EMCS NOXX MARELCO Quick start guide

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EXPERIENCE THE FREEDOM OF NO FOULING
Anti-fouling System Installation
& Operational Manual
Vessel Name/ Company
EMCS INDRUSTRIES LTD. Reference Number
Vessel Superintendent/ Project Manager
Revision
Date
Description
Signature
1 MARELCO ANODES & CONTROL PANEL
EMCS MAJOR ACCOUNTS MANAGER: GABRIELLE ALONSO
T: 250.656.5366 ext 200 |C: 250.661.5383. |F: 250.656.5344 | E: [e-mail]
Commercial: www.emcsindustries.com | Recreational: www.thenoxx.com

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Table of Contents
SECTION A. MARELCO™
1. INTRODUCTION 4
2. GENERAL DESCRIPTION 4
(i) Marine Growth Protection 4
(ii) Corrosion Protection 5
3. MARINE INSTALLATIONS 6
(Sea Chests, Main Treatment Tank, Auxiliary Treatment Tank
SECTION B. SYSTEM DESCRIPTION
1. CONTROL PANEL 9
(i) Panel Exterior 9
(ii) Panel Interior 11
Meter Card 12
Anode Card 13
Meter Card - Open Circuit Fault Level Mode High 14
Meter Card - Short Circuit Fault Level Mode Low 16
2. SAFETY CAPS 18
3. ANODES 18
(i) MG Anodes 18
(ii) TC Anodes 18
4. CABLE 19
5. POWER 19
6. MARINE INSTALLATION REQUIREMENTS 20
(i) Sea Chests 20
SECTION C. INSTALLATION
1. CONTROL PANEL 21
2. CABLE 21
3. SAFETY CAPS AND ANODES 22
4. POWER 23
5. SYSTEM CALIBRATION 23
SECTION D. ANODE REPLACEMENT
1. ANODE REPLACEMENT PROCEDURE 19
SECTION E. OPERATING VARIABLES
1. FRESH WATER 25
2. ICE 25
3. IN PORT - SEA WATER 25
4. PARTIAL ANODE OPERATION 25
SECTION G. DRAWINGS

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GENERAL DESCRIPTION
SECTION A.
(1) INTRODUCTION
Marine growth fouling of sea water cooling systems has posed a problem to ship owners, offshore
operators, and industry for many years. Tremendous costs are incurred due to partially blocked cooling
systems; equipment damage caused by system failures; increased demand on equipment, and higher fuel
consumption due to reduced cooling water reaching condensers. MARELCO™ aids in reducing these costs
and problems.
Since its first installation, MARELCO™ has proven that shore based industry, and ships of all types, will
reap immediate and lasting benefits.
For owners, a substantial reduction in operating, maintenance, and replacement costs will be realized
with MARELCO™ protection. Cost savings and benefits include:
(a) reduced fuel consumption;
(b) increased plant and equipment efficiency;
(c) reduced costs for cleaning sea chests, gratings, heat exchangers, condensers, pipes, valves, etc.
(d) increased life span of piping;
(e) less back up of equipment inventory;
(f) abolition of chemical costs, and;
(g) increased sea time - routine dry dockings only.
(2) GENERAL DESCRIPTION
MARELCO™ is a patented impressed current system employing specially alloyed anodes. MARELCO™
eliminates marine growth infestation and reduces corrosion in saltwater cooling systems. MARELCO™
provides continuous protection, demands negligible maintenance, and is easily applied to new or existing
installations.
(i) Marine Growth Protection
Marine growth fouling occurs where sedentary organisms ranging from fungi and bacteria to simple plants
and animals settle on surfaces immersed in sea water, thus affecting the operation and maintenance of
equipment. These organisms can greatly alter corrosion process and plug condensers, piping, and valves.
Fouling causes important increases in frictional resistance, fuel consumption, loss of production and
increased cleaning costs.

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Many methods have been tried, but always with associated problems. Historically, chlorination has
been used as the major chemical control of bio-fouling. Government regulations have placed increasingly
severe limitations on chlorine concentrations and duration, to the extent that intermittent chlorination at
the dosages permitted is not always an effective deterrent to the settlement and growth of marine
organisms. Chemical methods produce severe corrosion problems and can cost more to operate. Methods
must be capable of controlling primary fouling organisms, have low solubility, reduce pitting, be
compatible with existing equipment, and present no environmental hazards.
MARELCO™ meets these requirements by slowly dissolving special alloyed anodes into electrolytic
products (less than 10 mg/litre) which creates a environment hostile to primary forms of marine fouling
while at the same time reducing corrosion.
Impressed direct constant current is applied to the anodes, generating aluminum hydroxide from the
trap corrosion anode and copper ions into solution from the marine growth anode. Aluminum hydroxide
suspends the released copper, and being highly gelatinous spreads out into the slower moving areas of
the sea chests, where marine growth larvae are most likely to settle. Treatment is concentrated at the
inlet areas before water enters the various services. Sea water moving past the anodes acts as the mixing
agent, and the motive force to carry the suspension throughout the system.
Not only does the trap corrosion anode produce the colloidal suspension, it also actuates a corrosion
cell that protects the cathode from adverse reaction to copper. This dual system guarantees the
elimination of marine growth, reduction of corrosion, elimination of pitting, and is environmentally safe.
(ii) Corrosion Protection
Total corrosion prevention is rarely achieved, although it can be in specific instances. The concept of
corrosion control includes a broad spectrum of techniques ranging from acceptance of a finite life to some
quantitative diminution of the rate of attack, for example, in inhibited cooling watersystems.
MARELCO™ inhibits corrosion in water cooling systems by an electrochemical and barrier film
technique. The system produces a tiny, corrosion resistant and sacrificial film between the metal and its
environment. The trap corrosion anode creates ionic products which form a gelatinous alkaline coating
on the pipe surface or structure (the cathode) inhibiting corrosion up to 85% in a complete corrosion
protection system with the installation of treatment tanks. In practice, the pipe looks as if its internal
surface is coated.

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(3) MARINE INSTALLATIONS
Ships of all types and offshore rigs will benefit with MARELCO™ protection. Marine growth fouling can
be eliminated and corrosion inhibited in all sea water circulating systems.
The anodes located in sea chests, suction inlets, and sea bays,treat raw sea water before it enters the
various services. Additional anodes may be located within the services being protected. Components that
may receive protection include gratings, sea chests, sea wells, holding tanks, thrusters, piping, scoops,
condensers/heat exchangers, valves, fire pumps, sanitary systems, etc. Every installation is specifically
designed to meet the parameters of the system, and services it is to protect.
By eliminating bio-fouling and corrosion scale MARELCO™ ensures free circulation of water, resulting
in optimum plant performance. Dry docking and maintenance routines can be expanded. Down time due
to overheating will be reduced and sea time increased.
BASIC SYSTEM LAYOUT - SEA CHEST DIAGRAM

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MARELCO™ TREATMENT TANKS
Wiring for anodes to Control Panels is identical to the wiring of all other Anode products

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MARELCO™ ANODE CAGE

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Panel Dimensions
See drawings marked - Control Panel - Dimensions
SYSTEM DESCRIPTION
SECTION B.
This is an automatic electrolytic process for the prevention of marine growth fouling by algae, mussels,
barnacles, hydroid, etc., and other fouling organisms higher than single cell organisms.
Fouling prevention is ensured by the controlled dissolution of copper in water intakes. A complete
system comprises of an electronic control/monitoring panel, safety caps, anodes, cable and power.
(1) CONTROL PANEL
The MARELCO™ constant current control unit is a high quality steel dust/splash proof cabinet which
incorporates all solid state circuitry and heavy duty components produced to meet any specification
(explosion proof and complete watertight is optional). The cabinet exterior is corrosion and oil stain
resistant, coated with baked marine enamel. Power consumption is less than 0.5 kW.
(i) Panel Exterior Construction
-16 guage construction
-Seams continuously welded and ground smooth
-Doors are removable and interchangeable
-Nearly flush oil-tight latches hold door and body halves securely closed
-Latches are opened and closed with a security key (key included)
-Full-tinted acrylic window door
-Thru-hole rack angles welded in front
-Mounting holes on back of enclosure
-Oil-resistant gasket and adhesive

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READINGS SHEET | VESSEL: – _
Anode Ref Type Location Amps Volts
Date: SIGNED:

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(ii) Panel Interior
The fully automatic control unit utilizes power from the ship's on board services supply. The
transformer/rectifier converts the AC supply to low DC voltage.
The green light indicates "ON" when the unit is energized. The green light will run continuously
indicating that everything is functioning properly with the power supply.
The red-light indicator should be "OFF" at alltimes. When the red light is "ON" an anode card inside
the panel will register an "OPEN" or "SHORT" which causes the red indicator to illuminate.
Amperage remains constant to the calibrated settings. All internal electronic, monitoring, and control
components are mounted in sub-racks. The rack system is totally constructed of corrosion resistant
materials.

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METER CARD
Each control panel contains a meter card that indicates voltage and amperage to each anode. The
meter card incorporates the following features mounted on the face plate:

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ANODE CARDS
Identical anode cards incorporate the following features mounted on face plate:

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Warning: These settings are factory set and should not be adjusted unless you have specific
instructions from the manufacturer.
METER CARD - OPEN CIRCUIT FAULT LEVEL MODE
This mode is used to adjust the open circuit alarm level. The open circuit alarm will be activated when
the selected card's output voltage is higher than normal. This could be caused by:
-broken anode wire
-expired anode
-disconnected anode
-blown fuse on this anode card
-fresh water or no water in anode locations
TO ADJUST THE OPEN CIRCUIT FAULT LEVEL
-Select the anode card to be adjusted by pressing the "SELECT" button on the faceplate of the anode
card.
-The green "SELECTED" LED will be illuminated.
-Select the Open CCT fault level mode by pressing the " FAULT LEVEL (OPEN CCT)" button.
-The word "Hf' will appear on the first line of the LED readout.
-Set the required voltage by pressing the "INCREASE" or "DECREASE" buttons on the - anode card.
-To De-select the card press the "DESELECT CARDS" button Refer to Figure #3 on the next page.

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Warning: These settings are factory set and should not be adjusted unless you have specific
instructions from the manufacturer.
METER CARD - SHORT CIRCUIT FAULT LEVEL MODE
This mode is used to adjust the short circuit alarm level. The alarm will be activated when the following
occurs
-broken or damaged wire shorting to the cathode (steel)
-anode not properly insulated from the cathode (steel) TO AJUST THE SHORT CIRCUIT FAULT LEVEL
-Select the anode card to be adjusted by pressing the "SELECT' button on the face plate of the anode
card.
-The green " SELECTED" LED will be illuminated.
-Select the Short CCT fault level mode by pressing the " FAULT LEVEL (SHORT CCT) "button.
-The word "LO" will appear on the first line of the LED readout.
-Set the required voltage by pressing the " INCREASE" or "DECREASE' buttons on the anode card.
-To De-select the card press the "DESELECT CARDS" button.

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RED INDICATES CUSTOMER RESPONSIBILITY
YELLOW INDICATES EMCS TECHNICIAN COMMISSIONING RESPONSIBILITY
NOTE: ALL INSTALLS SHOULD BE SUPERVISED BY AN AUTHORISED MARELCO TECHNICIAN

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Custom Control Panels specially made for your vessel system are made available according to the application.
The below is an example of a Control Panel designed to avoid the use of Spare Anodes being used before it
necessary.
SEE FIG 4A ABOVE: IN THE EVENT A SPARE IS REQUIRED TO BE TURNED ON, THIS WILL AUTOMATICALLY PREVENT
THE USE OF THE MAIN MG ANODE. REMOVE COVER PLATE TO ACCESS THE SWITCHES AS SHOWN ABOVE
CUSTOM CONTROL PANELS

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(2) SAFETY CAPS
MARELCO™ safety caps are hydraulically tested to 100
p.s.i., and approved by Lloyds, C.S.I., the American Bureau of
Shipping and R.I.N.A.
EMCS Ltd. will supply the safety caps to be installed as per
instructions in Section C.
(3) ANODES
Standard anodes are constructed of extruded materials.
The highest grades of copper, aluminum, iron, and other
metals are used. Anodes can be formed to any configuration
allowing flexibility in positioning and arranging anode
locations. Various anode stud diameters are used to meet
military and ice breaking standards.
(i) MG Anodes
The MG anode is constructed of specially alloyed extruded material principally copper, plus various
alloys. It is always employed in conjunction with the TRAP (fC) anode. It reacts with sea water to produce
an environment that prevents biological fouling (I.E. shellfish, spat, spawn, etc.) from inhabiting.
(ii) Trap (TC) Anode
The Trap (TC) anode is constructed of specially alloyed extruded materials principally aluminum or iron,
plus various other alloys. It produces a colloidal suspension to support the products of the MGanode.
The size and shape of anodes vary according to the dimensions of the sea chest, pipes, gratings, water
conditions, flow rates and dry docking schedules.
Only in exceptional circumstances will the weight of anodes exceed man-handling proportions. Each
anode is stamped with a number corresponding to its position on the drawing. The number will be found
on the side of each anode, just below the tape.

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