Industry-Standard CAPAC ® Systems: Permanent Corrosion Protection

CAPAC ® ICCP systems consistently provide automatic, long-lasting protection against electrolysis and galvanic corrosion for various sea-going vessels and offshore structures. In comparison to sacrificial anode systems, these systems offer not only reliable corrosion prevention but also long-term cost savings.

Key Components of CAPAC® Systems

The CAPAC® system primarily includes three core components: Controllers, Anodes, and Electrodes, supported by a power supply. These elements work together to deliver superior corrosion protection for ships and offshore platforms.

Benefits of CAPAC® Systems

• Global Leadership: With over 3,000 systems installed worldwide, CAPAC® is widely recognized and approved by all major classification societies for all vessel types.
• Extended Lifespan: Furthermore, the systems are designed to offer a service life exceeding 20 years.
• Simple Operation: Automatic control ensures reliable protection. Compact anodes make shipping and installation easy.
• Increased Lifespan of Components: Rudders, propellers, shafts, and fittings enjoy longer lifespans due to precise control of corrosion protection.
• Reduced Maintenance Costs: Increased drydock intervals and reduced fuel costs through effective corrosion management.
• Trusted by Navies Worldwide: Supplying naval forces for over 50 years.

What is Cathodic Protection?

Cathodic protection, particularly impressed current cathodic protection (ICCP), uses DC current to shield submerged surfaces from corrosion.  As a result, it provides continuous, automatic protection, reducing the effects of electrolysis and galvanic corrosion significantly in both mobile and fixed offshore structures.

How ICCP Works

ICCP systems deliver a regulated DC current to submerged surfaces, effectively using zinc electrodes and metal oxide anodes. This system halts the electrochemical process of corrosion before damage occurs, making it a preferred solution for vessels such as LNG carriers, oil tankers, and cruise ships.

Advantages of Evoqua ICCP Systems

• Extended Component Life: Protects shafts, rudders, and other parts from electrolysis.
• Compact Design: Anodes are both lightweight and compact, making storage, shipping and installation simple.
• Reliable Protection: Automatic controls maintain consistent protection, adjusting for salinity and paint loss better than zinc anodes.
• Reduced Costs: Fewer drydocks and lower fuel consumption mean long-term savings.
• Longevity: Designed to last over 20 years with a single installation.

Ultimately, CAPAC® systems offer a proven, effective solution for preventing corrosion, ensuring long-term reliability, cost efficiency, and enhanced protection for vessels and offshore structures.

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Operational Benefits and Flexibility

The MARINE Mk4M system offers precise dosing, ranging from 0.2 to 0.5 ppm chlorine, ensuring stable performance under varying conditions, including temperature (10-30°C) and salinity (14-19g/l). Designed for flexibility, it seamlessly integrates with vessel-specific designs, using efficient Mk4M cells and the Power Supply Unit (PSU). Installation is straightforward, and an optional service exchange for the cells enables faster maintenance turnaround. Mk4M-SB Retro Kit

Additionally, existing Chloropac® electrolysers can be easily upgraded to Mk4M cells with a Retro-Fit Kit, extending the life of current equipment without significant capital expenditure. This retrofit replaces MK2M cells with Mk4M cells, which continue producing sodium hypochlorite (NaOCI) and hydrogen (H2) through seawater electrolysis. Sodium hypochlorite, a mild bleaching agent, effectively prevents marine growth, safeguarding seawater systems from fouling and equipment damage.
 

Installation and Support

The Retro-Fit Kits can be installed either by EWT technicians or qualified engineers provided by the operator. If there is any uncertainty regarding installation, operators can consult the EWT Spares and Service team for expert support.

The MARINE Mk4M system offers reliable, long-term protection against marine growth while reducing maintenance needs, providing a cost-effective solution for ship operators.

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Typical Chloropac® System Shipboard Installation

The MGPS Mk2M Chloropac® sodium hypochlorite generating system prevents marine growth in seawater piping, heat exchangers, sea chests, and coolers. Ship owners and operators prefer the MGPS Mk2M system, with thousands of installations worldwide. Continuous low-level hypochlorination proves more effective than other marine growth prevention methods. Chloropac MGPS has earned trust in the marine market for over 40 years.

The MGPS Mk2M Process

A small amount of seawater, 5.7m³/hr (25 GPM), constantly pressurized, passes at high velocity through MGPS Mk2M electrolytic cells, converting part of the salt to sodium hypochlorite. This solution returns to the sea chest, mixing with incoming seawater. The cooling water now contains a trace residual sufficient to prevent marine organism growth, keeping all circuits—from intake to discharge—free from fouling. The system can interconnect with seawater circulating pumps to automatically adjust sodium hypochlorite output to suit on-board flow rates.

Comparison MGPS Mk2M to Other Methods

Conclusion

In conclusion, the Chloropac system not only provides superior control but also offers lower maintenance costs and reduced environmental impact. Furthermore, it simplifies chemical handling compared to alternative methods of marine growth prevention.

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Chloropac® MGPS MARINE Mk4M: Enhanced Flexibility and Efficiency

The new Chloropac® MARINE Mk4M system offers advanced marine growth prevention with improved flexibility, operational stability, and increased uptime. With over 40 years of proven reliability in the marine market, the Chloropac® MGPS features industry-leading self-cleaning cells, now further enhanced with the MKIV design. Hundreds of installations worldwide demonstrate the system’s ability to provide significant operational cost savings over the lifetime of vessels.

Key Benefits of Chloropac® MARINE Mk4M

The system offers adaptable dosing levels, ranging from 0.2 to 0.5 ppm chlorine, ensuring stability across varying temperatures (10-30°C) and salinity levels (14-19 g/l). This flexibility guarantees reliable performance even in fluctuating marine environments. Moreover, the inclusion of efficient Mk4M cells and a streamlined Power Supply Unit (PSU) makes the installation process straightforward and hassle-free.

To further improve operational efficiency, the system allows for an optional service exchange of cells, enabling faster turnaround times for maintenance. Additionally, existing Chloropac® electrolysers can be upgraded to Mk4M cells, extending equipment lifespan without major capital expenditure.

The Chloropac® MARINE Mk4M continues to lead the industry, delivering efficient, reliable marine growth prevention with reduced maintenance and enhanced operational stability.

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System Features

• Low Pressure Drop through the electrolyser, ensuring minimal impact on system performance.
• Only 4 Cells per Electrolyser to cover the full range, simplifying system design.
• Clear Covers for easy visual inspection without removing the covers.
• Low Cell Maintenance with no O-rings required, reducing upkeep efforts.
• Quick and Easy Cell Replacement, minimizing downtime.
• Scalable Output: Additional power slices can be added to the SMPSU, allowing future system upgrades.
• Self-Regulating Output: The system automatically adjusts to varying seawater conditions (10°C – 35°C at 19 g/l salinity), ensuring consistent performance.

Chloropac® System: Effective Marine Growth Prevention for Shipboard Installations

The Chloropac® MLF system (Range SB50 – SB200) is a proven solution for preventing marine growth in seawater piping, heat exchangers, sea chests, and coolers. Ship owners and operators worldwide prefer this system, with thousands of installations already in place. Continuous low-level hypochlorination has shown to be more effective than other marine growth prevention methods, offering over 40 years of reliable service in the marine industry.

How the Chloropac® MLF System Works

The process begins by diverting a small volume of seawater—about 2m³/hr (or 9 GPM)—from a pressurized seawater line. This water flows through electrolytic cells at high velocity, where a portion of the salt is converted into sodium hypochlorite. This solution is then directed back to the sea chest, where it mixes with incoming seawater.

As a result, the cooling water contains a trace level of sodium hypochlorite, enough to prevent marine organisms from attaching and growing in the system. This method ensures all circuits, from intake to discharge, remain free from fouling. Additionally, the system can automatically adjust the sodium hypochlorite output based on the flow rate, ensuring optimal efficiency.

With its proven track record, the Chloropac® system continues to deliver effective, long-term marine growth prevention, minimizing maintenance costs and improving operational efficiency.

Comparison Chloropac® MLF system to Other Methods

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