive environment. Due to limited access, it was also essential that the skid mounted electrolysis tank unit could be divided into smaller units in order to simplify the installation process. Particular care was taken with the pipework design to avoid unnecessary bends and minimise pipework lengths in order to maintain the required flow rate throughout the system, said Zak Elshaw, project manager at Cathelco. Another interesting feature of the system is that it can be monitored and controlled remotely via a programmable logic controller (PLC). This saves time and manpower as flow rates and dosing levels can be verified from a central control room. In some sea water lift pump applications, it is possible to mount specially designed anti-fouling units at the bottom of the pumps, often inside the stilling tube or caissons. In other cases, where the area for mounting the anti-fouling units is more restricted, the alternative of using an electrolysis tank is a more practical solution. One of the advantages of using this approach is that anodes can be changed more easily when replacement is necessary. It also allows for larger volumes of water to be treated when the circumstances demand. 7

8 Cathelco Seafresh sees major increase in desalinator sales Cathelco Seafresh achieved a dramatic rise in sales during 2013 when a total of 61 units were sold to customers around the world. This is more than double the output for 2010, the year in which Seafresh Desalinators were acquired by Cathelco Ltd. We have a well established global agent network and this has been a major factor in selling our desalinators in markets as far apart as Ireland, Singapore, Dubai, China and the USA, said Chris Bell, general manager of Cathelco Seafresh. Since the takeover, the company have re-designed and extended their range of Ton desalinators which originally had the capacity to produce between 10 and 25 cubic metres of freshwater per day, although higher outputs could be achieved by using multiple units. The output range is now from 8 tonnes to 35 tonnes and will soon be extended to 50 tonnes. Two of the most recent orders have come from the Irish Navy for desalinators which will be installed on the L.E. Orla and L.E. Ciara, coastal patrol vessels measuring 62.6 metres in length with a top speed in excess of 25 knots and a crew of 39. This follows the successful installation of a desalinator on the L.E.Eithne in The vessels will be installed with Ton units with the capacity to produce 12 tonnes of freshwater per day. With touch screen control and a full range of diagnostic systems including an hour meter, digital water quality and plant operating status, the units are easy to control and monitor. Seafresh are also supplying a series of desalinators for Sovereign Global Maritime, the Dubai based maritime security services company which operates a small fleet of vessels. The M.V.Mura, M.V. Aladin and M.V. Sultan will each be installed with Ton units capable of producing up to 12 tonnes of potable water on a daily basis. Last year, the M.V. Suunta and M.V.Mirvak were fitted with H2016 units producing 6.5 tonnes of fresh water. Our desalinators are ideal for military and maritime security vessels as they are compact and provide excellent reliability whilst making very little demand on crew time, Chris Bell commented. Another order has come from Teekay Offshore Partners who are converting the Navion Clipper, formerly a shuttle tanker, into an FSO which will be operated by Salamander Energy plc in an oil field off Thailand. The FSO will have two Ton units each producing up to 35 tonnes of freshwater per day. In China, Guangxin Shipbuilding will be installing Ton units on two 78 metre platform supply vessels (PSVs) which are currently under construction. This follows the supply of H2012 desalinators for 14 vessels in During the past year, we have introduced a new medium duty range of Ton desalinators with 8-16 tonne daily capacities which have been built to a new space saving design, Chris Bell explained. This has been achieved by optimising the components and their layout so that the new models have a footprint which is 50% smaller than the original designs. Another important factor The new space saving Ton design is the use of a high pressure pump which is smaller and more closely matched to the requirements of the system within the output range. It also has the advantage of lower power consumption 5.5kW instead of 7.5 kw. During the last year, Seafresh has made a breakthrough in desalinators for smaller types of sailing yachts with the Ocean Whisper. By using some of the latest energy recovery technology the unit is extremely compact and lightweight, measuring just 70cm (length) x 35cm (width) x 25cm (height). These watermakers can easily be run from a DC battery supply, so the barrier to making fresh water at sea has been removed for the smaller yacht owner. Even larger yacht owners will enjoy the very low noise levels whilst at anchor, said Chris Bell. The Ocean Whisper units are available in three models with capacities of 30, 60 and 90 litres per hour, enough for the drinking and cleaning requirements of most yachts. All of the models can be manual or fully automatic. Cathelco Ltd Marine House, Dunston Road, Chesterfield, S41 8NY, United Kingdom Telephone Fax Worldwide: Telephone Fax sales@cathelco.com Website