K.C. LTD.
DRAWING TITLE
FINAL DRAWING & OPERATION MANUAL
ITEM
ANTI-FOULING SYSTEM (M.G.P.S)
SHIPYARD
MAWEI SHIPYARD
PROJECT No.
MW626-2
K.C. LTD. REF. No.
KM59263/B
0
REV
ORIGINALLY PREPARED
H.W.K.
DESCRIPTION
DWN.
DEC.26,14
APP.
DATE
K.C. LTD.
13, Noksansandan 261-Ro 14 Beongil,
Gangseo-gu, Busan 618-818, Korea
Tel : +82 51 831 7720
Fax : +82 51 831 7726
E-mail : kcind@iccp-mgps.com
Web : http://www.iccp-mgps.com
CAUTION
THIS DOCUMENT CONTAINS CONFIDENTIAL
AND PROPRIETARY INFORMATION OF
K.C. LTD.
THIS DOCUMENT ALWAYS REQUIRES PRIOR
WRITTEN CONSENT OF K.C. LTD.
FOR
(1)ITS REPRODUCTION BY ANY MEANS,
(2)ITS DISCLOSURE TO A THIRD PARTY,
(3)ITS USE FOR ANY PURPOSE OTHER THAN
THOSE FOR WHICH IT IS SUPPLIED
K.C. LTD.
DRAWING TITLE
FINAL DRAWING & OPERATION MANUAL
ITEM
ANTI-FOULING SYSTEM (M.G.P.S)
SHIPYARD
MAWEI SHIPYARD
PROJECT No.
MW626-1/2
Description
Page No
List of contents
1
Introduction
Sheet 2
2
Instructions for Control Panel
Sheet 3
3
Instructions for fitting Anode
Sheet 4
4
Wiring of System
Sheet 5
5
Troubleshooting
Sheet 6
6
In-service Instructions & current setting
Sheet 7-8
Instruction of anode renewal
Sheet 9
Specification
Sheet 10-11
System wiring diagram
Drg No. MW51-1
12
Detail of Control Panel
Drg No. MCKC12W
13
Detail of Junction box
Drg No. MJ04
14
Detail of Anode assembly
Drg No. MAKB22
15
Position of Anodes in Sea chest
Drg No. MAPSC19
16
Onboard spare list
Drg No. MSPR07-1
17
Log sheet
Sheet 24
18
K.C. LTD.
1589-6, Songjung-dong,Kangsu-ku,
Busan 618-818,Korea
Tel : +82 51 831 7720
Fax : +82 51 831 7726
E-mail : kcind@iccp-mgps.com
Web : http://www.iccp-mgps.com
-1-
7-8
9
10-11
K.C. LTD.
MGPS DOCUMENT
REV(0) : 14/10/05
INTRODUCTION FOR M.G.P.S
The system is based on the electrolytic principle consisting of copper and aluminium anodes which
are fed with a fixed impressed electrical current from control panel.
The System is designed to give continuous protection with the minimum maintenance against
marine growth and corrosion caused by marine growth in seawater service line. It will provide
complete protection through the full designated anode life.
Excessive anode current will result in an excessive rate of consumption of the anodes, and then
reducing their life and possibly leaving the water system unprotected if the anodes are worn out.
SYSTEM PRINCIPLE
The system produces anti-fouling ion using specially alloyed anodes.
There are two types known as the CU(copper) anodes and AL(aluminium) anodes.
CU Anodes are manufactured from copper as major part for system. The copper anode produces
ions which are transported by the seawater and carried into the pipework system to prevent marine
growth.
They release ions during electrolysis as following reactions.
Anodic reaction
Cathodic reaction
Cu → Cu2+ + 2e
2H2O + 2e → H2 + 2OH-
AL Anodes are manufactured from aluminium as supplementary part for system. The slow
dissolution of the aluminium anode produces ions which spread throughout the system and produce
an anti-corrosive layer on the internal surface of sea water cooling lines.
They release ions during electrolysis as following reactions.
Anodic reaction
Cathodic reaction
Product of Al(OH)3
Al → Al3+ + 3e
3H2O + 3e → 3/2H2 + 3OHAl3+ + 3OH- → Al(OH)3
-2-
K.C. LTD.
MGPS DOCUMENT
REV(C) : 02/05/29
INSTRUCTION FOR CONTROL PANEL
(KCAF/NM TYPE)
DISPLAY
The panel contains digital display according to the quantity of anode. Current setting for each
anode can be easily adjusted by up-down button and is shown in the digital display.
The alarm lamp will be ‘ON’ when improper current to each anode is set and any failure of system
operation. This alarm can be connected to vessel’s alarm system externally.
FIXING
Two mounting bars with four holes for M10 are incorporated on the back plate of the panel.
We recommend a bulkhead mounting in close proximity to the anodes to avoid voltage drop and
cutting cable run costs.
MAIN POWER SUPPLY CABLE
Run cable from available power source .... via gland to terminal marked 'Mains In'.
Be sure to connect correct cable to terminal.
SETTING UP
Once the cables have been run and connected, the System is ready to be switched on.
NOTE - the following procedure can only be carried out with the anodes in seawater.
1.
Switch on the main power.
2.
Set all anodes currents by pressing the buttons unless the readings of digital display
correspond to each current specified in Operation Manual.
3.
Switch off until ship starts engine(s) up and switch on when sea water pumps are running.
-3-
K.C. LTD.
MGPS DOCUMENT
REV(A) : 99/06/18
INSTRUCTION FOR FITTING ANODES
(JIS 5K-150A PAD FLANGE TYPE)
Before works, make sure anode overhaul height by the length of anodes & mounting sleeve over
the sea chest top. It is important that anodes are mounted in the vertical position unless otherwise
stated on the K.C. drawings for specific vessels.
JIS 5K-150A PAD MATING FLANGE
Drill and tap 8 holes M16 on 230 pitch circle diameter for 8 M16 studs x 65 long complete with
nuts.
FITTING
1. If K.C. Ltd have supplied drawings for your specific system.
Burn a hole in the strainer lid 180mm diameter in position stated on drawing.
Weld mating flange in position (weld on both sides) and fit 8 studs to mating flange.
2.
If K.C. Ltd have not supplied drawings.
Determine the position of the anode mounting flange and burn hole in top plate of sea chest
180mm in diameter. The anodes must be positioned between the sea water inlet grid and
suction pipes in the sea chest in case anode are installed in sea chest.
Recommended minimum dimensions for anode positioning 300mm between anode center and
anode center and 140mm between anode center and nearest steelwork.
3.
Weld mating flange in position on top of the sea chest (weld on both sides) and fit 8 studs to
mating flange.
4.
5.
Coat both mating flange to same specification as sea chest.
Bolt flange mounting complete with anode to mating flange.
Remember to fit gasket between flanges and ensure no mechanical load is applied to cable.
WARNING
It is required to have insulation test of anode after installation before ship`s launching.
HOWEVER NEVER TEST WITH HIGH VOLTAGE MEGGER TESTER.
TEST METHOD AFTER INSTALLATION ;
1. Use analog multi tester.
2. Select resistance range (10kR).
3. Direction (Anode : +, Hull : -)
4. Confirm the resistance value above 30kΩ between anode cable and hull.
-4-
K.C. LTD.
MGPS DOCUMENT
REV(D) : 18/11/05
WIRING OF SYSTEM
Client to supply all cables and connection boxes between :1.
2.
Power isolation switch and control panel.
Control panel and anodes including earth return leads.
Minimum Recommended Cable Specification
Marine rubber double insulated. Use one core per anode and one core per earth return.
The minimum core size for all cable is as follows : 0
25
50
-
25
50
100
metre cable run
metre cable run
metre cable run
Use 2.5 sq mm core.
Use 4.0 sq mm core.
Use 6.0 sq mm core.
Each anode is assembled with different cable color for easy identification as follows;
CU (Copper) Anode Cable
- Red
AL (Aluminium) Anode Cable - Blue
WIRING UP
An earth (-ve) return must be installed at each separate anode location i.e. if the system supplied is
designed for 2 sea chests/strainers then 2 earth returns must be used. Use a min of 1 earth return for
every 4 Anodes. Ensure that a separate core of a multicore cable or a completely separate cable is
used for this purpose. Use cable as specified above. Connect to the terminals available in the
rear of the control unit marked 'earth returns'.
We suggest the cable connections are made by welding a bolt on to the strainer or sea chest close to
the anodes (but no nearer than 250mm).
Fit junction box close to anodes and wire to control panel using recommended cable as per
attached wiring diagram and control box drawing.
After switching on, check the polarity of the anodes in relation to the hull.
All anodes are to be positive, relative to a negative hull.
-5-
K.C. LTD.
M.G.P.S. (HSY)
REV(D)20/07/10
Anti-fouling System (M.G.P.S)
TROUBLE SHOOTING (NEWMO)
NO.
01
02
03
04
FAILURE
Control panel
doesn’t work
POSSIBLE REASON
1)
Main fuse got damaged.
1)
Check main fuse.
2)
Main power is not supplied.
2)
Check circuit breaker in vessel’s
distribution board.
Check power switch of control
panel.
Anodes are not immersed in the
sea water.
1)
Fill sea water.
Anode cable has been severed.
2)
Check anode cable and connect
tightly.
3)
Cable disconnection.
3)
Check cable connection tightly
inside junction box or terminal
block of control panel.
Also secure the earth return
inside junction box.
4)
Some air pocket inside sea chest /
strainer.
4)
Purge out air pocket.
5)
Anode has been consumed.
(Impossible to adjust current by
the adjusting button)
5)
Change over two anode cables
(one in fault and the other in
normal operation) of terminal
block inside panel for the
identification of faulty anode.
Replace with new genuine anode.
6)
Power module got damaged.
(When any one of two led on
power module behind middle
plate of control panel turned
“OFF” or “Orange led”.
See the drawing of control panel.)
6)
Replace with new power module.
1)
Current has been set zero or max.
1)
Adjust normal current.
2)
Anode cable has been severed.
2)
Check anode cable connection
tightly.
1)
System got faulty.
1)
Contact K.C.ltd. for remedy.
‘0’ reading or
1)
no display on
display key pad
2)
of control panel
Alarm led light
(red) on
Alarm led light
(red) blinking
REQUIRED ACTION
-6-
K.C. LTD.
MGPS DOCUMENT
REV(A) : 99/06/18
IN-SERVICE INSTRUCTIONS
DESCRIPTION
Once the System has been installed it will perform two functions : 1. Eliminate marine growth and reduce the corrosion rate in the seawater service lines.
2. The System uses impressed current sacrificial anodes which last to designed life.
Once in service the anodes will require renewal within designed life.
Refer to instruction of anode renewal as specified separately.
Please ensure a reasonable dispatch time when ordering replacement anodes.
You will require the following : ANODE
CU (Copper)
AL (Aluminium)
CU (Copper)
AL (Aluminium)
PART No.
Q’TY
KBCU 420
KBAL 310
KBCU 150
KBAL 150
2
2
2
2
ANODE LOCATION
MAIN SEA CHEST
AFT SEA CHEST
When ordering, inform of maker's reference number specified on the cover sheet of this drawing.
ADJUSTMENTS
The control panel is fully automatic and therefore does not require any adjustments in service.
CHECKING
We suggest that as a matter of course the Control Panel should be checked every week.
When checking, see that all the digital display ammeters are working, this will determine all is
correct. When the anodes have nearly wasted, the digital display above the corresponding anode
will start to fall. When this happens, turn the anode current knob back to zero and leave it until
the anode renewal.
Reset once again at sea after renewal to current settings given previously.
-7-
K.C. LTD.
MGPS DOCUMENT
REV(D) : May.28,14
IN-SERVICE ADJUSTMENT AND CURRENT SETTINGS
The effective working of the system can only be determined by inspection and it is suggested that
if after some 6 months of operation the opportunity to examine a strainer, length of pipe or heat
exchanger, presents itself, this should be done.
In the event of there being signs of infestation, the current to each anode in this section should be
increased by a maximum of 0.4 amps, but if no fouling is present the current to each anode within
this section may be reduced by a maximum of 0.2 amps.
This routine can be repeated at intervals, the current being adjusted accordingly.
CAUTION : The higher the current setting the shorter the anode life.
The lower the current setting the greater the anode life.
ANODE POSITION : MAIN SEA CHEST
Current setting
Anode No.
Not in use
Normal
Cu1,2
0.1
0.6
Al1,2
0.1
0.6
ANODE POSITION : AFT SEA CHEST
Current setting
Anode No.
Not in use
Normal
Cu3,4
0.1
0.1
Al3,4,
0.1
0.1
Max.
2.0
2.0
Alarm point
Zero current Over current
0.0
2.1
0.0
Max.
2.0
2.0
Alarm point
Zero current Over current
0.0
2.1
0.0
2.1
NOTE :
1. Turn the current setting down for the strainer(sea chest) not in use as above but be sure to
return to normal current as above when the strainer(sea chest) comes in use.
2. When ship is passing the fresh/brackish water please note the output current from anodes
could be down around ‘0’ Amp and then it triggers alarming. So if the case comes, switch
off the system and after the ship passes over the fresh/brackish water please switch on again.
3. It’s very important to check and record all the readings on log sheet in order to keep your
valuable asset more safe and permanently operational.
Please be sure to send ship's log sheet at the beginning of every month via kcas@iccpmgps.com. Then we will carry out free professional diagnosis and report to confirm if the
system works well or not, which will lead to making budget cuts for ship’s maintenance
notably.
-8-
K.C. LTD.
MGPS DOCUMENT
REV(B) : 09/12/15
INSTRUCTIONS OF ANODE RENEWAL
Life of anodes is designed on specification and the time of anode exchange will be noticed from
falling down of digital display of each anode on control panel. Exchange of anodes can be
carried out as following procedures.
K.C. Ltd. provides renewal anodes in a complete assembled set including all accessories, flange
and cable. So customer is required to disconnect anode cable and flange bolts only for
replacement.
NOTE
Anode(s) positioned in sea chest : Renewal to be done during dry dock.
Anode(s) positioned in strainer
: Renewal to be done while ship is afloat.
Prior to works secure sea valves are firmly closed.
1.
Switch off main power supply on the control unit.
2.
Disconnect anode cable in junction boxes.
3.
Remove anode flange together with used anode from sea chest or strainer.
4.
Mark anode kind on counter flange.
5.
Install new anodes and connect up anode cables.
Be sure to connect correct anode and to put gaskets between anode flanges.
6.
Connect anode cable in junction box at the correct position and switch on control panel when
sea water pumps are running.
7.
Ensure current on control panel showing setting value given previously.
-9-
K.C. LTD.
SPECIFICATION FOR M.G.P.S
Shipyard
MAWEI SHIPYARD
Project No.
MW629-1/2
Sea water to be treated
Weight required for
system
710 m3/h from either of 2 Main Sea chests
120 m3/h from 2 AFT Sea chests
2 MAIN SEA CHESTS
CU(Copper) : 2 ppb×710 m3/h×3 years ×24 hours
×365 days×10-6 = 37.3 Kg
AL(Aluminium) : 0.5 ppb×710 m3/h×3 years ×24 hours
×365 days×10-6 = 9.3 Kg
2 AFT SEA CHESTS
CU(Copper) : 2 ppb×120 m3/h×3 years ×24 hours
×365 days×10-6 = 6.3 Kg
AL(Aluminium) : 0.5 ppb×120 m3/h×3 years ×24 hours
×365 days×10-6 = 1.6 Kg
Weight provided
by K.C. LTD.
per sea chest
2 MAIN SEA CHESTS
Cu (Copper) : ø120 ×420 mm = 42.6 Kg
Al (Aluminium) : ø120 ×310 mm = 9.5 Kg
2 AFT SEA CHESTS
Cu (Copper) : ø120 ×150 mm = 15.2 Kg
Al (Aluminium) : ø120 ×150 mm = 4.6 Kg
Anode location
1 Cu ×1 Al in each of 4 sea chest
Anode mounting type
JIS 5K-150A flange mounting sleeve
2 MAIN SEA CHESTS
2×KBCU 420 (Copper) anodes assembly
2×KBAL 310 (Aluminium) anodes assembly
2 AFT SEA CHESTS
2×KBCU 150 (Copper) anodes assembly
2×KBAL 150 (Aluminium) anodes assembly
1×KCAF 2080RE control panel with cable glands
8×Counter pad flange with Stud Bolt/Nut/Washers and Gasket
4×Junction box with cable glands
Scope of supply
1×Set standard spares(Fuse)
- 10 -
K.C. LTD.
Painting colour
Control panel to MUNSELL No. 7.5 BG 7/2
Electric source
AC 220V, 60Hz, 1PH
Electric power consumption
Max 240 Watt
Life time of anodes
3 years
SCOPE OF SUPPLY AND WEIGHTS PER HULL
S/N
Item
Type
Q’ty
Wt. Each
Total weight
1
○
Cu (Copper) anode assembly
KBCU 420
2pc
68.5 kg
137.0 kg
2
○
Al (Aluminium) anode assembly
KBAL 310
2pc
35.4 kg
70.8 kg
1
○
Cu (Copper) anode assembly
KBCU 150
2pc
41.1 kg
82.2 kg
2
○
Al (Aluminium) anode assembly
KBAL 150
2pc
30.5 kg
61.0 kg
3
○
Control Panel
KCAF2080RE
1pc
30.0 kg
30.0 kg
4
○
Pipe upstand Flange
JIS 5K-150A
8pc
10.0kg
80.0 kg
5
○
Junction box
ABS
4pc
1kg
4.0 kg
6
○
On board spares
-
1set
-
Total net weight of system
ON BOARD SPARES
Refer to the separate spare part list.
After 3 years working, replacement anodes required(see list above).
Replacement anode or guarantee work if required contact
K.C. LTD. (see first page)
- 11 -
:
-
465.0 kg
K.C. LTD.
1589-6, Songjung-dong, Kangsu-ku, Busan 618-818, Korea
Tel)+82 51 831 7720 Fax)+82 51 831 7726 Web : http://www.iccp-mgps.com E-mail : kcas@iccp-mgps.com
Daily Log for Anti-fouling System (M.G.P.S.)
Owner
Vessel Name
Project No.
date
Area of
operation
Anode Change Over Period :
Draft
m
Sea temp
°C
year
Logging Month
AMP
CU1
AL1
2014
SEA CHEST IN USE
CU2
AL2
PORT/HIGH
ST'BD/LOW
-
-
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Strainer inspected on
OBSERVATIONS
(v) as observed
Fouling in Strainer
Nil
Light
Medium
Heavy
PORT
ST'BD
Fouling in Pipeline
Fouling in Heat Exch.
Corrosion in Strainer
PORT
ST'BD
Corrosion in Pipeline
Corrosion in Heat Exch.
Remark
Submitted by
CAUTION
Chief Engineer
Customers are recommended for the purchase of genuine parts from us.
Imitated parts make the system get fatally damaged.
-18-