Estd. In 1981.

An ISO 9001 2008 Company

FIELD ASSESSMENT REPORT

ON
DAMAGED SEAWATER ELECTROLYZER
Shuweihat S1 Water and Power Plant, Abu Dhabi, UAE

SCIPCO PO Number: FEP1/503/2011/AB

TiTaN Job No: TSVX 001

Assessed by
R. Nagarajan TiTaN, India
G. Murugan TiTaN, India
Fazir T. Subair MTKhoory, U.A.E

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Estd. In 1981.

An ISO 9001 2008 Company

INDEX
1.

Introduction

2.

Objective

3.

Brief System Description

4.

Electrolyser failure

5.

Failure Evidences

6.

Possibilities for the failure

7.

Remedial action to be taken

8.

Recommendation

9.

Conclusion

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

1. INTRODUCTION
SCIPCO (Shuweihat CMS International Power Company, U.A.E) who is operating the Shuweihat
S1 Water and power plant along with a seawater based electrochlorination system made a request to
MTKhoory (Mohammed Tayyeb Khoory & Sons, U.A.E) / TiTaN (Titanium Tantalum products Ltd, India)
to assess their recently failed one of the electrolyser which is a part of the electrochlorination system
through service work order no: FEP1/503/2011/AB.

With TiTaNs vast experience on design and manufacturing of various capacity and types of
electrolysers in past 3 decades, TiTaNs Engineers accompanied by MTKhoorys Engineer visited
Shuweihat 1 water and power plant on 09th and 10th of May 2011 and made a detailed study on the
one of the failed electrode assembly (without shell housing) and on the operation of the
electrochlorination plant. According to the field assessment and observation, this report has been
prepared which has covered the findings on the failure, immediate remedial action to be taken and
recommendation as the outcome of the assessment.

This report has been drawn based on the assessment made on the available failed electrode assembly
at SCIPCO workshop with the help of the maintenance team of the SCIPCO and system operating
procedure explained by the operating team.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

2. OBJECTIVE
The purpose of this assessment and report is to find the possible root cause for the failure of the
electrolyzer and recommend the required remedial actions or suggestions to avoid further failure of the
electrolysers and smooth operation of the plant.
3. BRIEF SYSTEM DESCRIPTION
The seawater based electrochlorination plant located at the SCIPCO water and power plant (Shuweihat
S1) is being in operation from 2003 after erection and commissioned by Siemens who is the total
contractor for the power & water plant. Electrochlorination plant has been supplied by Severn Trent
Denora SRL.

Technical Data:
Generation Capacity of the EC plant

458 Kg/hr

Sodium hypochlorite Production concentration

1850 mg/l

No. of installed generators

3 Nos

No. of operating generators

2 Nos.

No. of electrolyzer per generator

3 Nos.

Generation capacity per generator

229 kg/hr

Seawater Flow rate per generator

123.8 m3/hr

Design DC Current per generator

7200 A

Design DC Voltage per generator

140 V

Raw seawater coming from seawater distribution system is filtered at two stages using gravel filter and
activated carbon filter before entering in to the hypochlorite generators. Polyelectrolyte is being dosed
in the raw seawater before entering in to the gravel filter to flocculate the suspended particles present
in the seawater and further it will be filtered and removed by gravel filter. Activated carbon filter is

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

removing organic compounds, residual chlorine and solid impurities. Both stage filtration is removing
all TSS from seawater size greater than 0.5 mm and up to a filtration level of 20 ppm.

Filtered seawater is entering into sodium hypochlorite generators. The plant consists of three
generators, which are connected hydraulically parallel to each other. Two sodium hypochlorite
generators can be operated at its full load continuously and remaining one is standby.

Each generator is connected with a dedicated transformerrectifier using DC bus bar which will supply
required DC power to electrolysers to generate sodium hypochlorite from seawater by electrolysis
process.
Each generator consists of 3 electrolyzer modules connected hydraulically and electrically series to
each other. After first and second electrolyzer modules, there is a hydrogen separator to remove the
generated hydrogen from the first and second electrolyzers.

Seawater flows from the first to the second and to third electrolyzers via hydrogen separator, which is
in the hydraulic path between the intermediate electrolyzers and most of the generated hydrogen is
separated from sodium hypochlorite + seawater and connected to the hypochlorite outlet header line
which is going to hypochlorite storage tanks.

When DC current is passed through electrolyzers when seawater passed through them the sodium and
the chloride are chemically dissociated and the chloride undergoes an electrolytic change and the
available chlorine is formed at the anode. Water also undergoes an electrolytic change with the result
that hydroxyl ions and hydrogen gas are generated at the cathode. The chlorine produced in this
process is termed as active chlorine. The hypochlorite generators are rated on their output of active
chlorine (Cl). However, in practice, the chlorine and hydroxyl ions do not remain in this form and there
is a consequential chemical reaction resulting in the formation of hypochlorite. It is in this form that
the chlorine is used.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

During the above main reaction, series of other side reactions occur in the electrolyzer due to the
other constituents such as Calcium, magnesium, sulphate, carbonates present in the seawater. This will
lead to the generation of calcareous particles such as calcium / magnesium carbonates, hydroxides and
sulphates. These calcareous deposits whose settling velocity more than the seawater velocity inside
the electrolyser will deposit over the electrode assembly which needs periodic cleaning using diluted
HCl acid.
The produced sodium hypochlorite + seawater along with hydrogen collected in the hypo tank.
Hydrogen is diluted using air and vented to atmosphere and hypochlorite is dosed at dosing locations
using suitable hypochlorite dosing pumps.
4.0 ELECTROLYSER FAILURE
Though the design capacity of the each sodium hypochlorite generator is 229 Kg/hr, it was not operated
at its full design load of 7200 ADC at any point of time from the date of its commissioning. As per
operating team feedback, so far all three electrolyzer modules are being operated at a load of 4000 A to
6000 A DC only. Moreover, to meet the shockdosing requirement, anyone of the generator is being
operated for short duration (15 mins in every 6 hours interval) and it is being stopped after shock dosing
is completed. Thus peak DC amps load was given to electrolyser in short duration.

After 7 years of operation from the date of commissioning, one electrolyzer out of three from generator
A found to be damaged in the month of April 2011. The damaged electrolyser was removed from the
generator and damaged electrode assembly was replaced with new assembly which was available as
spare. Damaged electrode assembly had been kept at the maintenance work shop for study and same
was dismantled and inspected by TiTaNs engineers with the help of MTKhoory and SCIPCO. From the
inspection and study, following are the observations

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

1
4
2

1.
2.

Bus bars
Base plates
3. End anode assembly

4. End cathode assembly

5. Bipolar assembly
6. Electrode studs with Teflon spacers

Visual examination of the dismantled electrode assembly revealed severe damage on the
electrode assembly and its base plates.

Base plates of end anode assembly found to be totally damaged due to heaving heating and
further burning

Coating on the end anodes assembly plates is totally consumed and few plates looked like
bare plates without coating.

In the first anode side bipolar plates as well as many more other bipolar plates, cathodes are
totally damaged and a thick oxide films have been formed over the surface of the plates.

Most of the cathode plates have lost their strength and plate thickness has come down to less
than 0.5 mm from its original thickness of 1.5 mm

In the first cathode side bipolar plates as well many more other bipolar plates, anodes are lost
their coating and got damaged heavily.

Most of the middle bipolar plates are got punctured with more than 5 to 10 holes

Many of the plates in the overall assembly are got short circuited and lost their strength and
coating.

Most of the titanium studs connecting the bipolar plates and PVDF spacers are got damaged.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

5.0 FAILURE EVIDENCES

Burning of PVDF
spacers due to burnt
particles from end
anode assembly, short
circuit and high heat
generation.

Electrodes short
circuit due to scale as
well as burning
particles

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

Heavy burning
happened at the anode
end side due to heavy
scale build up and
hydrogen
accumulation. High
busbar heat would
have initiated the
explosion / burning.
Heavy thick titanium
base plates was burnt
in heavy heat.

Note : Titanium is a highly reactive metal, combining readily at elevated temperatures with oxygen and
hydrogen to form interstitial solid solutions, which can cause embrittlement and cracking in heat affected zones
at base plates of welded joints.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

Tiny pieces from the

burnt anode end base
plates (top side) have
spilled over the
electrodes and created
the further burning of
electrodes

Short circuit of the

electrode plates and
burning of the PVDF
spacers created by the
tiny particles from
Anode end plate
burning.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

This is a burnt end

anode plate. Coating
made on the anode is
almost consumed

In the same plate coated

is totally gone at the one
end which was welded
to the anode end base
plate and also weld
fracture due to chloride
residues.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

This is end cathode assembly. Copper Bus

portions remains good but Cathode plates are
lost their strength and properties due to
hydrogen embrittlement.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

This is one of the first

cathode side bipolar plate
anode end. Coating is
almost consumed from
this plate and passive
layer formed due to TiO2

This is cathode end of the

same plate. Hydrogen
embrittlement occurred in
the bare titanium plate.

This is one of the first

anode side bipolar
plate cathode end.
Plate has lost its
strength and
properties due to
anode end plate side
explosion and further
heating.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

This is one of the

middle bipolar plate
which has lost its
strength and
properties due to
hydrogen
embrittlement.

All the middle bipolar

plates are punctured
and plates are totally
damaged due to short
circuit and burning.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

Most of the Titanium studs used in the bipolar

assemblies are got damaged and broken

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

5. POSSIBILITIES FOR THE FAILURE
There have been many possible causes for the failure of the electrolyzer. Some of the failure
possibilities have been tabulated as below.
S.No.
1.

Occurrence

Possible Causes

Heavy heating and burning

of Anode end assembly
base plates

2.

Short

2. Hydrogen accumulation at the anode end which was not

fully removed from the electrolyzer may be because of
obstacle due to heavy scale formation.

circuit

of

the

electrodes

3.

1. Heaving scaling build up at the anode end which was not

acid cleaned properly.

Uneven

Coating

consumption from the end

3. DC busbar heating which might have initiated the heavy

heating and subsequent burning of the end anode
assembly base plates.
1. Tiny pieces from the burnt end anode assembly base
plates spilled over the other electrode plates which has
formed a short circuit between anodes and cathodes
and it initiated burning of the other plates in the
assembly.
2. Heavy scaling formation or accumulation of scaling
between anode and cathode plates which was not able
to dissolute and remove from the electrodes while acid
cleaning is being done. This has caused short circuit on
some of the electrodes plates.
1. Localized heavy heating on the anode plates due to
heaving heating and burning which has initiated the loss
of coating.

anode plates and other

intermittent anode plates
4.

Cathode plates dissolution

and

loss

of

strength

2. Due to short circuit intermittent anode plates have lost

their coating.
1. Due to short circuit initiated by the scaling and burnt
metal particles, cathodes were dissolved and reduction
in thickness has occurred.

(passive layer formation)

2. Due to hydrogen penetration (Embrittlement) on the
cathodes, titanium has lost its properties and cannot be
used further for electrolysis application.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

5.

6.

Color change on the cathode Due to heavy heating oxide film has been formed over the
surface of the titanium plates, which has reduced the
plates.
properties of the plate.
Electrode deactivation
1.The electrodes undergo a natural consumption of the
catalytic material so that, after years of operation, a
deactivation of the anodes appears and the electrolyzer
voltage increases above normal values.
2. Permanent deterioration caused by scale buildup due
to inadequate acid washing over a period or prolonged
duration.
Bipolar assembly studs damage
1. Calcareous deposits over the studs has eaten away
the titanium material due to which thickness and
strength of the studs has come down.
2. Due to heavy heating by short circuiting of
electrodes, many of the studs were burnt and
broken in to pieces.

Burning and damage of PVDF

Due to shortcircuiting of electrodes.

spacers

6. REMEDIAL ACTION TO BE TAKEN

As per above findings and evidences, the electrolyser found to be fully damaged with least chances for
repair. Hence, complete electrode assembly needs to be replaced with new assembly. Moreover, in
generator A, the failed electrolyser has been replaced with new assembly which was available in stock.
Since presently new electrolyser is in operation along with other two old electrolysers, a chance of
further failure is possible in the same generator due to improper load sharing. Hence, it is strongly
recommended to replace the other two old electrolyser assemblies also with new assemblies to ensure
the smooth operation and long running without problems.

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

7. RECOMMENDATIONS:
Based on this joint field assessment by TiTaN / MTKhoory and above findings, following are the
recommendations which may be followed by the operational team which will be helpful to avoid
further failure of electrolyser or any other equipment in the electrochlorination plant.

Condition of the gravel filters and Activated carbon filters needs to be monitored
periodically and ensure the proper periodical back wash and healthiness of the filter
media. This is to avoid entering of any foreign particles or any other dissolved
contaminants in to the generators.

Tightness of the bus bar connection in each electrolyser needs to be checked

periodically.

Temperature of the bus bar end of the each electrolysers needs to be monitored
periodically to ensure that no unnecessary heating while in operation.

DC voltage of the individual electrolysers of each generator needs to be recorded to

ensure the healthiness of the individual electrolysers.

Performance of the each generator needs to be recorded periodically (as per format
given during assessment) to monitor the healthiness of the electrolysers and records to
be maintained.

The monthly performance and acid cleaning report shall be prepared and maintained.

Supply seawater quality shall be checked periodically to ensure there is no abnormal

things in seawater and it is as process requirement specified by OEM.

The frequency and duration of acid cleaning shall be strictly followed as per OEM
recommendations.

Operator should ensure the start up and shut down procedures are followed as per
OEM instructions/manual.(For eg, Gradual increase/decrease the amperage, proper
flushing etc.,)

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FIELD ASSESSMENT REPORT-DAMAGED SEAWATER ELECTROLYZER

Presently an unusual operating philosophy is being followed in SCIPCO as electrochlorination plant is

concerned. That means one hypochlorite generator out of three is in operation to meet the continuous
dosing requirement. While shock dosing, one more generator is being taken in to line for additional
hypo generation for short duration (15 mins once in 6 hours). Once shock dosing is completed, one
generator is being stopped. This is an unusual practice compare to general electrochlorination plant
operating procedure. During assessment, it was told that this operating procedure was recommended
by OEM. However being a high capacity plant (7000 DC Amps load per generator), it is not advisable to
start and stop the hypo generator very frequently. This sudden loading in to the electrolyser will spoil
the strength of the coating and reduce the life of the electrolysers. Moreover, this will reduce the life
of the thyristors present in the transformer rectifier unit.

As per global practice, to meet the shock dosing requirement excess hypochlorite has to be generated
and stored in the hypo storage tank and once in 6 hours (or as per design requirement), this excess
hypochlorite has to be shock dosed at the dosing locations. To meet this operating philosophy, only
hypo storage tank shall be adequately sized to hold the excess hypochlorite generated.

With our vast experience in electrochlorination field, TiTaN is strongly recommending to operate one
or two generators continuously depends no of desalination plants in operation and avoid intermittent
operation which is being followed presently. TiTaN can help SCIPCO for this change in operating
procedure if SCIPCO provides all necessary information.

6. CONCLUSION
From the field assessment, it is collectively concluded that electrode assembly taken out from
generator AElectrolyser 1 fully got damaged beyond repair due to various reasons as described above.
This needs to be replaced with new assembly.

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