K.C. LTD.

DRAWING TITLE FINAL DRAWING & OPERATION MANUAL

ITEM ANTI-FOULING SYSTEM (M.G.P.S)

SHIPYARD DSEC

HULL No. DSME H1192

VESSEL TYPE 180K BULK CARRIER

K.C. LTD. REF. No. 4771/C

0 ORIGINALLY PREPARED H.J.S. SEP.03,10

REV DESCRIPTION DWN. APP. DATE

K.C. LTD.
1589-6, Songjung-dong, Kangsu-ku, CAUTION
THIS DOCUMENT CONTAINS CONFIDENTIAL
Busan 618-818, Korea AND PROPRIETARY INFORMATION OF
K.C. LTD.
Tel : +82 51 831 7720 THIS DOCUMENT ALWAYS REQUIRES PRIOR
WRITTEN CONSENT OF K.C. LTD.
FOR
Fax : +82 51 831 7726 (1)ITS REPRODUCTION BY ANY MEANS,
(2)ITS DISCLOSURE TO A THIRD PARTY,
E-mail : [email protected] (3)ITS USE FOR ANY PURPOSE OTHER THAN

Web : http://www.iccp-mgps.com THOSE FOR WHICH IT IS SUPPLIED

K.C. LTD.
DRAWING TITLE FINAL DRAWING & OPERATION MANUAL

ITEM ANTI-FOULING SYSTEM (M.G.P.S)

SHIPYARD DSEC

HULL No. DMHI. 1051/52 & DSME. 1192/93

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 7-9 7-9
Maintenance instruction Sheet 10 10
Instruction of anode renewal Sheet 11 11
Specification Sheet12-13 12-13
System wiring diagram Drg No. MWAT4W 14
System piping diagram Drg No. MPD11 15
Detail of Control Panel Drg No. MCKC4W 16
Detail of Plug & receptacle Drg No. MJ05 17
Detail of Anode assembly Drg No. MAKB14 18
Detail of Cathode assembly Drg No. MASUS02 19
Detail of anode treatment tank Drg No. MAT10 20
Detail of Flow meter Drg No. MFM19-2 21
Detail of Injection nozzle Drg No. MNOZZLE07-1 22
Detail of Water strainer Drg No. MWST02 23
Detail of air blowing kit on strainer Drg No. MSAB01 24
Onboard spare list Drg No. MSPR07-1 25
Log sheet Sheet 26 26
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 : [email protected]
Web : http://www.iccp-mgps.com

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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 Cu → Cu2+ + 2e

Cathodic reaction 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 Al → Al3+ + 3e

Cathodic reaction 3H2O + 3e → 3/2H2 + 3OH-
Product of Al(OH)3 Al3+ + 3OH- → Al(OH)3

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 K.C. LTD. MGPS DOCUMENT
REV(E) : 05/12/29

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.

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 K.C. LTD. MGPS DOCUMENT
REV(C) : 28/10/08

INSTRUCTION FOR ANODE TREATMENT TANK

INSTALLATION

The anode treatment tank is made from mild steel. Inside surface of anode treatment tank had been
coated by polyethylene coating thick 3mm. Therefore special care should be given against
welding or any other hot works which may damage this lining.
It is also required not to have any hard shocks during transportation.

It is recommended to install anode treatment tank on bottom floor of engine which should be
placed to sea chests as near as possible and to stabilize anode treatment tank by using lifting lug
hole bolted onto the hull.

Over the anode treatment tank the anode overhaul height must be given.

After installation of anode treatment tank according to the design, mount anodes on the lid of
anode treatment tank.

MAINTENANCE

1. Clean anode floc inside tank, flow meter and strainer every month regularly.
2. Open the air vent every day to prevent air pocket inside tank.
3. Keep the valve in use fully open. On the contrary keep the valve not in use fully closed.
(It’s no problem to have readings of flow meter at more than max range.)
4. It’s required to have DRAIN-OFF operation once a month or when flow meter readings is
shown less than 20m3/h.
5. During dry dock clean tank, flow meter, injection line and injection nozzle.

CAUTION
1. Purge air pocket fully before opening cleaning hole.
2. Keep wearing gloves and mask during tank cleaning.

DRAIN-OFF operation;
Turn off main power in control panel.
Close inlet valve of anode tank and open drain valve and then remove hydroxide created by
anodes.

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 K.C. LTD. MGPS DOCUMENT
REV(D) : 18/11/05

WIRING OF SYSTEM

Client to supply all cables and connection boxes between :-

1. Power isolation switch 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
SUS (Stainless steel) Cathode Cable - Black

WIRING UP

An earth (-ve) (cathode) lead must be installed direct to the earth return plate installed onto the
anode treatment tank body.

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 terminal block of the control
panel marked ‘earth returns’.
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 cathode.

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K.C. LTD. M.G.P.S. (HSY)
REV(C)19/03/09

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 2) Main power is not supplied. 2) Check circuit breaker in vessel’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 2) Anode cable has been severed. 2) Check anode cable and connect
of control panel 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 anode 4) Purge out air pocket.

treatment tank.
5) Anode has been consumed. 5) Change over two anode cables
(Impossible to adjust current by (one in fault and the other in
the adjusting button) normal operation) of terminal
block inside panel for the
identification of faulty anode.
Replace with new genuine anode.
6) Power module got damaged. 6) Replace with new power module.
(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.)

03 Alarm led light 1) Current has been set zero or max. 1) Adjust normal current.
(orange) on 2) Anode cable has been severed. 2) Check anode cable connection
tightly.

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 K.C. LTD. MGPS DOCUMENT
REV(A) : 99/06/18

IN-SERVICE INSTRUCTIONS
(Anode treatment tank)

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.
Renewal can be carried out with the vessel in afloat.
Please ensure a reasonable dispatch time when ordering replacement anodes.

You will require the following : -

ANODE PART No. Q’TY ANODE LOCATION

CU (Copper) KBCU 490 2

ANODE TREATMENT TANK
AL (Aluminium) KBAL 490 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 two (2) Weeks.

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 tank)

When opening the tank lid for regular check inside tank, do not fail to remove all anodes mounted
onto the lid. Lifting up tank lid without anodes removal and lifting it down gives serious stress to
stud and results in anode breakage.

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 K.C. LTD. MGPS DOCUMENT
REV(B) : 08/07/30

UNEVEN WEARING OF COPPER ANODE

When anodes are positioned at strainer (filter box) or independent tank, anodes should be regularly
checked for the wear down.
Regarding uneven wearing (particularly wear down in the middle) of copper anode you may spray
with tar epoxy paint about 3~4 times 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.

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 K.C. LTD. MGPS DOCUMENT
REV(A) : 99/06/18

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 higher the current setting the shorter the anode life.
The lower the current setting the greater the anode life.

ANODE POSITION : ANODE TREATMENT TANK

ANODE REF CURRENT SETTINGS

CU 1,CU 2 0.5Amps
AL 1 ,AL 2 0.7 Amps

CAUTION

Customers are recommended for the purchase of genuine parts from us.
Imitated parts make the system get fatally damaged.

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K.C. LTD. MGPS DOCUMENT
REV(A) : 08/08/28

MAINTENANCE INSTRUCTIONS

▷ For Long Term Preservation

- Control panel : to be Installed in Engine room (dry space)

- Anode ass’y (working): to be installed on the anode treatment tank
- Anode ass’y (spare) : to be stored in inner space where free from impact and moisture

▷ For Maintenance System

1) Every Day
- Open the air vent every day to prevent air pocket inside anode treatment tank.
2) Every Week
- Record the current of digital display on the log sheets provided.
3) Every Month
- Clean anode floc inside tank, flowmeter and strainer.
- Fill out the log sheet and return to K.C.LTD. for professional diagnosis/comment.

CAUTION

1. Purge air pocket fully before opening Anode treatment tank lid.
2. Keep wearing gloves and mask during anode treatment tank cleaning.

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 K.C. LTD. MGPS DOCUMENT
REV(B) : 09/12/15

INSTRUCTIONS OF ANODE RENEWAL

(Anode treatment tank)

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.

1. Switch off main power supply on the control unit, and close inlet and outlet valves to the
anode treatment tank.

2. Close sea water inlet and outlet valves in anode treatment tank

3. Open drain and air relief valves and then empty the anode treatment tank.

4. Disconnect anode cable in junction boxes.

5. Remove anode flange together with used anode from the anode treatment tank.

6. Open cleaning hole of the anode treatment tank and clean up inside of the anode treatment
tank.

7. Install new anodes on the anode treatment tank and connect up anode cables.
Be sure to connect correct anodes and to put gaskets between anode flanges.

8. Connect anode cable in junction box at the correct position.

9. Close cleaning hole of the anode treatment tank and fill the anode treatment tank with sea
water by opening inlet and outlet vales.

10. Switch on main power supply in the control panel when sea water pumps are running.

11. Ensure current on control panel showing setting value given previously.

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 K.C. LTD.
SPECIFICATION FOR M.G.P.S

Client DSEC
Project No DMHI. 1051/52 & DSME. 1192/93

Sea water to be treated 1,000 ㎥/h from either of sea chests

Cu (Copper) : 2.0 ppb x 1,000 ㎥/h x 5 years x 24 hours

Weight required for system
x 365 days x 10-6 = 87.6 kg
Al (Aluminium) : 0.5 ppb x 1,000 ㎥/h x 5 years x 24 hours
x 365 days x 10-6 = 21.9 kg

Weight provided
Cu (Copper) : 490mm x 120øx2= 99.0 kg
by K.C. LTD.
Al (Aluminium) : 490mm x 120øx2 = 31.0 kg

Anode location 2 Cu x 2 Al in one anode treatment tank

Anode mounting type JIS 5K-150A flange mounting sleeve

Scope of supply 2 x KBCU 490 Anodes assembly

2 x KBAL 490 Anodes assembly
1 x KASUS 550 Cathode assembly
1 x KCAF 2040NM control panel with cable glands
1 x Anode treatment tank (800A x 900H)
2 x Plug & receptacle
2 x Flow meter
1 x Strainer with air blowing kit
1 x Set standard spares

Painting colour Control panel to Munsell 7.5 BG 7/2

Electric source AC 220V, 60HZ, 1PH
Electric power consumption Max 120 Watt

Life time of anodes 5 years

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 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 KBCU 490 2pc 72.5 kg 145.0kg

② Al (Aluminium) anode assembly KBAL 490 2pc 38.5kg 77.0 kg

③ SUS (Stainless steel) cathode assembly KASUS 550 1pc 30.2 kg 30.2kg

④ Control Panel KCAF 2040NM 1pc 20.0 kg 20.0 kg

⑤ Anode treatment tank 800A x 900H 1pc 690.0 kg 690.0 kg

⑥ Plug & receptacle MJ05 2pc 2.0 kg 4.0 kg
⑦ Flow meter KC-FM-018 2pc 3.0 kg 6.0 kg
⑧ Strainer with air blowing kit 5K-65A 1pc 21.0 kg 21.0 kg
⑨ On board spares - 1set

Total weight of system 993.2 kg

ON BOARD SPARES

Refer to the separate spare part list.

After 5 years working, replacement anodes required(see list above).

Replacement anode or guarantee work if required contact :

K.C. LTD. (see first page)

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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 : [email protected]
Weekly Log for Anti-fouling System (M.G.P.S.)
Vessel Name Owner
Project No. Anode Change Over Period : year Logging Month

Note. 1. Clean anode floc inside tank every month regularly.

2. Open air vent everyday to prevent air pocket inside tank.
3. Keep the valve in use fully open with the valve not in use closed.

AMP SEA CHEST IN USE Flow meter(m³/h)

week
CU1 AL1 CU2 AL2 PORT ST'BD HIGH LOW
Jan 1
2
3
4
Feb 1
2
3
4
Mar 1
2
3
4
Apr 1
2
3
4
May 1
2
3
4
Jun 1
2
3
4
Jul 1
2
3
4
Aug 1
2
3
4
Sept 1
2
3
4
Oct 1
2
3
4
Nov 1
2
3
4
Dec 1
2
3
4

OBSERVATIONS Strainer inspected on

(v) as observed Nil Light Medium Heavy - -
Fouling in Strainer
Fouling in Pipeline
Fouling in Heat Exch.
Corrosion in Strainer
Corrosion in Pipeline
Corrosion in Heat Exch.

Remark
Submitted by Chief Engineer
Customers are recommended for the purchase of genuine parts from us.
CAUTION
Imitated parts make the system get fatally damaged.

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