K.C. LTD.
DRAWING TITLE
DRAWING & INSTALLATION/OPERATION MANUAL
ITEM
ANTI-FOULING SYSTEM (M.G.P.S)
CLIENT
TECHNAVA SA
HULL No.(VESSEL NAME)
SARA
K.C. LTD. REF. No.
KM64477
K.C. LTD. MODEL
ANFOSYS
0
REV
ORIGINALLY PREPARED
J.W.L
DESCRIPTION
DWN.
APR.02,15
APP.
DATE
K.C. LTD.
13, Noksansandan 261-Ro 14 Beon-gil,
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
DRAWING & INSTALLATION/OPERATION MANUAL
ITEM
ANTI-FOULING SYSTEM (M.G.P.S)
CLIENT
TECHNAVA SA
HULL No.
SARA
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
7-8
Instruction of anode renewal
Sheet 9
9
Specification
Sheet 10-11
10-11
System wiring diagram
Drg No. MSWD4W-1
12
Detail of Control Panel
Drg No. MCKC6W
13
Junction Box Details
Drg No. MJ02
14
Detail of Anode assembly
Drg No. MAKA21
15
Position of Anodes in Sea chest
Drg No. MAPSC15-2
16
Onboard spares list
Drg No. MSPR07-1
17
Log sheet
Sheet 18
18
K.C. LTD.
165, Mieumsandan 3-ro, Gangseo-gu,
Busan, Korea
Tel : +82 51 250 2808
Fax : +82 51 831 7726
E-mail : kcind@iccp-mgps.com
Web : http://www.iccp-mgps.com
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
K.C. LTD.
MGPS DOCUMENT
REV(E) : 05/12/29
INSTRUCTION FOR CONTROL PANEL
(KCAF/RE 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.
K.C. LTD.
MGPS DOCUMENT
REV(C) : 09/07/02
INSTRUCTION FOR FITTING ANODES
(JIS 5K-100A FLANGE WITH PIPE UPSTAND TYPE)
Before work, make sure of anode overhaul height by the length of anode & mounting sleeve over
the sea chest top.
1.
Pipe upstand (100A) to be supplied and fitted by client. Pipe to have minimum bore of
95mm inside after coating or lining to ensure clearance of anode mounting assembly.
Flange to be JIS 5K-100A.
If K.C. Ltd. have supplied drawings for specific system.
Burn a hole in the sea chest top plate to suit outside diameter of pipe in position stated on
drawing.
If K.C. Ltd. have not supplied drawings.
Determine the position of the pipe upstand and burn a hole in the top plate of the sea chest to
suit pipe outside 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 220mm between anode centers
and 120mm between anode center and the nearest steel works.
Weld pipe upstand in position, ensuring:1.1 Pipe is welded to the sea chest top plate on both top and bottom surfaces.
1.2 Flange top surfaces must be horizontal unless otherwise stated.
1.3 We recommend that any special paint or coating applied to the sea chest be also applied to the
pipe upstand.
2.
Bolt flange mounting complete with anode to mating flange on pipe upstand.
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.
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.
K.C. LTD.
M.G.P.S. (HSY)
REV(D)20/07/10
Anti-fouling System (M.G.P.S)
TROUBLE SHOOTING (ANRE)
NO.
FAILURE
01
Control panel
doesn’t work
02
03
04
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.
1)
‘0’ reading or
no display on
display key pad
2)
of control panel
Alarm led light
(red) on
Alarm led light
(red) blinking
REQUIRED ACTION
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)
PART No.
Q’TY
KACU 450
4
ANODE LOCATION
SEA CHESTS
AL (Aluminium)
KAAL 500
2
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.
WARNING (In case anodes are installed in strainer)
When opening the strainer lid for regular check inside strainer, do not fail to remove all anodes
mounted onto the lid. Lifting up strainer lid without anodes removal and lifting it down gives
serious stress to stud and results in anode breakage.
K.C. LTD.
MGPS DOCUMENT
REV(F) : Aug.13,14
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 : STRAINER
Anode No.
Cu1,2,3,4
Al1,2
Current setting
Not in use
Normal
0.1
0.3
0.1
0.3
Max.
2.0
2.0
Alarm point
Zero current Over current
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.
CAUTION
Customers are recommended for the purchase of genuine parts from us.
Imitated parts make the system get fatally damaged and worse yet the system
breaks down and stops in the end.
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.
K.C.LTD.
SPECIFICATION FOR M.G.P.S
Client
VESSEL NAME
TECHNAVA SA
SARA
Sea water to be treated
360 m3/h from either of 2 sea chests
Weight provided
by K.C.LTD. per sea chest
Cu(Copper)
Al(Aluminium)
Anode location
Anode mounting type
2 Cu ×1 Al in each of 2sea chests
JIS 5K-100A flange mounting sleeve
Scope of supply
4×KACU 450 anodes assembly
2×KAAL 500 anodes assembly
: ø 82.5 ×450 mm ×2 = 43.1 Kg
: ø 82.5 ×500 mm = 7.2 Kg
1×KCAF2060RE control panel with cable glands
6×JIS 5K-100A pipe upstand flange with bolt/nut/washer & gasket
2×Junction box
1×Set standard spares
Painting colour
Electric source
Electric power consumption
Control panel to Munsell No. 7.5 BG 7/2
AC 220V, 50Hz, 1PH
Max 180Watt
Life time of anodes
3 year
K.C.LTD.
SCOPE OF SUPPLY AND WEIGHTS PER HULL
S/N
Item
Type
Q’ty
Wt. Each
Total weight
1
○
Cu(Copper) anode assembly
KACU 450
4pc
32.0 kg
128.0 kg
2
○
Al(Aluminium) anode assembly
KAAL 500
2pc
17.6 kg
35.2 kg
3
○
Control Panel
KCAF2060RE
1pc
29.0 kg
29.0 kg
4
○
Junction box
ABS
2pc
2.0 kg
4.0 kg
5
○
Pipe upstand
JIS 5K-100A
6pc
10.0 kg
60.0 kg
6
○
On board spares
-
1set
Total net weight of system
ON BOARD SPARES
Refer to the separate spare part list.
After 3 year working, anode replacement is required (see list above).
Replacement anode or guarantee work if required contact :
K.C. LTD. (see first page)
256.2 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
AMP
CU1
CU2
AL1
2015
Logging Month
SEA CHEST IN USE
CU3
AL2
PORT/HIGH
ST'BD/LOW
Heavy
-
-
CU4
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
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.