K.C. LTD. Og DRAWING TITLE FINAL DRAWING & OPERATION MANUAL ITEM ANTI-FOULING SYSTEM (M.GP.S) SHIPYARD STX SHIPBUILDING CO.,LTD. HULLNo. S-1218 VESSEL TYPE 3,500 TEU CONTAINER CARRIER K.C. LTD. REF. No. 3093/D 0 | ORIGINALLY PREPARED H.WH. REV | DESCRIPTION Wn. MAR25,08 SH DATE. K.C. LTD. 1589-6, Songjung-dong, Kangsu-ku, Busan 618-818, Korea Tel: +82 51 8317720 Fax : +82 51 831.7726 E-mail : keind@jcep-mgps.com Web : http://www.icep-mgps.com ‘as pocumezer CONTAINS CONTIDENTIAL. Sp mRomiziany inrOHMATION OF ‘his DOCUMENT ALWAYS REQUIRES PRIOR Warrvin consent oF ke LID (hits neva (us piseu (GsUscrora Penrose OrNER RIAN “THoSE FOR WHUCH TIS SUPPLIED any eas,K.C. LTD. DRAWING TITLE FINAL DRAWING & OPERATION MANUAL ITEM ANTI-FOULING SYSTEM (M.GP.S) SHIPYARD STX SHIPBUILDING CO., LTD. HULLNo. S-1209/10/1718 K.C. LTD. REF. No. 3093 Description Page No List of contents 1 Introduction Sheet 2 2 Instructions for Control Panel Sheet 3 3 Instructions for fiting Anode Sheet 4 4 Wiring of System Sheet 5 5 ‘Troubleshooting Sheet 6 6 In service instruction & setting Sheet 7-9 19 Instruction of anode renewal Sheet 10 10 General specification Sheet 11 u Scope of supply and net weights Sheet 12 2 System wiring diagram Drg No. MWS1-1 13 Detail of contro! panel Drg No. MCKC6W 4 Junction box wiring Drg No. M104 15 Detail of Cu Anode assembly Drg No.MAKF15 16 Detail of Al Anode assembly Drg No. MAKSI8 7 Position of Anode in Sea chest Drg No.MAPSC15 18 Onboard spares list Drg No. MSPRO7-1A 19 Log sheet Sheet 20 20 K.C.LTD. 1589-6, Songjung-dong,Kangsu-ku, Busan 618-818,Korea Tel: +82 51 8317720 Fa $2 51 831.7726 E-mail : keind@icep-mgps.com Web : http://www.icep-mgps.comK.C. LTD. Po INTRODUCTION FOR M.GP.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 refease ions during electrolysis as following reactions. Anodic reaction Cu > Cu +26 Cathodic reaction 2H,0 +2e > Hp + 20H” 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 AL > AP +3 Cathodic reaction 3H:0 +3e > 3/2H2+30H Product of AKOH)3 AP*+30H" > AKOH);K.C. LTD. seme 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. EIXING ‘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 Be sure to connect correct cable to terminal. gland to terminal marked 'Mains In’ 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. is” INSTRUCTION FOR FITTING ANODES (IS 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. IS SK-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 and locknuts. FITTING ‘ILK.C. Ltd have supplied drawings for vour specific system. Burn a hole in the sea chest top plate 180mm diameter in position stated on drawing. Weld mating flange in position (weld on both sides) and fit 8 studs to mating flange. 2. IfK.C. Ltd have not supplied drawings. Determine the position of the anode mounting flange and bun hole in top plate of sea chest 150mm in diameter. ‘The anodes must be positioned between the inlet grid and main suction outlet. Recommended minimum dimensions for anode positioning 300mm between anode center and anode center and 120mm between anode center and nearest steelwork. 3. Weld mating flange in position on top of the top plate (weld on both sides) and fit 8 studs to mating flange. 4. Coat both mating flange to same specification as sea chest. 5. Bolt flange mounting complete with anode to mating flange. Remember to fit gasket between flanges and ensure no mechanical load is applied to cable.K.C. LTD. oat WIRING OF SYSTEM Client to supply all cables and connection boxes between :- 1. Power isolation switeh and control panel. 2. 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 metre cable run Use 2.5 sq mm core. 25 - 50. metre cable run Use 4.0 sq mm core. 50 - 100 metre cable run 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. ifthe 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.mere K.C. LTD. ee Anti-fouling System (M.G.P.S) ‘TROUBLE SHOOTING (NEWMO) No.] FAILURE POSSIBLE REASON REQUIRED ACTION 01 [Control panel | 1) Main fuse got damaged. 1) Check main fuse doesn’t work | >) "Main power isnot supplied 2) Check eirouit breaker in vesser’s distribution board. Check power switch of control panel. 02 [0 reading or | 1) Anodes are not immersed in the | 1) Fill sea water. no display on sea water. display key pad Gfeontrol penet |2) Anode cable fas been severed. —[2) Cheskanode cable and connect tightly. 3) Cable disconnection. 3) Check eable 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/ | 4) Purge out air pocket. strainer. 3) Anode has been consumed. 3) Change over two anode cables (impossible to adjust current by (one in fault and the other in the adjusting button) rrormal operation) of terminal block inside panel forthe identification of faulty anode. a Replace with new genuine anode. 6) Power module got damaged. | 6) Replace with new power module (When any one of two Ted on power module behind middle plate of control panel turned “OFF” or “Orange led” See the drawing of contol panel.) 03 [Alarm led ight | 1) Current has been set zero or max. |1) Adjust normal current. forange)on | >) ‘anode cable has been severed. 2) _ Check anode eable connection tightly. ‘Alarm led light | 1) System got fauly. 1) Contact K.C. Ltd. for remedy, (red) onK.C. LTD. eeaE IN-SERVICE INSTRUCTIONS. DESCRIPTIO! 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 PART No. QTy ANODE LOCATION CU Copper) KFCU 740 4 SEA CHEST AL (Aluminium) KSAL 1,000 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 di I 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.K.C. LTD. ene UNEVEN WEARING OF COPPER ANODE Regarding uneven wearing of copper anode you may spray with tar epoxy except 300mm long from the anode bottom after complete dry up of copper anode surface, which can help anode dissolved from bottom. Refer to the below drawing. (MOUNTING SLEEVE MEAT SHRINKABLE TUBE. (steman) ‘TAR EPOXY PAINT AFTER, ‘COMPLETE DRY UP OF SURFACE ANODE LENGTHK.C. LTD. mesa 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. NOTE : The his surrent setting the sho je life. ‘The Jower the current setting the greater the anode life ANODE POSITION : SEA CHEST ANODE REF CURRENT SETTINGS PORT cu LR 0.9 Amps ALI 1.7 Amps sTB’D cus 0.9 Amps AL2 1.7 Amps NOTE : Tur the current setting down to 0.4 Amp for the strainer not in use but be sure to return to operating current as above when the strainer comes in use. CAUTION ‘Customers are recommended for the purchase of genuine parts from us. Imitated parts make the system get fatally damaged.K.C. LTD. sar” INSTRUCTIONS OF ANODE RENEWAL Life of anodes is designed specified in specification, but it will be more or less depending upon the operation of the vessel and it will be noticed timing of anode exchange 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, provide 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 positioned in sea chest: Renewal to be done during dry dock. Anode positioned in strainer: Renewal to be done in 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 contro! panel when sea water pumps are running. 7. Ensure current on control panel showing setting value given previously. -10-K.C. LTD. SPECIFICATION FOR M.GP.S Client Project No STX Shipbuilding. Co., Ltd S-1209/1 0/17/18 Sea water to be treated 2,022 m'sh from either of 2 sea chests Weight required for system per sea chest Weight provided by K.C.LTD. per sea chest Cu(Copper) : 2ppb x 2,022 m'/h x $ years x 24 hours «365 days x 10° = 177.1 kg. Al(Aluminium) : 0.5ppb x 2,022 m'/h x 5 years x 24 hours x 365 days x 10° =44.3 kg Cu(Copper) —: 740mm x 1350 x 2= 189.7 kg Al(Aluminium) : 1,000mm x 1500 x 1 = 50.0 ke Anode location Anode mounting type 2.Cu x 1A in each of 2 sea chests JIS SK-150A flange mounting sleeve Scope of supply 4 x KF CU 740 Anodes ass'y 2 x KS AL 1000 Anodes assy 1 x KCAF 2060NM control panel with cable glands 2. Junetion box with cable gland 6 « Cable connector 6 « Pad flange with installation accessory 1 x Set standard spares Painting colour Electric source Electric power consumption Control pane! to Munsell 7.5 BG 7/2 AC 220V, 60HZ, IPH Max 180 Watt Life time of anodes 5 yearsK.C. LTD. SCOPE OF SUPPLY AND WEIGHTS PER HULL SIN Item Type Qty Wt Each _Total weight @ —Cu(Copper) anode ass’y KF CU 740 4po 116.4 kg 465.6 kg @® Al(Aluminium) anode ass'y KS AL 1000 2pe TS kg 143.0 kg ® Control Panel KCAF 2060NM Ipe 29.0 ke 29.0 kg ® Junction box ABS 2pe 2.0 kg 4.0kg © Pad flange 5K-150A 6pe 6.6 kg 39.6 ke ® Onboard spares - Iset Total net weight of system 681.2 kg BOARD SPARES Refer to the separate spare parts list. For replacement anodes required after 5 years, See list above (only anodes required). Replacement anode or guarantee work if required contact, K.C. LTD. 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LTD. "ANODE [ANODE LENGTH] QTY HRP Pea BY OD re PGE SEE: HR ke 7 KORA | 70mm 2 fra cu | 740mm {2 Trea. arn OF Dr Frn 2 [rove [omemuint Parra co a os nee a “E>‘SHIP NAME / HULLNo: S—1209/10/17/18 SUPPLY no nee PAREN REMARK NAME [WORKING] SPARE 1 MAINFUSE 3.154 MAMFOOL 1 2 - KC, LTD. 7 ais eraser fn spanepanrsust 2 — ae [amen i Drona ne ‘HISTORY ave [sus PPP sas [PRON sparta agi1589-6, Songjung-dong, Kingsu-k, Busan 618-818, Keres Tel}i82 51 451.7720 Faxj+#2 51 431 7726 Exmall: keas@icep-mepscom Web :bup:/iwww.josp-mgps.com SEA CHEST INUSE PORT] _ STB [ovSERVATIONS Sane nepecied oF las obsened m Hssy [Fouingn Svamer Faxing im Ppa Feaiing Heat Ea [Conosion Sater [Corasionn Pipeline [Carosionn Heal Ech Romark ‘Submitted by Chief Engineer ‘cauTION -20-