Seawater pipework anti-fouling ICCP corrosion protection Ballast water treatment Reverse osmosis desalinators Product Portfolio
Cathelco - world leading technology for the shipping, offshore and renewable energy markets Cathelco can now offer a complete portfolio of products to customers in the shipping, luxury yacht and offshore energy markets. Although the company are best known for their range of seawater pipework anti-fouling systems and ICCP hull corrosion protection equipment, the scope of operations goes much further than this and continues to expand. A key development is the launch of a highly innovative Ballast Water Treatment system based on a combination of filtration and UV technology. This will join a portfolio which now encompasses Cathelco Seafresh desalinators and uniquely designed ICCP systems for offshore wind turbines. An important factor in the company s growth has been the ability to constantly innovate and adapt products to provide higher performance and greater reliability in specific market sectors. An example is provided by the recently introduced C-Max ICCP anode range which combines effectiveness, ease of installation and greater economy. After firmly establishing itself in the commercial shipping market, Cathelco has gone on to develop specialised systems for military vessels, advanced ICCP systems for the most demanding offshore applications and, at the other extreme, miniaturised systems for luxury yachts. All of this has resulted in a vast accumulation of experience based on more than 40,000 installations. It also provides the springboard for further innovation. Today, Cathelco operates from a modern, purpose built factory in the United Kingdom, but its sales and technical support network stretches across the world with almost 50 agent/installers. In key shipbuilding and repair centres such as Singapore and Korea, Cathelco now operates its own subsidiaries. It has also established strategic stocks of equipment in Brazil, Canada, China, Dubai, Germany, Iceland, and South Africa. Through experience, innovation and the ability to provide customers with effective and economical solutions, Cathelco is committed to maintaining its position as a global leader. Contents Page 3 Seawater pipework anti-fouling systems for commercial vessels. Page 4 Systems for naval vessels Page 5 Systems for luxury yachts Page 6/7 ICCP systems for commercial vessels Page 8 Systems for offshore platforms Page 9 ICCP systems for offshore wind turbines Page 10 Ballast water treatment systems Page 11 Cathelco Seafresh reverse osmosis desalinators Page 12 Worldwide Agents 2
Seawater pipework anti-fouling systems for commercial vessels The Cathelco seawater pipework anti-fouling system is the most widely used of its type in the world with a record of more than 30,000 installations. Its effectiveness has been proved on vessels of every size ranging from VLCCs and container ships to supply vessels and tugs. The success of the system is the result of a number of factors including reliable performance, ease of installation and automatic operation requiring very little attention from the crew. Based on the electrolytic principle, the system usually consists of copper and aluminium anodes which are mounted in seachests or strainers and wired to a control panel. In the case of cupro-nickel pipework, a ferrous anode is used instead of the aluminium anode. In operation, the copper anodes produce ions which are carried by the flow of seawater, creating an environment in which barnacles and mussels will not settle or breed. The concentrations of copper are very small, generally less than 2 parts per million, but this is sufficient to prevent larvae from settling. At the same time, the aluminium anodes produce ions which assist the action of copper ions by flocculating the released copper. The cupro-aluminium film builds up to the internal surfaces of pipes to suppress corrosion. A range of control panels and anodes have been developed to provide a versatile and economical solution for all sizes of vessels. In the specialised area of box cooler systems, Cathelco continue to work alongside Blokland Non-Ferro in the development of integrated anti-fouling systems which provide the maximum level of effectiveness. Key benefits of the system Based on the electrolytic principle, providing continuous and reliable protection without the use of chemicals. A dual system combining pipework anti-fouling and corrosion suppression. Saves maintenance costs by eliminating pipework cleaning. A range of control panels and anodes to suit vessels of every size. Every system custom designed for its particular application to ensure greater effectiveness. Easy installation anodes can be installed in seachests or strainers at newbuilding or retrofit. Environmentally benign does not involve the use of chlorine based chemicals or other biocides. Approved by classification societies. Does not interfere with the production of fresh water using reverse osmosis desalination systems. 3
Systems for naval vessels and submarines Seawater pipework anti-fouling systems The ships and submarines of more than 40 navies around the world are fitted with Cathelco seawater pipework anti-fouling systems. Frigates usually involve a combination of seachest and strainer mounted anodes. As the pipework is generally cupronickel, pairs of copper and ferrous anodes are used to provide effective anti-fouling and corrosion suppression. Aircraft carriers require the treatment of large volumes of seawater using multi-anode installations covering the requirements of engine cooling water systems, refrigeration, air conditioning and fire fighting systems. Fast patrol craft typically have small inlets which can be protected with specially designed dual purpose anodes with copper/aluminium or ferrous elements on a single assembly. Compact control panels aid installation in confined areas. Submarines. Cathelco regularly supply equipment to world leading submarine builders including DCNS, Kockums, HDW, TNSW and the Australian Submarine Corporation. Often custom designed, these systems are based on compact, dual purpose anodes. Dual-purpose anode ICCP hull corrosion protection systems Warships require specialised ICCP systems which prevent hull corrosion, but do not interfere with the electrical war-fighting capability of the ship. I-Shield a major development in ICCP technology combines the optimum level of control, flexibility, monitoring and data logging in the military environment. Multi-zoned system for optimum corrosion protection. Low electro-magnetic signature for ultra low ripple power supply. Driven by mathematical model for greater effectiveness. Accurate control with the ability to maintain controlling reference electrode within +/-5mV of set mv point. C-Max disc anodes Patroltek. Specifically designed for the operational requirements of fast patrol craft where high levels of turbulence in the stern area can result in an increased risk of corrosion. Recessed anodes and reference cells maintain a smooth hull profile. Shaft grounding assemblies available to earth propeller to hull prevents bearings from pitting. Built to AQAP1 and NATO quality assurance procedures for military applications. In-built anti-shock and anti-vibration mounts to withstand high speed operating conditions. Reference electrode Bespoke solutions. Cathelco can supply bespoke ICCP systems for naval vessels with sophisticated data logging and the ability to control multiple units from one location. The C-Nexus controller has advanced controlling and monitoring features for complex anode/reference electrode arrangements on steel and aluminium hulls or waterjet units. 4
Systems for luxury yachts Rudder Bonding Shaft Earthing Assembly Control Panel ICCP System Control Panel Anti fouling System Control Panel Di-electric shield ICCP Anode Shaft Earthing Assembly Anti fouling anodes installed in seachest Reference Cell Seawater pipework anti-fouling Nano Systems By miniaturising control panels and anodes, Cathelco enable luxury yacht owners to benefit from an effective and reliable pipework anti-fouling system. This can be powered from the yachts battery supply (12V to 24V d.c.) with the option of a solely anti-fouling function or combined anti-fouling and corrosion suppression. Mini Systems These have been designed for larger luxury yachts with a number of seawater inlets. Operating from the yacht s 220V/110V single phase supply, Mini systems come with a variety of anode options to simplify installation. These include anodes with integral cathodes to protect plastic strainers and pipework. The control panels are compactly designed to fit within areas where space is at a premium and feature clear digital read-outs ICCP hull corrosion protection Minitek for steel hulls Designed to protect steel hulls against corrosion, the Minitek system consists of a control panel and an arrangement of hull mounted anodes and reference electrodes. The anodes are flush mounted and have a 15 year life far longer than sacrificial anodes. Also, the current to the anodes is automatically adjusted to provide the optimum level of corrosion protection. Alutek for aluminium hulls Aluminium hulls can corrode due to the proximity of dissimilar metals such as bronze propellers and steel components. The Alutek system neutralises corrosive activity by using flush mounted anodes connected to a control panel. Anode output is carefully governed using a combination of monitoring electrodes, controlling electrodes and shield sensors. This gives far superior performance than sacrificial anode systems with the advantages of optimised protection, reduced weight, less drag and a lower yard installation cost. 5
Impressed current cathodic protection RUDDER BONDING REFERENCE ELECTRODE C-MAX LINEAR ANODE REMOTE MONITORING UNIT SHAFT EARTHING ASSEMBLY CONTROL PANEL 50-75A & 100A Linear Anodes Designed with a single current emitting element either 25 or 32mm diameter, these anodes are exceptionally lightweight and versatile. Size: 740mm x 400mm Weight: 7 Kg 125-200A Linear Anodes Produced with two 32mm diameter elements these high performance anodes are easy to install. Size: 740mm x 400mm Weight: 7 Kg 225-300A Linear Anodes Designed for the largest vessels, these anodes have three elements to produce outputs of up to 300A. Size: 1380mm x 400mm Weight: 14kg 6
systems for commercial vessels Most operators recognise the need to combine modern hull coatings with a purpose designed impressed current cathodic protection system. The C-Shield system suppresses corrosion on the wetted surface of the hull using an arrangement of hull mounted anodes and reference electrodes connected to a control panel. This neutralises corrosion cells and eliminates problems that arise through dissimilar metals and the proximity of components such as propellers. C-MAX DISC ANODE REFERENCE ELECTRODE Disc Anodes Generally used on forward systems, these are produced in two sizes:- 50-100A. Size 370mm diameter. Weight: 4kg 125-175A. Size 526mm diameter. Weight 9kg CONTROL PANEL Reference Electrodes Cathelco zinc reference electrodes are fully diver changeable. They are also available with silver/silver chloride elements. Size: 125mm diameter Weight: 9kg Control panels Thyristor These panels can be used for systems of up to 1,000 amps with 8 anodes and 4 reference electrodes being controlled by an individual panel. They are ideal for the requirements of cruise ships, VLCCs, container vessels and many other types of ships. Modular Extremely lightweight and compact, these control panels can be used on installations of up to 350 amps. The modules are interchangeable and can be easily removed and replaced, if necessary. C- Max anodes A new range of linear and disc anodes combining maximum performance with easier installation. The most important feature is that they are diver changeable, enabling them to be replaced without the need for drydocking. The linear anodes are fitted using self-snapping torque nuts, ensuring the correct tension. The disc anodes are installed using a specially designed cofferdam which simplifies diver replacement at sea. Shaft earthing Even on ships fitted with ICCP or sacrificial anodes, propeller shaft bearings are vulnerable to corrosion. This is because turning shafts are electronically insulated from the hull by the lubricating oil film in the bearings and the use of non-metallic bearings in the tail shaft. As a result there is the risk of spark erosion in the bearings and cavitation damage to the tips of propellers. These problems can be eliminated if the shaft is earthed to the hull using a propeller shaft slipring. Cathelco supply complete shaft earthing assemblies consisting of a pair of high silver content graphite brushes mounted in a balanced brush holder, running on a copper slipring with a solid silver inlay track. There is the option of continuously monitoring the system using an inbuilt millivolt meter. 7
Systems for offshore oil and gas applications Seawater pipework anti-fouling systems FPSOs usually have numerous seawater intakes serving engine cooling, product processing, fire fighting and a range of auxiliary services. These can be protected against blockages caused by bio-fouling using the Cathelco system with anodes installed in seachests, strainers or specially designed electrolysis tanks. Seawater lift pump protection Cathelco pump protection antifouling units are available for oil platforms, semi-submersibles and jack-up rigs. These are designed to be mounted at the bottom of pumps, often inside the stilling tube or caisson. They consist of special copper and aluminium anodes housed within a steel framework and fed with an electrical current from a control panel. The anode mounting frame acts as the cathode, creating a completely self contained unit which is electrically isolated from the pump using a specially designed isolation kit. In cases where access to deep well pumps is difficult, anodes can be mounted in a deck level electrolysis tank. Cathodic protection systems Cathelco have considerable experience in the design of ICCP systems for platforms, semisubmersibles and jack-up rigs operating throughout the world from the South Atlantic and Gulf of Mexico to the North Sea and Arctic waters off Russia. A key aspect of design is the careful positioning of anodes to achieve the most effective pattern of current spread, whilst avoiding areas of shadowing. Platforms As offshore platforms may have a design life in excess of 30 years, it is vital that anodes and reference electrodes are diver changeable. For ice class applications specially strengthened cofferdams and anodes are available. FPSOs With prolonged intervals between drydocking, ICCP systems for FPSOs must provide reliable and effective corrosion protection. Diver changeable anodes and reference electrodes are essential, whilst the design must take into account factors such as paint loss and anchor chains. Semi-submersibles These are generally complex structures requiring design expertise in the positioning of anodes and reference electrodes for maximum effectiveness. C-Max diver changeable anodes are ideally suited for this purpose, sometimes used in conjunction with sacrificial anodes to protect corrosion hot spots. Reference Electrode Disc Anode Linear Anode Control Panel Anti-fouling pump protection units for offshore platforms 8
Corrosion protection for offshore wind turbines Jacket Structures Monopile Structures Tripod Structures Splash zone protection Anode Anode Remote control and monitoring Reference Electrode Reference Electrode Reference Electrodes ICCP anodes mounted on brackets. Eliminates need for Anode mounted on bracket Anode Anode Anode Reference Electrode Anode Anodes Current penetrates seabed by up to 5 metres Protecting the whole of the underwater structure The Cathelco ICCP system can be used to protect jacket, tripod and monopile structures. The anodes and reference electrodes have been specifically designed for wind turbine applications with the aim of achieving greater flexibility for installation. This ensures that they can be positioned in a configuration which achieves the best possible distribution of the current field to eliminate corrosion One of the major advantages of ICCP systems is that they have a much higher driving voltage than sacrificial anodes. This enables the current to reach a depth of up to 5 metres below the seabed (mudline) extending corrosion protection to the buried foundations of the structure. Remote control and monitoring The performance of the ICCP system can be monitored in three ways. On the turbine, data is display on the control panel and automatically recorded for security. The system can also be controlled from an on-shore central control room using an Ethernet connection. In addition, the condition of the system can be monitored remotely over the internet from any location. Anodes Cathelco wind turbine anodes are lightweight and easy to install using self- snapping torque nuts. For wear resistance, the current emitting elements are made from mixed metal oxide on a tubular titanium substrate. The element is mounted in an epoxy casting with an ABS backing sheet. They are rated to a depth of 140 metres. Reference electrodes Two types of reference electrodes are available. The more widely used zinc reference electrodes are made from high purity zinc to provide a stable and accurate reading. Silver/silver chloride reference electrodes are mainly used for monopile structures because they are highly accurate and more stable at higher negative potentials. 9
Ballast water treatment systems Filtration and UV technology with innovative features The Cathelco BWT system is based on a combination of filtration and UV technology, well established processes which are effective against a broad range of marine organisms. However, as a whole, the system has a number of innovative features which put it ahead of its competitors. The BWT units are available with capacities from 50m3/hr to 2,400m3/hr or up to 1,200m3/hr per single system. During uptake the sea water passes through the filtration unit where larger organisms and sediments are removed. At regular intervals the retained material is automatically back flushed and discharged. The sea water continues to the UV treatment chamber where smaller organisms, bacteria and pathogens are rendered harmless. During discharge the sea water bypasses the filter unit and goes directly to the UV chamber where it is disinfected for a second time. Helix flow Through computer analysis, Cathelco engineers have produced pipework that makes the sea water travel in a helix as it passes through the UV chamber. Therefore, the maximum surface area is exposed to the light, increasing the efficiency of the process. UVT sensors To adjust the power of the lamps to fluctuating sediment loads in the sea water the flow is monitored by UVT sensors. These measure the transmittance of the seawater and send a signal to the control panel which adjusts the power supply accordingly. In addition, UV intensity meters monitor the lamps, indicating when replacement is necessary. Unique ball cleaning system The system uses specialised foam balls to polish away any residue that has accumulated on the quartz tubes or interior surfaces of the UV chamber. This avoids the risk of damage caused by mechanical cleaning methods. UV Chambers Control Panels Unique ball cleaning system Helix maximises exposure to UV light 10
Cathelco Seafresh reverse osmosis desalinators Reliable watermakers for small commercial vessels and luxury yachts Cathelco acquired Seafresh Desalinators in 2010 and quickly began a product development programme to enhance the range. With the benefit of Cathelco s international sales and service network the desalinators are increasingly being sold on a worldwide basis. These include installations on all types of small commercial craft including research vessels, offshore supply vessels, tugs and fishing craft. There has also been an increase in sales to the luxury yacht market where there are many advantages in producing potable water at sea. The Ton series with outputs of up to 40 cubic metres per day are completely automatic in operation. They incorporate water quality sensing systems which test the product water electronically, rejecting water that does not meet the standard. Another important feature is that they are designed as three or more modules for greater flexibility during installation. The H2O series with outputs up to 276 litres per hour are ideal for small vessels and luxury yachts. They are also fully automatic in operation with temperature compensated electronic water quality testing. All H2O models are available in frames or can be supplied in component form enabling items to be distributed to make the most efficient use of space. Ton Series Outputs from 10 to 40 cubic metres per day. Automatic salinity control and dump feature. Small footprint - typically 1050 (L) x 800 (W) x 1600mm (H). Media prefilter and product softening filter. Flow meters for monitoring input feed and product water generation. Optional remote control from the bridge. H2O Series Outputs from 36 to 276 litres per hour. Easy to install and simple to operate. Fully automatic, temperature compensated electronic water quality sensing. Available in frame or can be supplied in space saving component form. Option of remote control operation. Available with additional pre and post treatments. 11
A portfolio of products for the shipping, offshore and renewable energy markets Seawater pipework anti-fouling systems Commercial/cruise vessels Naval vessels FPSOs/FSOs Offshore platforms Semi-submersibles/jack-up rigs Luxury yachts ICCP hull corrosion protection systems Commercial/cruise vessels Naval vessels High speed craft Luxury yachts FPSOs/FSOs Semi-submersibles/jack-up rigs Bow and stern thruster tunnels Water jet systems Shaft earthing systems Offshore Wind Turbine cathodic protection Jacket structures Monopile structures Tripod structures Transformer platforms Accommodation platforms Ballast water treatment systems Capacities from 50m3/hr to 2,400m3/hr Reverse osmosis desalinators Commercial vessels Naval vessels Luxury yachts Worldwide Service Network Our worldwide network of sales and service centres can provide immediate advice and assistance on the complete range of Cathelco products. Agents contacts details are available on our website: www.cathelco.com Abu Dhabi Algeria Argentina Australia Belgium Brazil Bulgaria Canada (East & West Coast) Chile China (Hong Kong, Shanghai, Qingdao) Croatia Cyprus Denmark Ecuador Egypt Finland France (Atlantic & Mediterranean Coasts) Germany Greece Holland Iceland India Indonesia Iran Ireland Israel Italy Japan Korea (Seoul & Pusan) Malaysia Mexico New Zealand Norway Peru Philippines Poland (Gdansk & Szczecin) Portugal Romania Russia (Murmansk, St Petersburg, Vladivostok) Singapore South Africa (Durban & Cape Town) Spain Sweden Taiwan (Kaohsiung & Taipei) Thailand Turkey United Arab Emirates USA (East, West & Gulf Coasts) Vietnam Venezuela Cathelco Ltd, Marine House, Dunston Road, Chesterfield S41 8NY United Kingdom Telephone: +44 (0) 1246 457900 Fax: +44 (0) 1246 457901 Email: sales@cathelco.com Web: www.cathelco.com