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Framo

Mounting Instruction

Main contents
1 Introduction 1401-0001-401

2 Location on board 1401-0002-401

3 Equipment handling - Storage at yard 1401-0003-401

4 Installation of submerged cargo pumps 1401-0004-401

5 Installation/Storage of portable equipment 1401-0005-401

6 Installation of submerged ballast pumps 1401-0006-401


Installation of hydraulic power unit, closed loop
8 1401-0034-4
system
9 Installation of electrical equipment 1401-0009-401

10 Yard equipment 1401-0010-401

12 Installation of deck mounted cargo heat exchangers 1401-0012-401

14 Installation of submerged tank cleaning pumps 1401-0026-4

17 Hydraulic piping 1401-0017-401

18 Cargo piping 1401-0018-401

19 Hydraulic oils - Oil filling - Flushing 1401-0019-401

20 Framo commissioning - Testing 1401-0020-401

June 2003
Framo No. 1401-0001-4
Feb-2000

Mounting Instruction

Introduction

CONTENTS

1 Framo documentation
2 Ordering new parts - Return of parts
3 Addresses
Framo Mounting Instruction No.1401-0001-4
Feb-2000
INTRODUCTION Page 2 of 4

1 FRAMO DOCUMENTATION
The Framo documentation consists of instructions and drawings for installation, operation and
service. This documentation is our property. It is not to be traced, copied or published without our
written consent, nor to be misused in any way.

Framo Mounting Instruction is the general requirements to the yards for handling and installation
of a Framo cargo pumping system, and it contains general instructions for handling, storage and
installation of Framo equipment, in addition to design and installation of the hydraulic piping
system.

It is based upon practical experience from installation of high pressure hydraulic systems in co-
operation with yards and owners all over the world. Kindly follow the instructions carefully to ensure
a successful installation and a well functioning cargo pumping system. Please make special
attention to the following:

Think safety during design:


- Appropriate location of equipment.
- Sufficient service space.
- Appropriate lifting equipment for maintenance and repair of installed equipment.
- Appropriate marking of noisy areas.

Think safety during installation:


- Use of correct and approved lifting equipment.
- Be aware of foreign voltage from interfaced equipment and switch off the main
switch before any work on electrical equipment.
- Hydraulic oil (on mineral oil base) has a flash point between 180-230°C,
and any leakage must not come in contact with heated surfaces.
- Hydraulic pipe connections, flanges, valves etc. must not be located above
or close to heated surfaces.

Think cleanliness during installation:


- Maintain a high standard of cleanliness at all times.
- Keep pipes and components clean and protected during the whole production- and
installation period.

Others:
- Do not paint mechanical parts of switches (valve shutdown switches, or equal), manometers,
level gauges or similar equipment, or flexible rubber elements (flexible hoses, dampers etc.)
- Never weld on Framo equipment without special agreement.

The instructions are also based upon the authorities' requirements. These are however revised
from time to time, and it is therefore necessary to keep oneself informed about the alterations and
discrepancies between the different national authorities and classification societies.

If drawings are sent to Framo for information or comments, yard must call attention to eventual
deviation from Framo Mounting Instruction by giving remarks on the drawings.
Framo Mounting Instruction No.1401-0001-4
Feb-2000
INTRODUCTION Page 3 of 4

Documentation for yard’s design and installation is supplied to the yard shortly after receiving
the order, and contains the following:

FRAMO MOUNTING FRAMO DRAWINGS FRAMO DRAWINGS


INSTRUCTION PUMPING SYSTEM PIPING SYSTEM

General General Arrangement Piping specifications


recommendations Framo specification
and requirements Layout drawings
for design, handling Equipment drawings
Component drawings
and installation of Technical data
the Framo cargo Supplied only if hydraulic
pumping system. System drawings
piping system is included
in Framo supply

Framo Service Manual includes information for initial start-up, operation and maintenance of the
system. The manuals are supplied to the yard before commissioning.

FRAMO SERVICE MANUAL FRAMO SERVICE MANUAL


PUMPING SYSTEM PIPING SYSTEM

Technical data Piping specification


Initial start up Layout drawings
Operation
Maintenance
Supplied only if hydraulic
Drawings - Part lists piping system is included
in Framo supply

2 ORDERING NEW PARTS - RETURN OF PARTS


When ordering new parts due to repair, guarantee claim or simply because parts are missing,
please give the following information:
- Yard / Hull no. / Name of vessel.
- Yard claim no.
- Framo sales order number (see cover for Framo Documentation).
- Item no., identification no., part name (from Framo Specification or Packing List)
and quantity required.
- Required delivery date at yard/vessel, marking etc.

When parts are returned in connection with guarantee claim or repair, the following must be given:
- Yard / Hull number / Name of vessel.
- Framo sales order number (see cover for Framo Documentation).
- Reason for return.
- Name and number of part, vessel's claim no. if applicable.
The parts must be protected against rust and be properly packed.

Return of parts to: Frank Mohn Services AS.


Attention: Guarantee claim co-ordinator
Hardangerveien 150
N-5226 NESTTUN
Framo Mounting Instruction No.1401-0001-4
Feb-2000
INTRODUCTION Page 4 of 4

3 ADDRESSES
Sales Department
FRANK MOHN A/S Telephone: (47) 55 99 90 00
P.O. Box 98 Slåtthaug Telefax: (47) 55 99 93 80
N-5851 BERGEN, Norway E-Mail: marine@framo.no
Internet: www.framo.com

Project Management
The Project Department is totally responsible for every order on Framo Cargo Pumping
System. To handle each individual order, a Project manager in the Project Department will be
appointed. The Project manager is the main contact during the project- and installation period.

If the order contains hydraulic- or cargo piping, this part of the order will be handled by the
Piping Department which will handle the engineering, documentation and supply of piping.
A Project engineer in the Piping Department will be appointed accordingly.

Checking of the installation during commissioning and follow-up during the guaratee period is
handled by the Service Department. A Project engineer at the Service Department will be
appointed, and will be the main contact during the commissioning and guarantee period.

Contact addresses:

Project Department
FRANK MOHN FUSA AS Telephone: (47) 55 99 96 00
P.O. Box 10 Telefax: (47) 55 99 97 84
N-5641 FUSA, Norway E-Mail: project.marine@framo.no

Piping Department
FRANK MOHN FLATØY A/S Telephone: (47) 55 99 94 00
Flatøy Telefax: (47) 55 99 95 84
N-5918 FREKHAUG, Norway E-Mail: piping.marine@framo.no

Service Department
FRANK MOHN SERVICES AS Telephone: (47) 55 99 92 00
P.O. Box 44 Slåtthaug After 1600 hrs.: (47) 90 99 00 06
N-5851 BERGEN, Norway Telefax: (47) 55 99 93 82
E-Mail: service@framo.no
Framo No. 1401-0002-4
Rev. B Dec-2001

Mounting Instruction

Equipment - Location on board

CONTENTS
1 Framo cargo pumping system
2 Location in general
3 Submerged cargo pumps
4 Submerged ballast pumps
5 Location of other equipment
6 Framo control system
7 Hydraulic power units
8 Hydraulic transmission equipment
9 Hydraulic oil storage / Clean oil drain tank
Framo Mounting Instruction No.1401-0002-4
Rev.B Dec-2001
EQUIPMENT - LOCATION ON BOARD Page 2 of 8

1 FRAMO CARGO PUMPING SYSTEM


The Framo hydraulic system is designed as a central hydraulic ring line system. The hydraulic
power unit delivers oil to the main pressure line, and from this line it is possible to run a number
of hydraulic motors as long as the oil delivery is sufficient. In order to control the speed of the
motor and to prevent over-speed, a control valve is fitted for each motor.

For most of the systems delivered today, the hydraulic power packs, system tank, oil cooler and
main filter are assembled, tested and supplied from our factory as complete compact power units.

Fig. 1 Framo cargo pumping system

2 LOCATION IN GENERAL
The following factors must be considered when selecting suitable locations for the equipment:

- Most efficient suction and stripping possibility


- Cargo piping layout
- Hydraulic piping layout
- Cable layout
- Noise
- Ventilation of power pack room
- Sufficient service space
Framo Mounting Instruction No.1401-0002-4
Rev.B Dec-2001
EQUIPMENT - LOCATION ON BOARD Page 3 of 8

3 SUBMERGED CARGO PUMPS


Note! Submerged cargo pumps should be installed at the aft end or in the lowest part of
each tank, located either to port or starboard (to allow optimal tank emptying).

Arrangement on deck For operation the following valves and


An obstruction-free zone must be prepared connections must have free access:
above the pump, making it possible to lift the - Local control valve
complete pump out of the tank if necessary. - Stripping valve
- Cargo valve (if not remotely operated)
- Cofferdam purging connection
- Cargo pipe purging connection
Flexible clamp Cargo pipe
- Exhaust trap drain valve
Cargo valve - Hydraulic pressure service valve
Stripping pipe

Stripping valve

Exhaust trap
Service valves
Local control valve Drop line
High pressure pipe
Valve for
Low pressure pipe drop line

CL pipestack

d
h ea
B ulk Pipestack parallel
to bulkhead

Pumps with intermediate support


Location of bracket
for intermediate support
Pipe stack centerline (through the
center of cargo pipe and hydraulic
pipes) to be parallel to the bulkhead
where the bracket for the
intermediate support is welded.

Location of brackets
for lower support ring
Position of suction well

Clearance between
suction bellmouth and well
Suction well
Cargo tanks should be designed with suction wells for optimal :
- Cargo pumping
- Stripping
- Service access
Fig. 2
For further information see section 4.
Framo Mounting Instruction No.1401-0002-4
Rev.B Dec-2001
EQUIPMENT - LOCATION ON BOARD Page 4 of 8

4 SUBMERGED BALLAST PUMPS


Submerged ballast pumps should be installed as low as possible and in the aft part of the ship.
Suction lines to be designed with ample size to reduce pipe losses and cavitaiton.

Arrangement on deck
An obstruction-free zone must be
prepared above the pump, making it
possible to lift the pipe stack and the
pump head out of the tank if
necessary.

For easy operation the following


valves and connections must have
free access:
- Local control valve
- Evacuating control unit
- Hydraulic pressure service valve

The header tank must have free


access for inspection and filling.

For further information see section 6.

Fig. 3 Arrangement of ballast pump in tank


Framo Mounting Instruction No.1401-0002-4
Rev.B Dec-2001
EQUIPMENT - LOCATION ON BOARD Page 5 of 8

5 LOCATION OF OTHER EQUIPMENT


- Hydraulic driven pumps on deck, see section 7.
- Hydraulic driven thruster motor, see section 11.
- Deck mounted cargo heat exchangers, see section 12.
- Submerged cargo heat exchangers, see section 13.

6 FRAMO CONTROL SYSTEM


The Framo cargo pumping system is normally operated/monitored from the Framo control panel,
consisting of hydraulic system control panel and cargo pump control panel.
The control panel should be installed in the cargo control room or other indoor location where living
quarter conditions can be kept. It should also be sufficiently illuminated and arranged for good
contact/communication to the cargo manifold area to ensure a proper and safe cargo handling.
The panels are sometimes designed for installation in yard’s console, but the above recommenda-
tions still apply.
The control system may also be interfaced with, and operated from vessel’s integrated control system.
Local panels / motor starters should be installed in the vicinity of the controlled equipment.

Emergency stop arrangement


Framo supplies three emergency stop buttons as standard. One to be located close to the power
pack room, and two for location on deck, normally installed close to manifold.

7 HYDRAULIC POWER UNIT (HPU)


Location of the hydraulic power unit (HPU) must be considered in an early stage of the ship’s
planning, and one has to take into consideration:
- Minimum noise level in accommodation area
- Minimum noise emitted from the ship
- Optimum pipe routing
- Easy access for maintenance
Generally, HPU room location is recommended as shown below.
For further information, see section 8.

Fig. 4 Location of hydraulic power unit


Framo Mounting Instruction No.1401-0002-4
Rev.B Dec-2001
EQUIPMENT - LOCATION ON BOARD Page 6 of 8

8 HYDRAULIC TRANSMISSION EQUIPMENT


Location of electrical equipment shall comply with ’degree of protection by enclosure’ (IP).
Electrically operated hydraulic control valves supplied by Framo must be installed in safe area:

- Electrical/hydraulical remote control assembly for the hydraulically driven pumps, controlling
the pump speed, (normally installed on main deck level).
- Thruster pilot control valve assembly, must be installed as close to the thruster motor
as possible. For more details, see section 11.

Separately supplied pilot filter for these valves must be located as close to the valves as possible.

Fig. 5 Location of hydraulic transmission equipment


Framo Mounting Instruction No.1401-0002-4
Rev.B Dec-2001
EQUIPMENT - LOCATION ON BOARD Page 7 of 8

9 HYDRAULIC OIL STORAGE / CLEAN OIL DRAIN TANK


The hydraulic oil storage / clean oil drain tank incl. necessary equipment is yard supply.
Design requirements are described in section 10.

Framo recommend to install the storage/clean oil drain tank below the HPU, either as two sepa-
rated tanks, or as a combination tank for storage- and clean oil drain. With this location, eventual
overflow from the system tank and drainage from the HPU will gravitate down to the clean oil
drain tank.

The storage tank/clean oil drain tank must be installed in-door, and the ship bulkhead or shell
plating must not be part of the tank. This to avoid condensation and water in the hydraulic oil due
to temperature differences. Neither must heated surfaces with temperature above 60°C be part of
the tank, (fuel tanks etc.).

The transfer unit must be located close to the storage/clean oil drain tank to minimise the suction
side pressure drop.

Fig. 6 Separate storage- and clean oil drain tank


Framo Mounting Instruction No.1401-0002-4
Rev.B Dec-2001
EQUIPMENT - LOCATION ON BOARD Page 8 of 8

Fig. 7 Combined storage- and clean oil drain tank


Framo No. 1401-0003-4
Feb-2000

Mounting Instruction

Equipment handling - Storage at yard

CONTENTS
1 Goods receival
2 Preservation, packing and marking
3 Handling of Framo equipment
3.1 Handling of power units
3.2 Handling of submerged cargo- and ballast pumps
3.3 Handling of heat exchanger
3.4 Handling of portable equipment

4 Storage at yard
4.1 Storage in dry and clean conditions
4.2 Warehouse storage
4.3 Outdoor storage
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 2 of 9

1 GOODS RECEIVAL
Immediately after receipt of equipment, please check that the supply corresponds to the packing
list. Any missing items must be reported to Frank Mohn Fusa AS without delay.

The equipment should be carefully inspected for transportation damage. Damages should be
recorded, photographed, witnessed and reported to carriers and to Frank Mohn Fusa AS.

2 PRESERVATION, PACKING AND MARKING


Preservation
Stainless steel components are pickled, cleaned and ready for installation.

Mild steel components are protected against corrosion by means of priming or painting outside and
protecting oil inside. The preserving oil is mixable with the hydraulic oil, and will give sufficient
protection for about 1 year provided that the blank flanges are kept on.
Un-primed mild steel seal faces are normally protected by a removable corrosion preventive
coating (Tectyl).

Packing and marking


Generally most of the Framo components are packed in plastic-covered wooden boxes.

Electrical equipment
like electrical cabinets, starters and control panels have also silica gel inside for protection against
moisture. Ventilation openings and cable entrances on electrical motors are in addition covered by
fire resistant tarpaulin.

Power units
are normally covered by plastics and shipped in containers. If they are shipped on open flat racks,
they are covered by light tarpaulin (reinforced plastic) in addition to the plastics.

Submerged cargo- and ballast pumps


are supported by special wooden racks. If the length is more than 14 meters they are split in two
sections to simplify handling and transport.

Smaller pump units, deck trunks etc.


are fastened on pallets and covered by plastics.
The deck trunks seal faces are protected by plywood.

Prefabricated pipes
are packed on transport racks with wooden frames and covered by plastics.
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 3 of 9

Dispatch documents are


- Packing list: Address and dispatch information in addition to the listed items
- Packing specification: Case- and pallet number
- Container specification: Container-, case- and pallet number if shipped in containers

These documents are packed with the components.


For further information see below:

Packing list

Contents
FM order no.
Customer
Dispatch information
Item See Framo specification *
Item details Package no., Identification no.,
quantity, description etc.

* Every component is marked with an item number according


to the packing list.

Packing specification

Contents
FM order no.
Packages no. Every case or pallet is marked
with packages no.
Packages details Dimension and weight

Container specification
If the equipment is shipped in containers, the content in each
container is given in this specification.

Contents
FM order no.
Packages no.
Packages details Dimension and weight
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 4 of 9

3 HANDLING OF FRAMO EQUIPMENT


Even if the components used in Framo Cargo Pumping Systems are of rigid construction, they
should always be handled with care. Never step or climb on the equipment.
Be careful not to destroy or remove the transport protection before final installation onboard.
Lifting, lowering and handling in general should be done slowly and carefully to avoid damage to
motor bearings caused by vibration and shocks.

Note! Handling information given on the package must be strictly followed.

Stainless steel components must not be in direct contact with mild steel.

3.1 Handling of power units


General info
The power units are equipped with 4 lifting lugs. All of them must be used when lifting. Normally, a
lifting device with 4 slings of equal length can be used to lift the power unit. Avoid contact between
exposed parts of the power unit and the lifting slings.
If special lifting tools are required, these are supplied by Framo together with the power unit.

Note! Forklift must never be used to lift the power unit.

Transportation in container
Normally the power units are shipped in closed containers and should be taken out of the container
as shown for the cargo pumps on page 6.
If the power units are shipped in containers with open top, please note that these containers have a
narrow passage at the top. Therefore, the power units must be lifted free for easy guiding and
taken out broadwise. Special care must be taken not to collide with the side walls of the container.

Fig. 1

Transportation on flat rack


If the power unit is wider than the container width, it is transported on a flat rack with a special cage
for protection. This cage must be removed before the power unit can be lifted off the flat rack.
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 5 of 9

3.2 Handling of submerged cargo- and ballast pumps


The pumps are designed to withstand flexing and bending of the vessel’s structural members
(bulkheads etc.). For this reason the pump bend easily, but as long as this bending is well within the
elastic limits, it will do no harm to the pump. Incorrect and careless handling might, however, put
undue strain on the pumps, causing permanent damage.

The only acceptable way to lift pumps out of the wooden racks is to lift each pump/pump section
separately.

Fig. 2

The pumps shall under no circumstances be lifted like this:

Fig. 3

Note! Damage to pump due to incorrect lifting and handling will not be covered by Framo’s
guarantee.
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 6 of 9

If the pumps have been shipped in a closed container, they have to be pulled out as shown below.

The following equipment is necessary for unpacking and lifting (Framo supply):
- Two softslings. Minimum working Load Limit (WLL): 5 000kg. Length: 18 meters
- Four softslings. Minimum working Load Limit (WLL): 1 000kg. Length: 2 meters

1. Four pallets in a good condition (yard supply) to be placed as shown in fig. 4 - 6.

Fig. 4

2. The two softslings (L = 18m) must be fastened on the horizontal beam of the transportation
frame and to a forklift.
To pull the transportation frame out of the container the forklift must have a constant tension on
the softslings. Pull load is approximately 60% of transportation frame and pumps weight.

Fig. 5

3. The other two pallets must be placed as shown in fig. 6. They must not interfere with the lifting
points.

Fig. 6
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 7 of 9

Softslings
Minimum WLL= 5000 kg
Minimum lenght = 18 m

o
Warning !
Max. 30 Avoid contact

For securing and roping only !


Do not hook any lifing arrangement
to this frame construction.

Lifting Softslings
point Length = 2m

Fig. 7 Lifting of pumps on a transportation frame.

3.3 Handling of heat exchanger


Handle the equipment unpacked in the packages supplied from Framo.
If they are delivered in wooden rack like the cargo pumps (fig. 3) use instructions from chapter 3.2
for handling.

3.4 Handling of portable equipment


Handle the equipment unpacked in the packages supplied from Framo.
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 8 of 9

4 STORAGE AT YARD
Generally it is preferred that all Framo equipment should be stored in-door.

The equipment must be stored away from corrosive or chemically damaging fumes.
Storage even for a short period in an area where work activities such as welding, grinding, sand-
blasting, painting, etc. is going on is prohibited.

For protection and easy identification, keep the equipment in the packages supplied from Framo
until installation onboard. If only some items in a box are needed for installation, keep the others in
the box until installation.

Blank flanges must not be removed before final installation.

The protection on electric motors must be kept on until start up, and will then be removed by the
Framo commissioning engineer.
Control panels must be covered after installation onboard.

As informed in chapter 2, Framo equipment is preserved for 1 year storage. This includes also
cargo- and ballast pumps due to the internal mild steel hydraulic motor and high pressure pipe.

Note! For long time storage (1 year or more), contact Framo for special instruction.

The minimum storage conditions for Framo equipment are given below.

4.1 Storage in dry and clean conditions


All electrical components must be stored in a dry, clean room where temperature is kept steady
above dew point. Typical components are:

- Electrical control panels


- Main electric boxes
- Starters
- Electrically driven power units *

* Electrically driven power units may be stored in warehouse without steady temperature provided
that the electric motor heating elements are connected and switched “on”.

Note! Connecting power voltage to termistors will damage the termistors and eventually the
motor windings.

Warnings should be placed on the motors when the heaters are connected.

4.2 Warehouse storage


The following must be stored in a dry, clean warehouse:

- Diesel driven power units.


- Hydraulically driven components.
- All valves and fittings for the hydraulic system.
- Deck trunks in mild steel.
- Portable cargo pump.
- Flexible hoses.
- Mild steel pipes.
Framo Mounting Instruction No.1401-0003-4
Feb-2000
EQUIPMENT HANDLING - STORAGE AT YARD Page 9 of 9

4.3 Outdoor storage


Following equipment may be stored outdoor, provided it is properly protected with tarpaulin to protect
it from iron dust from grinding, welding spatter, sea water spray, sand and bird droppings.
(Stainless steel may corrode if surface is polluted)

- Cargo coolers/heaters.
- Deck trunks in stainless steel, (flange protection must be kept on).
- Pump supports.
- Stainless steel pipes.
- Submerged cargo pumps and ballast pumps.

Submerged cargo pumps and ballast pumps


must be stored with their axis in a horizontal position, preferably in the same wooden rack as they
were received. If the pumps have to be removed from the rack, they should be supported in at least
three points as shown below.

Note! The pumps must not be in direct contact with mild steel.

Tarpaulin
Cargo pump

Supported in three points

Fig. 8

Oil in drums.
To prevent water from leaking into the hydraulic oil, the drums have to be stored horizontally and
in such a way that the drum bungs are wet by the oil.

The hydraulic oil is mixed with special additives, which improve the oil quality. If the oil is mixed
with water, the additives may lose effect, or in worst case, give negative effect. Corrosion will
occur and abnormal wear will lead to breakdown of the system.

Fig. 9
Framo No. 1401-0004-4
Feb-2000

Mounting Instruction

Installation of submerged cargo pumps

CONTENTS
1 General
2 Orientation in tank
2.1 Arrangement on top plate
2.2 Nozzle loads
2.3 Location of brackets for intermediate
support(s)
3 Installation of deck trunk and brackets
for intermediate and bottom support
3.1 Framo dummy
3.2 Deck trunk
3.3 Bracket for bottom support
3.4 Bracket(s) for intermediate support
3.5 Recommendation for welding stainless
steel to carbon steel
4 Prefabrication of deck piping
5 Assembling of pipe stacks
6 Installation of pumps in tank
6.1 Installation of SD100/125/150/200/250
6.2 Installation of SD3000/350
6.3 Additional information for pumps
above 20 meter
7 Pump with cofferdam header tank
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 2 of 22

1 GENERAL
Figures in this instruction are made for all cargo pumps. It is supposed that a “dummy equipment
package” intended for the pump type to be installed, is available. For further information,
see drawings for the actual cargo pump, deck trunk, support, suction well and dummy.

STC The Framo hydraulically driven


(Speed Torque Controller) submerged cargo pump consists
of three main parts:

Top plate
Top plate
The cargo pump is supported by
a deck trunk welded to the deck.
Resilient A special gasket and a resilient
top plate connection
Deck trunk bolt arrangement will prevent
noise and cargo leakage.

Pipe stack
The pipe stack connects the
pump head to the top plate.
Pipe stack Dependent on pump length,
Intermediate Cargo pipe the pipe stack is supported by
support intermediate support(s).
Cofferdam pipe

Hydraulic return pipe

Hydraulic pressure pipe


Pump head
Cargo stripping pipe
The pump head is welded or
Cofferdam check pipe flanged to the pipe stack and
supported by the bottom support.

The cargo tank should be


designed with suction well for
Pump head optimal tank emptying. It should
be installed at the aft end of each
Bottom support tank and preferably with tank top
sloping towards the suction well.
Prefabricated suction well can be
quoted for on request.
Suction well

Fig. 1
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 3 of 22

2 ORIENTATION IN TANK
Note! Submerged cargo pumps should be installed at the aft end or in the lowest part of
each tank, located either to port or starboard (to allow optimal tank emptying).

The overview below indicates how the orientation of the pumps affects location of the suction well,
location of pipe stack support(s) (if any) and location of the cargo line and hydraulic line connections.

Cargo stripping line Two first clamps


resilient mounted
Cargo discharge valve

Pilot line
Cargo line
Stripping valve

Service valves Alternative orientation


Cofferdam of STC
connection Spools to be
removed for service
Drop line

CL pipestack

d
hea Intermediate
B ulk support

Bracket for CL
intermediate
support
CL

Centerline (CL ) to be parallel to bulkhead where


the bracket for intermediate support is welded

Bottom support

Suction well

Alternative orientation
of suction well Space for service.
See dimensional drawing
for suction well.

Fig. 2
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 4 of 22

2.1 Arrangement on top plate


Valves must be placed in areas which are easily accessed by pump operator.

Air/inert gas supply


for purging of cargo and cofferdam pipe
1/2” closing valve with snap-on coupling
(1 coupling included for each pump)
Free area for service,
installation/lifting of pump

Air/inert gas supply


pressure 6-7 bar

Flex. hose with snap on couplings


(normal length 2m)

Cofferdam Purging connection


venting pipe (purging of cofferdam pipe)
ND15,
stainless steel
Min. 2000

Exhaust trap
Purging connection
(purging of cargo pipe)
Drain valve
500

500

Min. 500 Min. 1500

Fig. 3

2.2 Nozzle loads


To ensure proper installation and avoid leakage between pump top plate and deck trunk the
maximum allowable nozzle loads for the cargo pumps are given below:

)25&(6020(17 
DSSUR[[$3, 
($&+12==/( 6' 6' 6' 6' 6' 6' 6' 81,7
) [        N1
) \        N1
) ]        N1
0 [        N1P
0 \        N1P
0 ]        N1P

Too high nozzle loads will give leakage, and


Z
noise will be generated by mechanical contact
FZ
between top plate and deck trunk. MZ
Nozzle loads on cargo pumps have no influence Y
MX FX
on rotating parts of the pumps. X
MY
FY

Fig. 4
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 5 of 22

2.3 Location of brackets for intermediate support(s)


Bracket is part of the ship design and supplied by yard. It is important
that the yard is aware of the forces acting in the tank area (sloshing,
structural deflection etc.).

Brackets to be designed according to forces shown in table below:

Centerline to be
parallel to bulkhead
38037<3( )>N1@ )>N1@
6'  
6'  
6'  
F2
6'  
6'  
F1 6'  
6'  

Fig. 5

High stress concentration High stress concentration

Acceptable solutions Not acceptable solutions

Fig. 6

Supports for all cargo pumps except SD300 and SD350 may enter the cargo tank through standard
man-hole openings. Due to the size the supports of SD300 and SD350 must be placed in tank
before the deck is closed.

All welding on suction well and deck trunk has to be finished before installation of the brackets.
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 6 of 22

To find pump lenght (L) and location for the bracket(s) relative to the suction well, following
calculation(s) has to be done:

Pump length: Lower edge


of top plate

S
L = TB + S - C

H
Deck trunk

50-100 mm
2QHLQWHUPHGLDWHVXSSRUW

Approx.
+HLJKW>PP@ )DFWRUN 

$ N [/
 ˆN ˆ


7ZRLQWHUPHGLDWHVXSSRUWV

+HLJKW>PP@ )DFWRUVN N  

$ N [/
 ˆN ˆ


$ N [/
 ˆN ˆ


Lower edge of
L

L = Pump length [mm] intermediate support


Intermediate support
S = Gasket, approx. 2 mm.
C = Pump clearance, see page 12

TB
A1 = Intermediate support height [mm]
A2

A2 = Intermediate support height [mm]


H = Deck trunk height [mm] *
TB = Height from bottom of suction well to
top of deck trunk [mm]

* Standard deck trunk height, 500 mm.


A1

(High deck trunks complicate cleaning


work.)

Final figures (A1, A2 and L) to be sent to


Framo as soon as possible.
Suction well
bottom
C

Fig. 7
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 7 of 22

3 INSTALLATION OF DECK TRUNK AND BRACKETS FOR INTERMEDIATE


AND BOTTOM SUPPORT
Prior to pump installation the deck trunk and brackets for intermediate and bottom support have to
be welded into the tank. Use of Framo dummy gives a correct installation of deck trunk, bottom
support brackets and bracket(s) for intermediate support.
The following installation procedure is based upon use of Framo dummy.

3.1 Framo dummy


The dummy has brackets for all flanged pipe connections on the pump’s top plate for adjustment
and prefabrication.

It is neccessary to remove the flange protection for deck trunk (plywood) when using
the top plate dummy. It is important to remount the plywood after use of dummy.

The “dummy equipment package” and assembling of measuring pipe are shown on fig. 8a and 8b.
For length of dummy (LD), see Framo specification.

Laser

Top plate dummy


Label ( length of dummy)

Brackets for location


of flange connections

Adjustment screws
for deck trunk height

Support dummy

Make sure that


rubber element
is installed.
“LD”

Measuring pipe
(one or several sets)
Pipe no.2
(Marked with two
white tape rings)
Tape rings
to be of
equal color
Support dummy

Pipe no.1
Distance plate
(Marked with one
white tape ring)

Measuring tape

Fig. 8a Framo dymmy Fig. 8b Assembling of measuring pipe


Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 8 of 22

Calibration of laser
The laser is to be controlled before use to detect any
inaccuracy during transportation. Battery 1,5 volt
Control and adjust the laser as follows: (Size C)

- Grease the laser flange to make turning of


the laser easier. Adjustment screws

- Locate the laser on the top plate dummy OFF ON

installed on the deck trunk. See fig. 16.

- Turn the laser on. Mark the spot where the


centre of the beam hits the suction well. Laser Laser flange

- Turn the laser 90° and mark where the


centre of the laser beam now hits the
target.

- Repeat the turning in steps of 90° until a


full circle is completed, and mark the spots
for each step.

- The collection of spots should be within a


circle of Ø=20 mm.

- If not all spots are within this circle, adjust


the laser by the two adjustment screws,
The collection of spots to hit
using a screwdriver. within a circle of Ø=20 mm

- After the adjustment, re-check the laser as 20 mm


described above.

- Continue the above procedure until the


accuracy of the laser is as specified above.
Mark the spots
CAUTION! Avoid staring straight into the laser beam.

Fig. 10
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 9 of 22

3.2 Deck trunk


Note! It is important that the deck trunks are welded into the ship at the latest possible
stage to ensure correct pump clearance C, according to page 12.

1 a) Mark pump center b) Position of cargo and hydraulic flange


connections for the pump, see
b) Cut hole in deck for deck trunk. pump’s dimensional drawing.

Y Edges parallell
to centre line CL
X

Position of
hydraulic valve
Position of
Pump center line cargo flange

Centre line CL
through centre of cargo line
and hydraulic flange connections

Fig. 13
Y

c) If the pump has intermediate


support(s):
Suction well X
Fig. 11
Edge parallel to bulkhead
where the intermediate Position for laser
support bracket shall
2 When connecting the top plate dummy be welded Holes for
measuring pipe
to the deck trunk, please note: Adjustment
screws
a) Sealing surface has
to be protected in order
to avoid scratches.

Trunk
Deck trunk
Welding seam must not Fig. 14
be orientated in ship's
transverse direction

Fig. 12
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 10 of 22

3 Trunk alignment 4 Height adjustment


8 mm distance plate
Laser
in the suction well

Position of PUMP Ø
measuring pipe: SD 100 230
Adjustment nuts SD 125 230
Highest point
in bottom of the SD 150 230
suction well SD 200 300
SD 300 350
SD 350 400

Laser beam
Ø

5 Spot welding

Spot weld the


deck trunk to deck

Pump center

Laser beam
Ø20

Approx. 0,5mm

Measuring pipe
not to touch
distance plate
Laser beam to hit within: Ø=20 mm

Fig. 16
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 11 of 22

6 Welding 7 Checking
Ruler

Remove
Laser adjustment
R
screws

After finishing the installation


of the first trunk, measure the
The trunk is distance “TB” in 0O, 90O, 180O, 270O
to be welded at a distance R from the center line
according to with the supplied calibrated
classification measuring tape.
requirements.
Flat bar to

TB
be locked to
measuring tape.
PUMP R
SD 100 115
SD 125 115
SD 150 115
0 SD 200 150
SD 300 175
SD 350 200

0
90

0
180 0
0
R

Check for correct height 270


0

and straightness, by using


the measuring pipe and laser.

Fig. 17
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 12 of 22

8 Adjustment of procedure.
After measuring the first trunk in accordance with 7 , proceed with the next trunk and
adjust procedure according to the table below if necessary. The number listed in the table
below includes gasket and cargo pump tolerances. Proceed with welding of trunks until
recommended height is reached.


 6' 6' 6' 6' 6' $FWLRQ
6'
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7% PLQ /      WKHQH[WWUXQNVWRREWDLQDFFHSWDEOH
DYHUDJHFOHDUDQFH

5HFRPPHQGHGFOHDUDQFH
7% /     
5HSHDWSURFHGXUH
PLQ

8VHDGLVWDQFHSODWHZLWKUHGXFHG
7% PLQ / ! ! ! ! ! WKLFNQHVVLQRUGHUWRREWDLQ
DFFDSWDEOHDYHUDJHFOHDUDQFH

7REHFKHFNHGDIWHUSXPS
&  +- 
 +-
   +-
   +-
   +-
  LQVWDOODWLRQ
7% LVWKHPLQLPXPYDOXHRI7%
PLQ

/LVWKHVSHFLILHGOHQJWKRIWKHFDUJRSXPS

Gasket
Ruler Approx. 2 mm
(L)

Important:
Install the deck trunk in
R correct height relative
to the suction well.

Too low clearance:


TB

- Service impossible

Too high clearance:


- Unacceptable cargo residue.
C

Fig. 18
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 13 of 22

3.3 Brackets for bottom support

All welding on suction well and deck trunk has to be finished before installation
of the bottom support brackets.

1 2a SD125/150

Support dummy

Brackets

Laser beam

2b SD100/200/300/350

Support dummy

Pump center

3a SD125/150 3b SD100/200/300/350
Laser
beam Laser
beam
0O 0O
Blue tape
Blue tape
Mirror
Mirror
Adjust brackets
before welding O
Mark Mark 90
Bolts

Bolts 90
O
a

Fig. 19
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 14 of 22

3.4 Bracket(s) for intermediate support

1 2 Laser beam to
hit dummy center

0O
Bolts
Measuring pipe 90
O

Laser beam
Mirror

Blue tape

Mark

CL CL

Pump center

Centerline CL must be parallel to the bulkhead


where the intermediate support shall be welded.

Fig. 20

3.5 Recommendations for welding stainless steel to carbon steel


Sometimes it becomes necessary to weld stainless steel to carbon or low alloyed steel. A typical
example is stainless steel wells welded into carbon steel tanks.
The dilution of the weld metal by the base material must then be considered to avoid the formation
of hard brittle structures.
This is done by using a welding consumable with different composition to both base materials.
Carbon steel filler metal will result in a high alloyed martensitic microstructure on the stainless steel
side of the weld. Filler metal of the same composition as the stainless steel will result in the same
microstructure on the carbon steel side. This microstructure will result in extensive cracking, often
very difficult to observe.
The correct filler metal shall instead be “overalloyed” stainless steel or Ni-based alloys to secure a
ductile weld metal. These filler metals will tolerate a substantial dilution from the carbon steel
without hardening.
The composition should be specially balanced to ensure that the total alloy content is adequate to
accommodate dilution effects and which have a ferrite content sufficient to provide high resistance
to hot cracking.
Preheating shall not be performed on austenitic stainless steel, since this will promote carbide
precipitation in the grain boundaries and the formation of sigma-phase (a hard and brittle phase
that dramatically increases the risk of cracking).
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 15 of 22

4 PREFABRICATION OF DECK PIPING


When the trunk is installed, the top plate dummy can be used for adjustment/prefabrication of the
piping.

- Remove the laser from the top plate dummy.


- Assemble the brackets for the current connections.
- Bolt the top plate dummy to the trunk in correct position (see dimensional drawing for top plate).

The dummy can now be used for adjustment of the piping by fixing the pipe flanges to the relevant
positions/brackets on the dummy.

Hydraulic piping
Connections for
Cargo pipe other pipes

Fig. 21

Be careful not to damage the sealing surface on the deck trunk and
protect the seal faces by the supplied plywood after this operation.

5 ASSEMBLING OF PIPE STACKS


The pump is to be assembled in a horizontal position. Every pump part is to be supported in at least
two points.
Note! The pumps must not be in contact with carbon steel.

Pump no. Pump no.

Fig. 22

Check that pump no. on all the pump parts are identical. Pump no. is placed on top plate and
flange for volute casing. Locate the pump parts in correct positions one after another.
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 16 of 22

Note !
All pipes must be checked for Bolt, washer
and nut
foreign bodies before
connection. Any parts left in the Seal rings
pipes (screws, nuts, plastic bolts
rags, etc.) may cause serious
damage to the pump. Connection pipe

Clean all o-ring grooves and seal


faces with a dry rag.
Circlip
Check all seal elements, back-up
rings, grooves and seal faces.
Pay special attention to the O-ring O-ring
teflon rings and be absolute sure
Back-up ring Back-up ring
of no deformation nor radial
grooves.
Never install damaged seal
elements.

Assemble connection pipe and Fig. 23


seals on the flange of lower part.
Cargo stripping pipe
Guide the two parts together. Be -bolts
Option
vacuum drain
careful when the connection pipe -washers -bolts
enter the hydraulic pressure -nuts -washers
-seal ring
pipe. -nuts
Bracket -seal ring
Assemble bolts and nuts.
Cargo pipe
Tighten the bolts according to Cofferdam check pipe -bolts
the table below. -socket bolts -washers
-seal ring -nuts
-seal ring
Option
temp. sensor
-bolts
-washers
-nuts
-seal ring

Hydraulic pipes
-bolts
-washers
-nuts
-seal rings
-connection pipe
-circlip
Fig. 24 Split flanges

All screws and nuts have to be assembled with specified torque.


If no torque is specified, use the following torque:

ACID RESISTANT BOLTS AND NUTS, QUALITY A4-80

M6 M8 M10 M12 M16 M20


9.2 Nm 22.3 Nm 44.2 Nm 76.2 Nm 190 Nm 370 Nm

Acid resistant bolts are to be coated with “Molybdenum disculphide” (Molycote)


or similar on threads and under bolt heads/nuts prior to assembling.
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 17 of 22

Pumps shipped as one complete unit are pressure tested before leaving Framo works. Pumps
delivered in two parts or more have to be pressure tested after assembling. Blank off cofferdam
check pipe (see fig. 25). The blank flange is a part of the Framo supplied standard tool.

Cofferdam Blank off Air pressure


check pipe cofferdam check pipe or nitrogen

Relief valve

Fig. 25 Pressure test of pump

Unscrew the complete relief valve and connect a manometer to the G1/4 connection (not Framo
delivery). Connect air/nitrogen supply to the snap-on coupling on the purging connection (flex. hose
with snap on couplings is Framo delivery), and increase pressure to max. 3 bar. Stop the
air/nitrogen supply and observe the pressurized volume for 15 minutes.

Flush the split flanges with soapy water to be sure of no leakage.

Reinstall the complete relief valve and assemble the blank flange on the outlet from cofferdam
check pipe.
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 18 of 22

6 INSTALLATION OF PUMPS IN TANK


The Framo cargo pumps have two different resilient arrangements on top plate. Installation of each
arrangement is described separately.

Preparations:

Welding, sandblasting and grinding must be finished and tank must be


properly cleaned before installation of pump in tank.
For carbon steel tanks, also coating must be finished before installation.

Pickling
Pickling will be required prior to installation if the pump has been exposed to iron dust during
storage or corroded surfaces/spots are detected. Framo recommend Avesta Pickling Paste or
equal types for stainless steel.
Follow the manufacturer’s procedure for pickling before starting the work.

Blank flanges
Blank flanges and seals on top plate shall be left until connection of the pump to the vessel’s piping
systems. The blank flanges on the pump’s suction opening and the protection around the pump
shaft shall be removed only by the Framo service engineer before water is filled into the tank.

Transport securing (Only on pumps with vacuum stripping pipe)


The steel wire on lower vacuum stripping pipe shall also be removed by the Framo service engineer.

Special tools required for installations are supplied by Framo in the toolbox.
See tool list for descriptions.
Support ring Framo supply
Bottom support /Intermediate support(s)
Fasteners : Yard supply
Install the support(s) on the bracket before Material : Stainless
the pump. Tighten upper nuts and lock nuts to Quality : A4-80
174 Nm (Fig. 26). Flat washer
Support bracket Yard supply
If coated surfaces on bracket for support:
1) Assemble upper nut, use 174Nm torque. Coating touch up
2) Retighten to specified torque. Flat washer
3) Assemble lock nut, use 174Nm torque. Upper nut (Torque 174 Nm)
Lock nut (Torque 174 Nm)

Deck trunk Fig. 26 Bottom and intermediate support


Remove the flange protection and inspect the
sealing surface on the deck trunk flange.
Required surface roughness is Ra 1,6 µm. If the Never grind across Correct grinding
sealing surface has been damaged (scratches, seal face direction
grooves) during transport or installation, the
damages must be removed by careful grinding/
polishing by abrasive paper.

Note! If grinding/polishing is required, this


must be done according to figure below. Fig. 27 Sealing surface - deck trunk
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 19 of 22

6.1 Installation of SD100/125/150/200/250


Clean the gasket groove in the top plate. Stretch the gasket
over the top plate, -take care not to damage the gasket.
Install the gasket carefully in gasket groove while the pump is
still lying on the ground.

Install two guide pins in top plate (180° apart).


Two guide pins
Install lifting tool on the top plate (supplied by Framo in the
toolbox)
Fig. 28
Lift the pump to a vertical position. Preferably two cranes should be used for this operation, one to
keep the pump clear of the ground and the other for lifting. The pump shall not be allowed to slide
along the ground during lifting.
All pumps above 12 metres should be lifted by using a snatch block together with the crane on the
lower part of the pump. Minimum length of the wire through the snatch block = 2 x length of the
lower part of pump.

Snatch
block
Lower part Upper part

Split pump above 20 meters.


See chapter 10.3
Fig. 29

Lower the pump until the top plate rests on the


deck trunk. Be careful when the guiding pins
enter the deck trunk holes.

Fig. 30
Install rubber bushings and hexagon head bolts under the
trunk flange. Use Loctite on the bolts. Gasket
Tighten bolts in a diagonal sequence to 44 Nm. Remove
the two guide pins, and install the two remaining rubber
bushings and bolts. Tighten bolts to 44 Nm. Rubber
bushing

When pump installation is completed:


Check that the distance from pump suction opening to the Hexagon
suction well bottom is according to the table on page 12. head bolt
Fig. 31
Remember: Don’t remove any blank flanges.
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 20 of 22

6.2 Installation of SD300/350


Clean the gasket groove in the top plate. Stretch the gasket over the top plate, -take care not to
damage the gasket. The gasket has to be greased with teflon grease before installation in the top
plate. Gasket and grease are supplied by Framo. Install the gasket carefully in gasket groove while
the pump is still lying on the ground.

Install lifting tool on top plate (supplied by Framo in the toolbox).

Lift the pump to a vertical position. Preferably two cranes should be used for this operation, one to
keep the pump clear of the ground and the other for lifting. The pump shall not be allowed to slide
along the ground during lifting.
All pumps above 12 metres should be lifted by using a snatch block together with the crane on the
lower part of the pump. Minimum length of the wire through the snatch block = 2 x length of the
lower part of pump.

Snatch
block
Lower part Upper part

Split pump above 20 meters.


See chapter 10.3
Fig. 32

Two guide pins

Lower the pump until the top plate rests on the deck
trunk. Use 2 guiding pins to get the correct position.

Fig. 33

Remove the guiding pins. Assemble bolts, nuts, washers


and bushings and tighten bolts in a diagonal sequence
to 44 Nm.

When pump installation is completed:


Check that the distance from pump suction opening to
the suction well bottom is according to table on page 12.
Fig. 34
Remember: Don’t remove any blank flanges.
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 21 of 22

6.3 Additional information during installation of pumps above 20 meter

Note !
The pump has to be pressure tested
after assembling and installation in tank.
That demand an arrangement in tank
which give access to the split flanges.

Lower the lower part of the pump


until the top is approx. 0.5 m from
deck trunk.

Fig. 35

Place the installation tool on the deck


trunk (see actual tool drawing).

Continue lowering until the pump’s


lower part is resting on the tool.
Remove the ring screw and lifting
plate.

Clean all o-ring grooves with a dry rag,


and assemble parts shown in fig. 23 and 24
Fig. 36
Before lifting upper part of the pump,
assemble guiding bolts on top plate (see
fig. 27).

Lift the upper part of the pump


in position above deck trunk, remove blind
flanges and clean the flanges with a dry rag.
Continue the lowering and guide it in correct
position. Be careful when the connection pipe
enter the high pressure pipe.

Before connecting lower and upper part of the


pump the gasket between top plate and deck
trunk must be placed upon the deck trunk.

Use the procedure described on page 18 for


pressure testing of the pump.
Framo Mounting Instruction No.1401-0004-4
Feb-2000
INSTALLATION OF SUBMERGED CARGO PUMPS Page 22 of 22

7 PUMP WITH COFFERDAM HEADER TANK


Permanent liquid filled cofferdam is used when the submerged cargo pump is handling only one
type of cargo (oil production & storage vessels).

Filling of cofferdam
- Fill the cofferdam through the headertank until the Header tank
liquid level stabilises just above low level mark on
the sight glass.

- Use a ISO VG10 hydraulic oil in the cofferdam.


(DIN51524 (1) HL, for instance Shell Morlina Oil 10).
Due to expansion and air in the system, the level will
stabilize between 2 to 7 days after filling.

- The cofferdam volume depends on pump size and


pump length. The following formulas give approx.
volume required to fill the cofferdam to header tank
low level mark : (volume in litres)

S D 100 (L x 0,6) + 3
SD 125/150 (L x 0,6) + 12
S D 200 (L x 3,7) + 8
S D 250 (L x 3,7) + 14
S D 300 (L x 4,3) + 13
S D 350 (L x 5,1) + 19

L=Pump length in metres. (See Framo Specification) Fig. 37


Framo No. 1401-0005-4
Rev. A Mar-2003

Mounting Instruction

Installation/storage of portable equipment


Framo Mounting Instruction No.1401-0005-4
Rev. A Mar-2003
INSTALLATION OF PORTABLE EQUIPMENT Page 2 of 3

1 STORING ON BOARD

The portable pumping equipment must be stored easy accessible


in a clean and dry area.
The concentric hose can be stored on brackets on the bulkhead
(see fig.1), or on a suitable hose reel, or lying in a shelf.
The cargo hose and extension hoses can be stored on a suitable
hose reel, or lying in a shelf.
The pump and hoses must always be safely supported and
fastened in order to avoid wear or damages due to ship
movements. It is especially important that the hoses are not
hanging or laying over sharp edges, or that sharp objects are
placed upon them.
The bending radius for the hoses during storage must be
according to dimensioning drawings.
For TK150 / TK6 control valve + snap-on couplings are delivered in
an equipment box. For TK80 control valve is connected to pump,
while snap-on couplings are delivered in an equipment box.
Equipment boxes are delivered with bracket for installation in fixed
location together with the portable pump.

Fig. 1

Fig. 2

Portable winch:
The portable winch must be safely supported and fastened in order to
avoid wear or damages due to ship movements.
Framo Mounting Instruction No.1401-0005-4
Rev. A Mar-2003
INSTALLATION OF PORTABLE EQUIPMENT Page 3 of 3

2 COUPLING STATIONS FOR PORTABLE EQUIPMENT


The portable pump includes hydraulic hoses with a control valve either connected to the end of the
hose(concentric hose) or separately delivered. Standard length of this hoses are 10 and 18 m.
Separate extension hoses must be connected between the control valve and the coupling stations
(standard length of extension hoses is 10 and 18 m).
The hydraulic ring line must be equiped with coupling stations (pressure and return) for connection/
operation of the portable pump.
Each coupling station consist of a ball valve with blind flange for pressure connection, and a non-
return valve with blind flange for return connection. Snap-on couplings are delivered separately in
an equipment box, and are only mounted by ship crew when pump is connected for use.
The number and location of coupling stations must be selected so that the portable pump can be
used in every tank.
A coupling station should preferably also be located close to the pump storage, to simplify testing of
pump.
Installation of coupling stations in hydraulic ring line must be according to figures below. This to
avoid extra bending forces from the extension hoses on the coupling stations.

h = sufficient height above ship deck to avoid exceeding the


allowable bending radius of the extension hoses, and give
easy access for connection of the extension hoses.

Fig. 3
Framo No. 1401-0006-4
Rev.B Jan-2003

Mounting Instruction

Installation of submerged ballast pumps

CONTENTS
1 General
2 Arrangement and orientation in tank
2.1 Pump casing
2.2 Location of bracket for
intermediate support(s)
2.3 Arrangement on top plate
2.4 Evacuation system
3 Installation requirements
4 Example of pump installation
with Framo dummy
4.1 Framo dummy
4.2 Pump casing
4.3 Bracket(s) for intermediate support(s)
4.4 Deck trunk
5 Assembling of pipe stacks
6 Installation of pumps in tank
6.1 Additional information for pumps
assembled during installation in tank
6.2 Filling of liquid in cofferdam
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 2 of 23

1 GENERAL
Figures in this procedure are made general for all types of submerged ballast pumps. It is assumed
that a “dummy equipment package” intended for the pump type to be installed, is available. For
further information, see drawings for the actual ballast pump, deck trunk, intermediate support and
dummy.

The Framo hydraulically driven submerged ballast pump consists of:


- Pump casing/ Air separator
- Pump head
- Pipe stack
- Top plate
- Evacuating system

Pump casing/ Air Separator


The pump casing is bolted to a
foundation.
An ejector is connected at the
suction side.

Pump head
The pump head is mounted inside
the pump casing.

Pipe stack
The pipe stack consists of a hydraulic
pipe stack and an arrangement with
pipe and cable for the evacuating
system.
The hydraulic pipe stack connects
the pump head to the STC-valve.
Supports on the pipe stack prevent
horizontal movement and allow for
vertical expansion.

Top plate/ Control valves


The pipe stack penetrates the
top plate.
A sealing device (bellow) between
top plate and pipe stack allows the
pipe stack to expand.
The evacuation control system is
attached to the top plate.

Fig. 1
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 3 of 23

2 ARRANGEMENT AND ORIENTATION IN TANK

Fig. 2

The suction/discharge flange position has to be informed to Framo as soon as possible making it
possible to finalize the manufacturing drawings. See pump dimensional drawing.
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 4 of 23

2.1 Pump casing


Nozzle loads
To ensure good installation and to avoid high tensile forces on pump casing, the maximum
allowable nozzle loads to be as follows:

MAX. ALLOWABLE FORCES/MOMENT (approx. 2 x API 610)


SB200 SB300 SB400 SB600
EACH
NOZZLE 8" 10" 12" 14" 16" 18" 20" 24"
Discharge Suction Discharge Suction Discharge Suction Discharge Suction
Fx [kN] 5,0 6,8 8,0 9,0 10,2 11,6 12,9 15,6
Fy [kN] 4,0 5,4 6,7 7,2 8,5 9,8 11,1 13,8
Fz [kN] 3,2 4,5 5,4 5,8 6,7 7,6 8,5 10,2
Mx [kNm] 3,6 5,0 6,1 6,4 7,4 8,3 9,3 11,1
My [kNm] 1,8 2,5 3,0 3,2 3,7 4,2 4,8 5,9
Mz [kNm] 2,6 3,8 4,6 4,8 5,4 6,1 6,8 8,2

Fig. 3
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 5 of 23

2.2 Location of bracket for intermediate support(s)


Bracket is part of the ship design and supplied by yard. It is important to be aware of the forces
acting in the tank area (sloshing, structural deflection etc.).

Brackets to be designed according to forces shown in table below:

PUMP TYPE F1 [kN] F2 [kN]


SB200 7 12
SB300 7 12
SB400 11 18
SB600 11 18

Fig. 4

Fig. 5

Supports for all ballast pumps may enter the ballast tank through standard manhole openings.
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 6 of 23

To find the pump length (L) and location of the bracket(s), following calculations have to be done:

One intermediate support


A1 = 0,4 x L +/- 500

Two intermediate supports


A1 = 0,3 x L +/- 500
A2 = 0,6 x L +/- 500

Tree intermediate supports


A1 = 0,25 x L +/- 500
A2 = 0,5 x L +/- 500
A3 = 0,7 x L +/- 500

L = Pump length [mm]


A1-A3 = Intermediate support height [mm]
H = Deck trunk height [mm]

Final figures (L, A1 and A2 ) to be sent to


Framo as soon as possible.

Fig. 6
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 7 of 23

2.3 Arrangement on top plate


Trunk on deck

Fig. 7

Trunk in void space

Fig. 8
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 8 of 23

2.4 Evacuation system

Fig. 9

The start and stop of the ejector is controlled by two electric level switches located in the pump
casing. The signal goes to a solenoid valve(Exi) connected to the PLC. The solenoid valve controls
a pneumatic valve for start and stop of the ejector.

Note! In order to protect the pneumatic valves it is necessary to place a filter/water trap
in the air line.
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 9 of 23

3 INSTALLATION REQUIREMENTS
(independent of installation method)

To be confirmed before final installation of pump in tank.


The center line of deck trunk and the center line of pump should be identical after installation.
Maximum acceptable deviation is shown in fig. 10. This is to avoid excessive stress in the pipe
stack.
The figures below also indicates how to use the laser from the “dummy equipment package” to
check the tolerances.
For height control see fig. 11.

Fig. 10
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 10 of 23

LD = Height from top of


pump casing to
top of deck trunk

AD1- = Intermediate support height.


AD3 Height from top of
pump casing to
lower edge of intermediate
support dummy.

Fig. 11
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 11 of 23

4 EXAMPLE OF PUMP INSTALLATION WITH FRAMO DUMMY


The pump casing has to be placed in the section before it is closed. It is of importance that the pump
casing is protective covered until the installation of pump in tank. Prior to pump installation, the deck
trunk and brackets for pump supports have to be welded into the tank. Use of Framo dummy will help
you to get a successful installation of deck trunk and bracket of intermediate supports.
The following installation procedure is based upon use of Framo dummy.

4.1 Framo dummy


Note! It is necessary to remove the flange protection for deck trunk when using
the top plate dummy. It is important to remount the protection after use of dummy.

The “dummy equipment package” is shown on fig. 12.

Fig. 12
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 12 of 23

Calibration of laser
The lasers is to be controlled each time before use to
detect any inaccuracy during transportation. Control
and adjust the lasers as follows:

- Grease the laser flange to make turning of


the laser easier.
- Locate the laser on the top plate dummy
installed on the deck trunk.
- Turn the laser on. Mark the spot where the
centre of the beam hits the target.
- Turn the laser 90° and mark where the
centre of the laser beam now hits the
target.
- Repeat the turning in steps of 90° until a
full circle is completed, and mark the spots
for each step.
- The collection of spots should be within a
circle of Ø=20 mm.
- If not all spots are within this circle, adjust
the laser by the two adjustment screws,
using a screwdriver.
- After the adjustment, re-check the laser as
described above.
- Continue the above procedure until the
accuracy of the laser is as specified above.

CAUTION! Avoid staring straight into the laser beam.

Fig. 13
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 13 of 23

4.2 Pump casing

1 Pilot hole 2 Pump casing


- Mark the center of the pump casing. - Place the pump casing in the center marked.
- Measure the distances from this center to - Fasten the laser to the pump casing dummy
the bulkhead/frames (x,y). and place it on top of the pump casing.
- Use these distances (x,y) to find the - Turn the pump casing dummy in steps of 90°
center of the deck trunk in the deck. until a full circle is completed as described
on page 12. The collection of spots should
- Cut a pilot hole Ø250 for the deck trunk.
be within a circle of Ø= 20 mm.
- Calibrate the laser according page 12.
- If necessary tilt the pump casing until the
laser beam hits the center of pilot hole.
- Drill holes in foundation and fasten the pump
casing with counter nuts.

Fig. 14 Fig. 15
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 14 of 23

4.3 Bracket(s) for intermediate support(s)

3 Adjustment and welding


Note! Pump casing has to be protected against weld spatter, sand blasting and painting.

- Connect the intermediate support dummy to the bracket.


- Alignment (by use of mirror)
- Height adustment

Fig. 16
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 15 of 23

4.4 Deck trunk

4 Final hole for deck trunk


- Connect the top plate dummy with plexiglass to the deck trunk.
- Adjust trunk until the laser beam hits the center marked on plexiglass.
- Mark outside diameter of deck trunk.
- Cut final hole in deck for deck trunk.

Position of deck trunk


The deck trunk must be connected to the top plate
dummy with connections for STC valve in correct position,
see dimensional drawing of pump.

Fig. 17
Fig. 18

5 Adjustment 6 Welding and control


- Move the laser to the top plate dummy and The trunk is to be welded according to
calibrate the laser (ref. page 12). classification requirements.
- Trunk alignment Frequently check the position/alignment
- Height adjustment during welding.
- Spot welding

Fig. 19 Fig. 20
According to practical experience the distance between the top flange of deck trunk and the deck
will normally be reduced about 3-5 mm caused by the added heat when welding.
If such a reduction is expected, this must be taken into consideration.
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 16 of 23

5 ASSEMBLING OF PIPE STACK


Pumps delivered in two parts have to be assembled in a horizontal position. Every pump section is
to be supported in at least two points.

Note! All ballast pumps type SB400 and SB600 delivered in two or three parts and
SB200/SB300 pumps with total length above 20m have to be assembled
during installation, see chapter 6.1.

Fig. 21

Note! The pumps must not be in contact with mild steel during assembling.

Check that the pump no. on all the pump sections are identical. Pump no. is placed on top plate and
pump head flange. Place the pump sections in correct positions one after another.
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 17 of 23

Note !
All pipes must be checked for
foreign bodies before connection.
Any parts left in the pipes (screws,
nuts, plastic bolts, rags, etc.) may
cause serious damage to the
pump.

Clean all o-ring grooves and seal


faces with a dry rag.
Check all seal elements, back-up
rings, grooves and seal faces.
Never install damaged seal
elements.

Assemble connection pipe and


seals on the flange of lower part.
Guide the two parts together. Be
careful when the connection pipe
enter the hydraulic pressure pipe.
Assemble bolts and nuts. Tighten
the bolts according to the table
below.

Fig. 22

All screws and nuts have to be assembled with specified torque.


If no torque is specified, use torque according to following:

ACID RESISTANT BOLTS AND NUTS, QUALITY A4-80

M6 M8 M10 M12 M16 M20


9.2 Nm 22.3 Nm 44.2 Nm 76.2 Nm 190 Nm 370 Nm

Acid resistant bolts are to be coated with “Molybdenum disculphide” (Molycote)


or similar on threads and under bolt heads/nuts prior to assembling.
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 18 of 23

Level switch cable:


Unscrew cap on evacuating control unit. Use a pulling rope as shown in fig. 23. Unwrap the cable
and connect the end to the pulling rope.

Fig. 23

Pull the cable through the protection pipe and bracket for evacuating control unit.
The cable end must be long enough to reach the terminals. Cut the cable in a suitable length with
sufficient margin. Remount the cap.

Fig. 24

Pumps shipped as one complete unit are pressure tested before leaving Framo works. Pumps
delivered in two parts or more have to be pressure tested after assembling.

Connect air supply and manometer to connections shown on fig. 25 and carefully increase pressure
to max. 3 bar. Stop the air supply and observe the pressurized volume for 15 minutes (pressure
drop indicates leakage).

Flush the flange connections with soapy water to be sure of no static leakage.

Reinstall the plugs.

Fig. 25 Connections for pressure testing of cofferdam


Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 19 of 23

6 INSTALLATION OF PUMPS IN TANK


Preparations:
Note! Welding, sandblasting grinding and coating must be finished and tank
must be properly cleaned before installation of pump in tank.

Pickling
Pickling is required prior to installation if the pump has been exposed to iron dust during storage or
corroded surfaces/spots are detected. Framo recommend Avesta Pickling Paste or equal types for
stainless steel. Follow the manufacturer’s procedure for pickling before starting the work.

Blank flanges
Blank flanges and seals on top plate flanges shall be kept on until connection of the pump to the
vessel’s piping systems.

Special tools required for installation are supplied by Framo in the tool box.
See tool list for descriptions.

Intermediate support(s)
Install the support(s) on the bracket(s) before
installation of pump.
1) Assemble upper nut, use 190 Nm torque.
2) Tighten all bolts one more time,
use 190 Nm torque.
3) Assemble lower nut, use 190 Nm torque.

Deck trunk
Remove the flange protection and inspect the
sealing surface on the deck trunk flange.
Install two guide pins in top plate (180° apart). Fig. 26
Locate the sealant joint on the deck trunk flange
(ref. fig. 32b).

Pump casing
Remove protections from top flange, ejector pipe
and level switch pocket. Inspect the sealing
surfaces. Install two guide pins (180 apart) and
10 stud bolts. Put the gasket on the top flange.

Regarding SB200:
Remove the anodes in pump casing before
installing the pump (fig. 27). Fig. 27
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 20 of 23

Lifting of pumps
Pumps shipped as one complete unit
Lift the pump to a vertical position. Preferably two
cranes should be used for this operation, one to keep
the pump head clear of the ground and the other for
lifting (ref. fig. 28).
The pump head shall not be allowed to slide along the
ground during lifting.

Fig. 28
SB200/SB300 shipped in two sections (with total length < 20 m)
(To be assembled prior to installation)
The pumps have to be lifted by using a snatch block together with the crane on the lower part of the
pump. Length of the wire through the snatch block = 2 x length of the lower part of pump.

Fig. 29

All SB400/SB600 (regardless of pump length)


and SB200/SB300 with total length above 20m

Each section has to lifted separately.


See chapter 6.1 for installation in tank.

Fig. 30
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 21 of 23

- Lower the pump until the pump head approaches the pump casing.
- Remove the impeller protection. Apply grease to the o-ring in the house guide (see fig. 31a).
- Lower the remaining distance, be careful when the pump head flange reaches the guiding pins.
The pump seal ring will now enter into the pump casing sleeve, use lowest possible speed.
Note! At the same time one have to watch the top plate guide pins entering into the deck trunk.
- Remove guide pins, install the two remaining stud bolts, tighten the nuts in a diagonal sequence
and lock with counter nuts (see fig. 31b).
- Install the ejector pipe and fasten the lowest pipe clamp.
- Put the level switch into the pocket, and tighten up the flange (4 bolts).
(The SB400 is delivered with the level switch installed inside the pump head.)

Fig. 31a Fig. 31b

- Remove transport bracket (belonging to toolbox)


- If necessary use a plastic hammer on top plate in order to connect to deck trunk.
- Install bushings and nuts under the trunk flange. Tighten bolts in a diagonal sequence.
- Remove the two guide pins (belonging to toolbox), and install the two remaining bushings and nuts.

Fig. 32a Fig. 32b

Note! Transport bracket and guide pins should be included in toolbox when installation is completed.
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 22 of 23

- Remove the cap on evacuating


control unit.

- Connect cables according to


el. diagram.

- Remount the cap.

Note! When pump installation is completed.


Do not remove any blank flanges before
final connection to the piping system.
Fig. 33

6.1 Additional information for pumps


assembled during installation in tank

Note !
The pump has to be pressure tested after assembling and
installation in tank. This requires an arrangement in tank
which gives access to the flange connections in pipe stack.

Lower the lower part of the pump until the top is approx.
0.5 m from deck trunk.
Fig. 34
Install the installation tool on the deck trunk (see actual tool
drawing).
Continue lowering until the pump’s lower part is resting on
the tool. Secure the lower part before removing the lifting
tool.

Clean all o-ring grooves with a dry rag, and assemble parts
shown in fig. 22.

Before lifting upper part of the pump, assemble guiding


bolts on top plate (see fig. 32a).

Lift the upper part of the pump in position above deck Fig. 35
trunk. Remove blank flanges and clean the flange
connections with a dry rag. The gasket between top plate
and deck trunk must be placed upon the deck trunk.
Continue the lowering until the distance between the
flanges is 50-100 mm. Install lifting bolts (toolbox) and lift
the lower part by using the lifting bolts. Be careful when the
connection pipe enters the high pressure pipe.
For assembling of flanges, see page 17.
Regarding the level switch cable, see chapter 5.

Pressure test the pump.


Fig. 36
Framo Mounting Instruction No.1401-0006-4
Rev.B Jan-2003
INSTALLATION OF SUBMERGED BALLAST PUMPS Page 23 of 23

6.2 Filling of liquid in cofferdam


All the SB-pumps have liquid filled cofferdam.

- Cofferdam liquid:
Ethylene glycol or propylene glycol* : 50-60 %
Use pure glycol without additives.
Commercially available automotive anti-freeze
should never be used. Some of the additives in
anti-freeze tend to form deposits on seal parts
and thereby causing failure on the seals.
Corrosion inhibitor : 0.9%
(Rocor NB Liquid or equal) (initial dosing)
Other types of corrosion inhibitors for cooling
water systems can also be used. The corrosion
inhibitor must be compatible with glycol. The mix
ratio and the use of the corrosion inhibitor must
be according to the suppliers data sheets, as
this can vary for the different types available.
Demineralised water: 40-50%

Freezing point ~ - 35°C v. 50% glycol


Freezing point < - 40°C v. 60% glycol
Volumetric
expansion : 0 - 60°C ~ 63.5 x 10-5 litre/litre°C

Filling:
- Install the drain tool and unscrew the drain plug.
Connect a hose to the drain tool. It is then
possible to fill the cofferdam through the hose
while venting at the header tank.
Fill the cofferdam until liquid level stabilises at
max. level mark on the sight glass.
- Water/glycol to be filled after filling of
Fig. 37 hydraulic oil.

The cofferdam volume depends on pump type and pump length. The following formulas give
approx. volume (in litres) required to fill cofferdam to low level mark in header tank:

Pump Pump Pipe Header


Total
type head stack tank
SB200 2,5 L x 0,5 2,5 5 + (L x 0,5)
SB300 80 L x 3,5 10 90 + (L x 3,5)
SB400 95 L x 3,5 10 105 + (L x 3,5)
SB600 125 L x 3,5 10 135+ (L x 3,5)
L = Pump length in metres. (See Framo Specification)
* Other names for ethyleneglycol: monoethyleneglycol, 1.2 ethanediol, ethanediol.
Other names for propyleneglycol: monopropyleneglycol, 1.2 propanediol, propanediol.
Framo No. 1401-0034-4
Rev.B Jan-2003

Mounting Instruction

Installation of hydraulic power unit


Closed loop system

CONTENTS
1 General
2 Arrangement
3 Service space and lifting arrangement
4 Ventilation and heat dissipation
5 Foundation and mounting
6 Cooling arrangement
7 Cable/starter cabinet for electric equipment
8 Starting system for diesel engines
9 Fuel system
10 Exhaust
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan-2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 2 of 14

1 GENERAL
The hydraulic power unit (HPU) delivers oil to the main pressure line and consists of the following
main parts:

- Electric driven hydraulic


power packs
- Diesel driven hydraulic power
packs
- Main hydraulic oil filter
- Hydraulic oil cooler
- Common foundation
- Enclosure for separating high
pressure hydraulic oil from
hot surfaces.

A hydraulic power pack consists


of a hydraulic pump with a built
on pulsation damper, either
driven by an electric motor or a
diesel engine. Each hydraulic
power pack is resilient mounted
and exhaust, fuel and water
connections are delivered with
flexible connections.

The auxiliary hydraulic unit


consists of a hydraulic system
tank and electric driven feed
power packs.

Fig. 1 Hydraulic power unit (HPU) with 2 diesel driven and


2 electric driven hydraulic power packs.

Normally the hydraulic power units are supplied as shown in fig. 1, but they may also be
delivered with the auxiliary unit as a separate item or with the auxiliary unit, power packs and
filter/cooler unit delivered separately.
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 3 of 14

2 ARRANGEMENT
Normally the HPU is located at the same deck as the auxiliary unit with the hydraulic pumps facing
forward and with the motor shafts parallel to ship centre line. The shield must be extended to the
next deck. All hydraulic piping from HPU to consumers on deck will then be in the hydraulic room
and diesel engines/electric motors will be located in the engine room.
Fig. 2 and 3 shows an arrangement which gives:
- Minimum noise level in accommodation area
- Minimum noise emitted from the ship
- Easy access for maintenance
- Optimum routing of hydraulic and exhaust pipes.
- Shielding of high pressure hydraulic oil from engines/hot surfaces
and electric equipment (Shield to be extended as shown in fig. 12.)
- Machinery room ventilation can be used for the
electric motors/diesel engines.

Fig. 2 Recommended HPU room arrangement


Note! High pressure piping/flanges to be segregated
from ignition sources (exhaust, electric starters, etc.)

The auxiliary unit is normally a part of the


power unit. If it is delivered as a separate
item it may be oriented in any directions but
should if possible be located on the same
deck as the hydraulic power unit.
If not possible it should be located on a
higher deck level but not more than
8 meters above the hydraulic
power unit. This is limited
by the maximum allowable
drain oil pressure.

Fig. 3 Auxiliary unit located above the hydraulic power unit


Framo Mounting Instruction No.1401-0034-4
Rev.B Jan-2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 4 of 14

3 SERVICE SPACE AND LIFTING ARRANGEMENT


Service space
To have access for service, a minimum free space is
required around:
- Filter
- Hydraulic oil cooler
- Hydraulic pumps
- Electric motors/diesel engines

Please note that the required dimensions for service


space shown in the dimensional drawings are
absolutely minimum.
Fig. 4 Service space

There must also be space for:


- Correct location of ventilation ducts
- Cable trays
- Lifting tools
- Electric starters
- Local control panel
Ref. fig. 6, 8, 9 and 10.

Fig. 5 Service space


Framo Mounting Instruction No.1401-0034-4
Rev.B Jan2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 5 of 14

Lifting arrangement
Lifting arrangement is yard responsibility and must be installed above each power pack and the
hydraulic oil cooler. Monorail is recommended above the diesel engines and electric motors.
Approximately weights of the major components:
Electric motor: 2000 kg Hydraulic pump (single): 400 kg
Diesel engine: 2500 kg Hydraulic oil cooler: 1400 kg

Fig. 6 Space for lifting

4 VENTILATION AND HEAT DISSIPATION


It is important that the power unit gets sufficient air supply according to motor size and number of
motors. Yard is responsible for:
- Sufficient ventilation capacity
- Correct direction of air flow
- Acceptable air temperature
- Clean and water free air
Capacity
Calculation of necessary ventilation capacity is yard responsibility, but approximate air consumption
is given in fig. 7. For calculation of radiated heat see technical data.
This curve is based on temp. increase ∆T = 10°C.

Example: 3 x Diesel engines à 400 kW Total 1200 kW : 9 m3/s


2 x Electric motors à 400 kW Total 800 kW : 4 m3/s
Total : 13 m3/s
Required air flow - Power Unit Room

3500
Installed power P (kW)

3000
Electric motors
2500
2000
1500
1000
Diesel engines with water cooled manifold.
500
Cooling and combustion air
0 4 9
0 5 10 15 20 25
Required air flow V (m3/s)
Fig. 7
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan-2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 6 of 14

Air distribution
The air should be distributed to all parts of the room to avoid pockets of stagnant hot air and any oil
vapour from crankcase ventilation.

Arrangement for separating the hydraulic side from motor side with ventilation ducts on both side is
shown fig.8. When arranged like this, the ventilation capacity for the hydraulic room will be reduced.

Fig. 8 Ventilation/Service arrangement

Alternative location of venting duct for correct air flow:

Fig. 9 Totally enclosed electric motor Fig. 10 Open drip proof electric motor
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 7 of 14

Noise reduction
To avoid noise transmission to surrounding areas, some basic requirements to the power unit room
must be fulfilled if the HPU is installed in critical interface area. Key items are:

- Hydraulic room (with entrance of double door type).


- Noise trap on in- and outlet of ventilation in order to achieve effective absorption of high
frequency noise.
- Flexible and air tight penetrations for pipes and cables.
- Critical interface areas such as bulkheads against accommodation areas should be covered
completely by noise absorbing material. Ref. fig. 11.

Fig. 11 - Noise reduction


Framo Mounting Instruction No.1401-0034-4
Rev.B Jan-2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 8 of 14

5 FOUNDATION AND MOUNTING


The hydraulic power unit foundation to be welded (only outside) to a rigid deck structure and filled
with concrete to prescribed level.
Gutter and drain possibility is recommended (Yard supply).
Yard extension of shield is shown in fig. 12.

Fig. 12
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 9 of 14

Auxiliary unit (if delivered separately)


To prevent vibrations transmitting to the steel structure, the auxiliary unit must be mounted on rigid
foundation filled with concrete (minimum 70 mm thickness).

Auxiliary unit is resilient mounted as shown in the figure 13. Flat bars and rubber insulation are
supplied by Framo. For welding of flat bars to the foundation use the following procedure:

- Place the auxiliary unit with flat bars and rubber insulation on the concrete filled foundation.
- Spot weld the flat bars to the foundation (careful with the rubber insulation).
- Remove the auxiliary unit and the rubber insulation before the flat bars are welded to the
foundation with continuous fillet welding.
- Assemble the auxiliary unit after cleaning and painting of welding zone.

Fig. 13

If the filter/cooler unit is delivered separately, same procedure as above (fig. 13) to be used.
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan-2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 10 of 14

6 COOLING ARRANGEMENT
The hydraulic oil is cooled by sea water or fresh water automatically controlled by an electrically
operated on-off valve. The valve is operated from the Framo PLC (Programmable Logic Control).

The cooling water flow and max. pressure must be in accordance with the technical data given for
the system.

Note! - Too low water flow through the cooler may cause corrosion/fouling problems.
- Too high flow may cause erosion problems.

The water flow is controlled by means of orifices at the water inlet and outlet side of the hydraulic
oil cooler. This orifice is calculated and delivered by Framo. To verify that the flow is correct,
differential pressure between the two test points must be measured. If differential pressure is out of
the tolerances given in technical data, Framo must be contacted.

Fig. 14 Cooling system arrangement

When the power unit is installed above sea water level and sea water is used as cooling medium,
piping at the outlet side must be routed above oil cooler and a vacuum breaker must be installed.
Sea water piping should have sufficient zinc anodes.
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 11 of 14

7 CABLE/STARTER CABINET FOR ELECTRIC EQUIPMENT


Recommended cable routing:

Fig. 15

The hydraulic power packs are resilient mounted and therefore allowed to move relatively to the
foundation. Accordingly, cable trays and their supports must be connected to the foundation and not
to the hydraulic power packs. Welding on electric motors are prohibited.
The cables should be arranged to allow for removal of electric motors.

The starter cabinet should be located outside the hydraulic room (ref. fig.8).

Wiring between hydraulic power unit and local diesel engine control panel
To secure optimal performance and running conditions of the diesel engine, following details must
be noted (ref. fig. 8):
- Individual screened cables to be used for pick-up and actuator.
- The screens to be terminated to dedicated terminals, not to ground.
- Max. cable length and min. cross section to be respected.

8 STARTING SYSTEM FOR DIESEL ENGINES


Air starting
The piping from the reduction valves to the
starter shall be as short as possible in order
to limit pipe losses. Starter motor is supplied
with a flexible hose.

All connections should be made up with


Loctite pipe sealant or equivalent.
Teflon tape should not be used in starting air
systems.

Design the piping to ensure that drain does


not enter the starter motor. Install a drain
valve at lowest point (see fig.16).
Fig. 16
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan-2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 12 of 14

Electric starter:
- Only starter type battery should be used in order to provide sufficient starting current with limited
internal voltage drop. Refer to technical data for the project regarding recommended battery
capacity.
- Installation and charging of batteries must comply to class requirements with respect to location,
ventilation etc.
- Cables for starters must be dimensioned according to
fig.17 to minimize voltage drop.
- Make sure that good contact is obtained in all terminations in the starter circuit.

16
Total lenght for both
14 plus and minus cables

12
Cable lenght (m)

10

2
70 90 110 130 150 170 190
Cable cross section (mm2, copper)

Fig. 17
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 13 of 14

9 FUEL SYSTEM
The diesel engines are designed for fuel types DMA according to ISO 8217. Yard is responsible for
a service tank with minimum volume 100 litre per engine located according to fig.18. Stainless steel
tank material is recommended. Use pipe dimensions from HPU dimensional drawing.

Fig. 18 Requirement for fuel system between diesel engines and the service tank.

Yard is responsible for a system which serves the diesel engines with clean and water free fuel.
A typical arrangement with a 10 micron pre-filter (Framo supply) and a float valve is shown in fig.19.

Fig. 19
Framo Mounting Instruction No.1401-0034-4
Rev.B Jan-2003
INSTALLATION OF POWER UNIT, CLOSED LOOP Page 14 of 14

10 EXHAUST
To achieve rated power, exhaust back pressure must be below maximum level, ref. technical data.

Exhaust pipes from several engines shall have separate outlets. The exhaust piping should not be routed
at the hydraulic side of the shield. It must be routed in order to prevent entrance of water (ref. fig. 20).

Note! The exhaust system must be shielded .

The diesel engines are provided with a compensator at


the outlet of the turbocharger to prevent excessive
stress to engine.
The compensator for exhaust pipe allows a maximum
simultaneous lateral movement of ±10 mm and an axial
movement of ± 10 mm (ref. fig.21).
A combined silencer/spark arrestor is provided for each
engine as a separate item.
Keep the blank flange at the top of the exhaust
Fig. 20
compensator on until initial start-up to be sure there is
no water ingress.
Install the silencer as close as possible to the engine or near the outlet.
The silencer can be installed in any position from horizontal to vertical, however flow direction
indicated on the identification plate must be respected. When mounted horizontally note that the
soot collector must be at the lowest point enabling for periodically cleaning.

Fig. 21
Note! Installation, supporting and calculation data for the exhaust piping are given in separate
instruction from the engine makers instructions.
Framo No. 1401-0009-4
Apr-2000

Mounting Instruction

Installation of electrical equipment

CONTENTS
1 Framo control panel
2 Motor starters
2.1 Power pack starter
2.2 Feed pump starter (closed loop system only)
3 Electric motors
4 STC remote control valve
5 Interface to vessel´s integrated control system
6 Preservation
Framo Mounting Instruction No.1401-0009-4
Apr-2000
INSTALLATION OF ELECTRICAL EQUIPMENT Page 2 of 6

1 FRAMO CONTROL PANEL


The control panel should be installed in the cargo control room. It should also be sufficiently
illuminated and arranged for good contact/communication to the cargo manifold area to ensure a
proper and safe cargo handling.
Note that cargo operation require coordinated operation with other systems, such as cargo/ballast
valves, tank level and cargo pressure monitoring.
- The panel must not be powered until wiring and termination has been checked by Framo
commissioning engineer in co-operation with yard.
- EEx equipment to be installed according to applicable rules. Note that intrinsically safe cables
must be segregated.
- All field cables to be marked with terminal number for simplified service.
- Cable screens to be terminated close to inlet.
- If applicable, bypass switch for tripping cargo pumps at low inert gas pressure, shall be installed
on IG panel - not in Framo control panel.
- Selfstanding cabinets to be bolted to yards foundation, refer to dimensional drawing:

4(8) holes Ø12


A

Cabinet
Yard foundation
Plint

Yard
foundation View A-A Deck
A

Alternative type of control panel, ref. acknowledgement of order.

Alt. 1 Alt. 2
Framo supply
To be fixed
to bulkhead
Framo supply
To be fixed to bulkhead by yard
by yard

Bottom cable entry Bottom cable entry


= Access for terminations and service
Framo Mounting Instruction No.1401-0009-4
Apr-2000
INSTALLATION OF ELECTRICAL EQUIPMENT Page 3 of 6

Alt. 3

HYDR. SYSTEM
CONTROL PANEL

When operators panels are delivered for installation in yard’s common console,
the following must be noted:
- All internal/external components in addition to termination points must be accessible for service.
- Precautions to be taken to avoid electric noise interference between the different systems and
from external sources like walkie talkies etc:
• Refer to panel dimensional drawing for correct console cut out.
• Ensure good contact between all parts of the enclosure.
• Power- and signal cables/components to be separated.
• Separate the different sections with side walls. Any cut outs for cable transits to be minimized.

2 MOTOR STARTERS
For starters delivered by yard, the following must be noted:
- The individual stop contact from hydraulic system control panel to each starter must always trip
the motors when open, regardless of command (local/remote).
- Amperemeter to be provided for motors above 7,5 kW.
- Facilities for local- and remote start / stop to be provided. Local opeartion only for transfer pump.
- Overcurrent protection to be provided. Set point = rated current.
- Selfstanding cabinets to be bolted to yards foundation. Refer to dimensional drawing.

Yard to install circuit breakers with Framo supply


sufficient rating and breaking capacity for To be fixed
protection of the motor circuit. to bulkhead
Effort should be made to obtain optimal by yard
setting of the short circuit protection.
The setting shall be as low as possible
without interfering with the starting
current.
Bottom
cable entry

= Access for terminations


and service

Bottom cable entry


Framo Mounting Instruction No.1401-0009-4
Apr-2000
INSTALLATION OF ELECTRICAL EQUIPMENT Page 4 of 6

2.1 Power pack starter


- The thermistor amplifiers (one per power pack motor) must be installed in starters and
connected to the thermistors in the motor. Thermistor amplifiers shall trip the motor if activated.
(The amplifiers are delivered as loose items if starters are supplied by Yard).
- The running signal to control panel is also used for unloading the hydraulic pumps during
starting. The running signal must be given as soon as start is initiated and shall be maintained
as long as the motor is running. Refer to sketches below:
L1 L2 L3 AUTO TRANSFORMER
RUN SIGNAL TO L1 L2 L3 STAR - DELTA RUN SIGNAL TO
HYDRAULIC SYSTEM HYDRAULIC SYSTEM
K3 K2 CONTROL PANEL CONTROL PANEL
K2 K3 K1
U1 W1 V1 W1 V2
K2 K3 K2
U1 W2
~M K1 ~M
V1 U2

In order to obtain correct direction of rotation (counter clockwise), connect phases according to
applicable diagram.
- Due to size/weight of contactors, they must be installed on a rigid/stiffened plate to avoid
vibration interference during making and breaking.
- Arrangement for space heaters to be provided.
- Ratio of current transformer to be informed to Framo if amperemeter is required on ‘Hydraulic
System Control Panel’.

2.2 Feed pump starter (closed loop system only)


The feed pumps should be fed from different power supply sources if possible. This will increase
availability as one feed pump shall always run. Arrangement for space heaters to be provided.

3 ELECTRIC MOTORS
Refer to instruction “Installation of power unit” for recommendations regarding routing of power
cables, cable trays and supports. Yard must ensure that grounding of all motors and related
equipment is carried out.
Power pack motors are heavy consumers on board. Yard is responsible for dimensioning the power
cables with respect to thermal capacity and voltage drop during starting and full load operation.
If applicable, interface to power management system is normally implemented in power pack
starters. If starters are supplied by Framo, a power management system functional description
detailing quantity of signals, pulsed or maintained contacts etc. to be submitted. If applicable, by
pass switch shall be provided by yard.
Nuts for power cable termination points must be secured with lock nuts and tightened with torque
meter according to type of bolts/thread dimension used. This is also applicable to termination points
in starters and feeder panel.
In order to preserve original protection grade (IP), correct glands or sleeves must be used.
Refer to applicable documentation for details regarding starting methods and wiring diagrams.

Notes! Bolts, nuts, washers etc. must not be dropped into the motor as such foreign
particles will lead to short circuit of the motor.
Cables for motor-heating element and thermistors must not be interchanged,
as a voltage higher than 2.5 V will damage the thermistors.
Motor heating elements must be powered immediately after installation on board.
Framo Mounting Instruction No.1401-0009-4
Apr-2000
INSTALLATION OF ELECTRICAL EQUIPMENT Page 5 of 6

4 STC REMOTE CONTROL VALVE


1. The junction box supplied by Framo to be located close to the valves. Cables prepared with el.
connector are supplied by Framo with following lengths.
- From 1 -16 valves: 2.5 m
- Next 17 - 32 valves: 4.0 m
- Next 33 - 56 valves: 5.5 m
Glands for cables between junction box and valves are installed in bottom gland plate by Framo.
Glands for cables between junction box to control panel to be installed by yard unless otherwise
agreed.

2. Connect pilot pipes to suitable valves, giving orderly pipe installation.


3. Select a cable with suitable length and connect to the valve when pump no. (tank no.) and valve
correspondence is known.
4. Adjust cable length and terminate to dedicated terminals in junction box. Terminals in junction
box are grouped and marked with pump no. Refer to interconnection diagram for details.
5. After installation, yard to recheck uniform hydraulic connection from pumps to valve and el.
connection from valve to terminals in junction box. Valves to be permanently tagged by
Framo service engineer.

Pump no. X
Pump no. Y

Pump no. Z

To hydraulic system
control panel cable lengths as specified above
Note that distance is limited by
Cable

El. connector
P P

R R
From
pressure line

Pilot line
To return line
from pump
X
Y
Z
Framo Mounting Instruction No.1401-0009-4
Apr-2000
INSTALLATION OF ELECTRICAL EQUIPMENT Page 6 of 6

5 INTERFACE TO VESSEL’S INTEGRATED CONTROL SYSTEM


If the Framo cargo pumping system shall be operated from vessel’s integrated control system (ICS),
below listed hardwired signals are included as standard. If special signals are required, please inform.

Output from ICS (command) Input to ICS (feed back) Remarks

Start/stop - power packs Running Digital

System set pressure Actual system pressure Analogue

Cargo pumps set pressure Actual pump pressure Analogue, one for each pump

Common alarm Digital

Command (FM or ICS) Digital, select on FM panel

Note that following requirements applies:


- Digital signals to be voltage free (dry contacts) powered from receiving end.
- Analogue signals to be galvanic isolated between ICS and Framo systems. Isolators are
not included by Framo.
- Implementation of automatic start/stop functions to be approved by Framo.
- When changing command, it must be assured that no power packs or pumps are started
without operators action.

6 PRESEVATION
The cover protects the equipment and shall not be be removed before Framo service engineer
arrives for start up.

Electric motors for power packs are covered up by transparent


cover. The terminal cover can be removed separately for
termination of power- and aux. cables (ref. fig.1).

The transpartent cover for


indicators, switches and
lamps on control panels
and motor starters is fixed
on the back side of the
panel doors.
Accordingly, yard have
access to all termination
points without removing
the cover (ref. fig. 2).

Fig. 2
Fig. 1
Framo No. 1401-0010-4
Rev.B Nov-2002

Mounting Instruction

Yard equipment

CONTENTS
1 General
2 Hydraulic oil storage / Clean oil drain tank
3 Closing time for cargo valves
4 Hydraulic driven equipment
Winches - Cranes etc.
Framo Mounting Instruction No.1401-0010-4
Rev.B Nov-2002
YARD EQUIPMENT Page 2 of 4

1 GENERAL
In general we have the same requirements for installation of yard equipment connected to the
Framo system, as for equipment supplied by Framo.

The equipment must fit in with the Framo system regarding:


- Cleanliness
- Oil type and viscosity
- Hydraulic oil consumption and pressures
- Functioning without giving pressure peaks in the hydraulic system

Hydraulic system pressure, return pressure and other information are given on the Framo hydraulic
diagrams.
Equipment and connecting pipes must be properly cleaned prior to commissioning.
Oil used for flushing, testing and preservation must be compatible with the oils meeting Framo
requirements.
Note! Never use engine oil for combustion- or engine lubrication oil in combination with hydraulic
oil or its equipment, as this will damage the hydraulic oil.

2 HYDRAULIC OIL STORAGE / CLEAN OIL DRAIN TANK


The storage/clean oil drain tank incl. necessary equipment is yard supply, and shall in addition to
storage of oil make it possible to drain off clean oil from the system during service.
To avoid water mixing with the oil and simplify drainage of water, it is recommended to slope the
tank bottom down towards the bottom drain outlet. If the tank bottom is not sloped, the suction
outlet to hydraulic oil transfer pump must be minimum 100 mm above bottom drain outlet.
Hydraulic oil tanks must be vented indoor, not to open deck. Air filters should be used.
All pipes (except overflow) must have outlet openings below minimum oil level.

Fig. 1 Hydraulic oil storage tank and clean oil drain tank
Framo Mounting Instruction No.1401-0010-4
Rev.B Nov-2002
YARD EQUIPMENT Page 3 of 4

Storage volume depends on the ships operating trade area (easy or difficult supply of hydraulic oil)
and owner’s experience.
To be prepared for all possibility, we recommend the storeage volume to be approximately
30% of total oil volume in the system.

Minimum clean oil drain volume must be sufficient for draining of hydraulic pressure- and return
lines on deck and down to the power unit in addition to the power unit/auxiliary unit itself.
Recommended clean oil drain volume to be approximately 70% of total oil volume in the hydraulic
system.

The storage/clean oil drain tank may be used as two separated tanks or as a combination tank.
The storage/clean oil drain tank and its piping are parts of the hydraulic system with the same
requirements regarding cleaning as the system.

Tanks in mild steel must be degreased and grit- or sandblasted internally to SA 2.5 and given two
coats of a two-pack epoxy based cargo tank coating (resistant to hydraulic oil) of 100 micron each,
or according to the coating supplier’s recommendation.
The first coat to be laid without delay after grit- or sandblasting and dust cleaning.
Tanks in stainless steel should not be coated.

Pipes and parts for oil filling and air venting will remain empty for longer periods and may corrode.
The pipes are almost impossible to clean and coat properly inside, and we therefore recommend to
use only stainless pipes. Copper- or galvanised pipes must not be used.

Air filters may be assembled directly on the tanks to avoid pipes.

3 CLOSING TIME FOR CARGO VALVES


To prevent cargo pump over-speed and surge pressure in the cargo system, the cargo valves
must not operate faster than stated below without Framo approval.
Generally we recommend cargo- and drop line valves to be remotely operated. Manual operated
valves is recommended to have gear.

Cargo pump type Cargo pipe diameter Minimum opening time Minimum closing time
(mm) (seconds) (seconds)
SD100-SD125-SD150 100 – 150 15 15
SD150-SD200 151 – 200 20 20
SD200-SD250 201 – 250 25 25
SD300-SD350 251 – 400 30 30
SD350 > 400 30 30
Framo Mounting Instruction No.1401-0010-4
Rev.B Nov-2002
YARD EQUIPMENT Page 4 of 4

4 HYDRAULIC DRIVEN EQUIPMENT – WINCHES, CRANES ETC.


To ensure correct function of the complete system, the yard is responsible for the adaptation of
their equipment connected to the Framo cargo pumping system.
The Framo hydraulic system is operating at constant pressure, and hydraulic oil consumption is not
accepted from any equipment during stand still condition.

In addition to the general requirements, the equipment must comply with the following:
- Separate service valves for each unit’s pressure-, return- and drain line to be included by the
yard, making it possible to do service without stopping the complete system. The valves are to
be installed in the pipelines, not as part of the control valve assembly.
- Manometer test connections must be provided by the yard both on pressure- and return side,
making it possible to do trouble shooting and to check for pressure peaks.
- Air venting valves/plugs must be installed on the highest possible point on both
pressure- and return side of the equipment.
- The equipment must not transmit pressure surges into the system, and must therefore have
possibilities for limiting the response time (flow variation). Accelerating/retarding time from
0 – to maximum and from maximum – to zero oil consumption must be >2,0 seconds.
- The equipment must have a pressure compensated flow limiting valve on the pressure inlet side
to avoid motor over-speed.
- Hydraulic motor housing and shaft sealing system must be designed for a hydraulic return
pressure of minimum 10 bar to avoid separate drain lines.
- Shaft sealing systems must have protection against sea water, air and contaminant intrusion.
- If separate drain lines are installed, drain oil filter with dirty filter indication/alarm to be included
by the yard. Minimum filtration ratio B15 ³ 200.
- Separate hydraulic internal reservoirs or drain tanks are not acceptable.
- Generally Framo do not accept hydraulic cylinders connected to the system. For cranes with
hydraulic cylinders, use a separate hydraulic system with a hydraulic motor driven from the
Framo system.
- All equipment must be properly cleaned to meet ISO contamination code 4406 class 15/11 or
better prior to installation. Oil used for cleaning, testing and preservation must be compatible
with the oils meeting Framo requirements.
No. 1401-0012-4
Framo Rev.C May-2003

Mounting Instruction

Installation of deck mounted cargo heaters

CONTENTS
1 General
2 Arrangement
2.1 Nozzle loads
2.2 Service space and lifting arrangement
3 Installation
Framo Mounting Instruction No.1401-0012-4
Rev.C May-2003
INSTALLATION OF DECK MOUNTED CARGO HEATERS Page 2 of 8

1 GENERAL
The Framo cargo heater is a vertical deck mounted stainless steel heater. It consist of a channel
section and a cover. The channel section includes the heating elements, that are free to expand
vertically inside the cover. The cover can be lifted up/removed from the heater for inspection and
cleaning of the elements. A lifting hook for this operation is included in toolbox.

The Framo cargo heater can be delivered in 3 different sizes, HE225/750, HE400/1000
and HE500/1000:
HE400/1000

Thermometer

Cover Channel section

HE500/1000
Heating
medium
outlet

HE225/750

Thermostatic
valve

Heating
medium
Relief valve Flat gasket inlet
Heating
medium
Channel section
inlet
Channel section
Heating
medium
outlet

Heating
Heating
medium
inlet
medium
outlet
Fig. 1

The heater must be protective covered against


weld spatter, sandblasting during installation/ Do not remove
building period. protection before
initial start up
The heater is delivered with a protection cover that
must be kept on until commissioning is completed.

Pickling is required if the heater has been exposed


to iron dust during storage or corroded surfaces/
spots are detected. Framo recommend Avesta
Pickling Paste or equal types for stainless steel.
Follow the manufacturer’s procedure for pickling
before starting the work.

Fig. 2
Framo Mounting Instruction No.1401-0012-4
Rev.C May-2003
INSTALLATION OF DECK MOUNTED CARGO HEATERS Page 3 of 8

2 ARRANGEMENT
The cargo heater should be located close to the drop line. The following figures give examples of
optimal piping layout.

HE
225/ HE
750 500/
Cargo line 1000

Cargo valve

Bend for expansion

Fixed clamps Service spool

First clamp Cargo valve


resilient mounted Service spool HE
400/
1000

Service valves
Drain

Relief valve Service spools

Notice the following Thermostatic valve


Cargo valve
to get a proper installation:
Drop line
- The piping must be routed with built in
flexibility to avoid excessive nozzle loads at
the heater and pump connections, and to
reduce vibrations being transmittet to the
heater connections. See mounting instruction
for cargo piping.
- The cargo line to and from the heater should
be same size as the heater connections.
- Pipes to be supported to avoid excessive
load transfered to the heater connections.
- All piping must be self-draining.
(Sloping towards drop line or cargo pump)
- The cargo inlet line must have drain connection.
- Cargo valves must be located close to the
discharge line/drop line.
This is to avoid contamination of the cargo
pipes to the heater when it is not in use.
- Easy access for operation of valves.
Cargo pump inlet
- The relief valve should be connected to
the drain line/drop line.
- To prevent frost damages drain valve must
be installed at the heating inlet and outlet lines.
- Angular service spools that can be
removed for service. Drop line outlet
- The Framo cargo heater should be installed
where it is protected from sea that breaks Fig. 3
over the ship.
Framo Mounting Instruction No.1401-0012-4
Rev.C May-2003
INSTALLATION OF DECK MOUNTED CARGO HEATERS Page 4 of 8

On ships with webs the heater should be placed between the webs and not on top of the webs.
The heater must be placed near the drop line to ensure drain possibility from heater to drop line.

HE
HE
500/
400/
1000
1000

Fig. 4
Framo Mounting Instruction No.1401-0012-4
Rev.C May-2003
INSTALLATION OF DECK MOUNTED CARGO HEATERS Page 5 of 8

HE
HE
500/
400/
1000
1000

Fig. 5 Alternative arrangement


Framo Mounting Instruction No.1401-0012-4
Rev.C May-2003
INSTALLATION OF DECK MOUNTED CARGO HEATERS Page 6 of 8

2.1 Nozzle loads


The maximum allowable nozzle loads for the cargo heater are given below.

Note! The heaters must not be used as anchor points for piping.

Forces and moments


FX [N] FY[N] FZ[N] FR[N] MX[Nm] MY[Nm] Mz[Nm] MR[Nm]
HE500
Condensate outlet, F1 350 450 300 650 75 50 50 100
HE400/500
Cargo inlet/outlet, F2 2500 3000 2000 4350 2300 1200 1750 3000
HE400 steam inlet, F3 525 650 425 950 225 225 100 300

HE500 steam inlet, F4 900 1100 725 1600 700 350 525 950
HE225/400
Condensate outlet, F5 220 280 180 400 50 30 35 65
HE225 Cargo inlet/outlet, F6 1400 1800 1200 2500 1300 700 1000 1800

HE225 steam inlet, F7 350 450 300 650 75 50 50 100

HE400/1000
FZ
F2
MZ
MY FY

MX FX

FZ

F1
MZ
HE500/1000
FZ MY
FY
MZ MX
MY FY
F2 FX

HE250/750 F3 FZ
MX
FX MZ

MX
FX
MY FY

FZ FZ

MZ
MY MZ
FY FX FZ

FY MX F2 F2 MZ FZ
FZ F6 FZ FX F4 MX
F5 MX FZ MY FX
MZ MX MZ
MY MZ FX MZ F1 MX
FY FY FX
FY MY
FZ
FX F7 MY
MZ
MX F6 MY FY
FY
FX MY
MY MX
FY

MX FX

Fig. 6
Framo Mounting Instruction No.1401-0012-4
Rev.C May-2003
INSTALLATION OF DECK MOUNTED CARGO HEATERS Page 7 of 8

2.2 Service space and lifting arrangement


Free space to be left to allow for lifting of the cover for inspection of the heater.
Also see dimensional drawing.

Lifting hook
(included in toolbox)
Framo portable
tripod crane

4000

Foundation
(Yard supply)

Max. 500
Sloping deck

2100 2500

Fig. 7

If other lifting equipment is to be used, note the weigths of the


heater components in table below:

Component HE225/750 HE400/1000 HE500/1000


Cover 55 kg 70 kg 100 kg
Complete heater 175 kg 340 kg 550 kg
Framo Mounting Instruction No.1401-0012-4
Rev.C May-2003
INSTALLATION OF DECK MOUNTED CARGO HEATERS Page 8 of 8

3 INSTALLATION

1 Install the heater on the foundation. 2 Install the thermostatic valve and
the relief valve.

Do not remove
protection before
initial start up

Bolts and nuts in Gasket


stainless steel
Not Framo supply
Relief valve

Foundation Thermostatic valve


Yard supply

Fig. 8

Note! The cargo flanges on the HE500/1000 is


Fig. 9
marked with “Cargo inlet” and “Cargo outlet”.
It is important to check the labelling on
the flanges for correct installation.

3 Adjust the pipe connections to the heater.


Flange connections to heater connections must be adjusted during installation to
ensure no misalignment (axial, angular or radial gap) between the flanges.
Install the thermometers.
Bolts and nuts in stainless steel (not Framo supply)

Thermometers Adjust during intallation


Pipes to be supported Correct alignment
to avoid excessive of flanged connections
load transferred to
the heater connection. Heater
connection

To be welded
during installation
Drain valves

Adjust during Adjust during installation


installation

Fig. 10
Framo No. 1401-0026-4
Feb-2003

Mounting Instruction

Installation of submerged tank cleaning pumps

CONTENTS
1 General

2 Arrangement and orientation in tank


2.1 Arrangement on top plate
2.2 Nozzle loads
2.3 Location of brackets for
intermediate support(s)

3 Installation requirements
4 Example of pump installation
with Framo dummy
4.1 Framo dummy
4.2 Deck trunk
4.3 Bracket(s) for intermediate
support & bottom support

5 Prefabrication of deck piping


6 Assembling of pipe stacks
7 Installation of pumps in tank
7.1 Preparations
7.2 Installation
7.3 Additional information
for pumps above 20 meter

8 Filling of pumps cofferdam


Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 2 of 19

1 GENERAL
Figures in this instruction are made for tank cleaning pumps of type SD100/125/150-W5.
It is assumed that a “dummy equipment package” intended for the pump type to be installed,
is available. For further information, see drawings for the actual tank cleaning pump, deck trunk,
support rings and dummy.

The Framo hydraulically driven


submerged tank cleaning pump
consists of three main parts:

Top plate
The tank cleaning pump is
supported by a deck trunk
welded to the deck.
A special gasket and a resilient
bolt arrangement will reduce
noise and prevent cargo leakage.

Pipe stack
The pipe stack connects the
pump head to the top plate.
Dependent on pump length,
the pipe stack is supported by
intermediate support(s).

Pump head w/suction box


The pump head is enclosed by
the suction box equipped with
flange connection for the suction
pipe.
The pump head and suction box
are supported by the bottom
support.

Cathodic protection
The pump is equipped with
Zn- anodes which are connected
to the intermediate support
plates and pump head/suction
box to avoid galvanic corrosion.

Fig. 1
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 3 of 19

2 ARRANGEMENT AND ORIENTATION IN TANK


The following basic requirements must be taken into consideration:
- Optimum tank emptying. It is recommended to locate the pump as low as possible in the
ballast/freshwater tank.
- Access to the pump for operation, inspection and service.
- Access to anodes for inspection and replacement.

Fig. 2
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 4 of 19

2.1 Arrangement on top plate


Valves must be placed in areas that are
easily accessed by pump operator.

2.2 Nozzle loads


The maximum allowed external nozzle
Fig. 3
forces and moments to the Framo pumps
are given in table below:

EACH NOZZLE FORCES/MOMENT UNIT


(approx. 2 x API 610)
SD100-W5 SD125-W5 SD150-W5 Z
Fx 2,9 4,0 5,0 kN FZ
MZ
Fy 3,6 4,9 6,3 kN
Y FX
Fz 2,4 3,3 4,1 kN MX
Mx 2,7 3,7 4,6 kNm X
My 2,0 2,8 3,6 kNm MY
FY
Mz 1,4 1,9 2,4 kNm

Nozzle forces and moments on the tank cleaning pump have Fig. 4
no influence on the rotating parts of the pump, but too high
forces and moments will give:
- Leakage between the top plate and the deck trunk.
- Mechanical contact between top plate and deck trunk, causing vibration and noise.
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 5 of 19

2.3 Location of brackets for intermediate support(s)


Bracket is part of the ship design and supplied by yard. Forces acting in the tank area (sloshing,
structural deflection etc.) must be taken into consideration.

Brackets to be designed according to forces shown in table below:

Pump type F1 (kN) F2(kN)


SD100-W5 11 20
SD125-W5 14 23
SD150-W5 17 26

Fig. 5

Fig. 6

All welding of deck trunk has to be finished before installation of the brackets.
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 6 of 19

To find pump lenght (L) and location for Pump length: L = TB + S


the bracket(s) relative to the tank top,
following calculation(s) has to be done: L = Pump length [mm]
S = Gasket, approx. 2 mm.
One intermediate support
P = Bottom support height [mm].
Height [mm] Factor k1 (See dimensional drawing)
A1 = Intermediate support height [mm]
A1= k1 x L 0.35 ≤ k1 ≤ 0.4
A2 = Intermediate support height [mm]
H = Deck trunk height [mm] *
TB = Height from lower point of flexible
Two intermediate supports
bellow to top of deck trunk [mm]
Height [mm] Factors k2 k3 * Standard deck trunk height, 500 mm.

A1= k2 x L 0.25 ≤ k2 ≤ 0.3


Final figures (A1, A2 and L) to be sent to
A2= k3 x L 0.55 ≤ k3 ≤ 0.6 Framo as soon as possible.

Fig. 7
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 7 of 19

3 INSTALLATION REQUIREMENTS
(Independent of installation method)
To be confirmed before final installation of pump in tank.
The figures below also indicates how to use the laser and measuring tape from the “dummy
equipment package” to check the tolerances.

Fig. 8 Alignment control Fig. 9 Height control


Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 8 of 19

4 EXAMPLE OF PUMP INSTALLATION WITH FRAMO DUMMY


Prior to pump installation the deck trunk and brackets for intermediate and bottom support have to
be welded into the tank. Use of Framo dummy will help you to get a successful installation of trunk,
bottom support bracket and brackets for intermediate supports.
The following installation procedure is based upon use of Framo dummy.

Note! It is important that the trunk and brackets for supports are welded into the ship at
the latest possible stage to ensure correct position according to dimensional drawings.

4.1 Framo dummy


The dummy has brackets simulating all interfaces to flanged pipe connections on the pump’s top
plate for adjustment and prefabrication.

Note! It is neccessary to remove the flange protection for deck trunk (plywood) when using
the top plate dummy. It is important to remount the protection after use of dummy.

The “dummy equipment package” is shown below. For lengths, see Framo specification.

Fig. 10a Framo dummy Fig. 10b Measuring tape


Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 9 of 19

Calibration of laser
The laser is to be controlled before use to detect any
inaccuracy during transportation.
Control and adjust the laser as follows:

- Grease the laser flange to make turning of


the laser easier.

- Locate the laser on the top plate dummy


installed on the deck trunk. See fig. 9.

- Turn the laser on. Mark the spot where the


centre of the beam hits the target.

- Turn the laser 90° and mark where the


centre of the laser beam now hits the
target.

- Repeat the turning in steps of 90° until a


full circle is completed, and mark the spots
for each step.

- The collection of spots should be within a


circle of Ø=20 mm.

- If not all spots are within this circle, adjust


the laser by the two adjustment screws,
using a screwdriver.

- After the adjustment, re-check the laser as


described above.

- Continue the above procedure until the


accuracy of the laser is as specified above.

CAUTION! Avoid staring straight into the laser beam.

Fig. 11
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 10 of 19

4.2 Deck trunk


Note! It is important that the deck trunks are welded into the ship at the latest possible
stage to ensure correct pump position.

Fig. 14

Fig. 12

Fig. 15
Fig. 13
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 11 of 19

Fig. 16

Fig. 17
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 12 of 19

4.3 Bracket(s) for intermediate support / bottom support


Installation of deck trunk has to be finished before installation of brackets for bottom support and
intermediate supports.

The position (height) of the intermediate supports are marked on the measuring tape.

Check for correct position and height after welding, see fig. 8 and fig. 9.

Fig. 18
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 13 of 19

5 PREFABRICATION OF DECK PIPING


When the trunk is installed, the top plate
dummy can be used for adjustment/
prefabrication of the piping.

- Remove the laser from the top plate dummy.


- Assemble the brackets for the actual
connections (ref. drawing of top plate dummy).
- Bolt the top plate dummy to the trunk in
correct position (see dimensional drawing
for top plate).

The dummy can now be used for adjustment of


the piping by fixing the pipe flanges to the
relevant positions/brackets on the dummy.

Fig. 19

Note! Be careful not to damage the sealing surface on the deck trunk and
protect the seal faces by the supplied plywood after this operation.

6 ASSEMBLING OF PIPE STACKS


The pump is to be assembled in a horizontal position. Every pump part is to be supported in at least
two points.

Note! The pumps must not be in contact with carbon steel.

Fig. 20

Check that pump no. on all the pump parts are identical. Pump no. is placed on top plate and
flange for suction box. Locate the pump parts in correct positions one after another. Every part
is to be supported in at least two points

Note! Pumps with total length above 20 meters have to be assembled during installation in tank.
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 14 of 19

Note !
All pipes must be checked for
foreign bodies before connection.
Any parts left in the pipes
(screws, nuts, plastic bolts rags,
etc.) may cause serious damage
to the pump.

Clean all o-ring grooves and seal


faces with a dry rag.
Check all seal elements, back-up
rings, grooves and seal faces.
Pay special attention to the teflon
rings and be absolute sure of no
deformation nor radial grooves.
Never install damaged seal
elements.

Note!
Fig. 21
When assembling flange
connections in vertical position,
lower the upper pump section
slowly. Do not damage the
connection pipe.

Assemble connection pipe and


seals on the flange of lower part.
Guide the two parts together. Be
careful when the connection pipe
enter the hydraulic pressure pipe.
Assemble bolts and nuts. Tighten
the bolts according to the table
below.

Fig. 22 Split flanges

All screws and nuts have to be assembled with specified torque.


If no torque is specified, use the following torque:

ACID RESISTANT BOLTS AND NUTS, QUALITY A4-80

M6 M8 M10 M12 M16 M20


9.2 Nm 22.3 Nm 44.2 Nm 76.2 Nm 190 Nm 370 Nm

Acid resistant bolts are to be coated with “Molybdenum disculphide” (Molycote)


or similar on threads and under bolt heads/nuts prior to assembling.
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 15 of 19

Pumps shipped as one complete unit are pressure tested before leaving Framo works. Pumps
delivered in two parts or more have to be pressure tested after assembling.

Fig. 23 Pressure test of pump

Special tools for pressure testing are supplied by Framo. See tool list for descriptions.

Disconnect header tank and pipe to STC.

Blank off cofferdam check pipe (see fig. 23).


The blank flange is a part of the Framo supplied standard tool.

Connect air supply and manometer to the connection on STC and carefully increase pressure to
max. 3 bar. Stop the air supply and observe the pressurized volume for 15 minutes (pressure drop
indicates leakage).

Flush the flange connections with soapy water to be sure of no leakage.

Reinstall the complete header tank and pipe to STC.


Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 16 of 19

7 INSTALLATION OF PUMPS IN TANK


7.1 Preparations
Note! Welding, sandblasting and grinding must be finished and tank must be properly cleaned
before installation of pump in tank.
For carbon steel tanks, also coating must be finished before installation.

Pickling
Pickling will be required prior to installation if the pump has been exposed to iron dust during
storage or corroded surfaces/spots are detected. Framo recommend Avesta Pickling Paste or
equal types for stainless steel.
Follow the manufacturer’s procedure for pickling before starting the work.

Blank flanges
Blank flanges and seals on top plate shall be left until connection of the pump to the vessel’s piping
systems. By then the piping system has to be inspected for foreign bodies and cleaned.
The blank flange/protection cover on the pump’s suction opening and the protection around the
pump shaft must be kept on until pump has been installed and tank has been cleaned and
approved. The protection shall be removed only by the Framo service engineer.

Special tools required for installations are supplied by Framo in the toolbox.
See tool list for descriptions.

Bottom support /Intermediate support(s)


Install the support(s) on the bracket(s) before
installation of pump.
Tighten nuts as follows (fig. 24):

1) Assemble upper nut, use 190 Nm torque.


2) Tighten all bolts one more time,
use 190 Nm torque.
3) Assemble lower nut, use 190 Nm torque.

Deck trunk
Remove the flange protection and inspect the
sealing surface on the deck trunk flange.
Required surface roughness is Ra 1,6 µm.
If the sealing surface has been damaged Fig. 24 Bottom and intermediate support
(scratches, grooves) during transport or
installation, the damages must be removed by
careful grinding/polishing by abrasive paper.

Note! If grinding/polishing is required, Never grind across Correct grinding


this must be done according to fig. 25. seal face direction

Fig. 25 Sealing surface - deck trunk


Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 17 of 19

7.2 Installation
Clean the gasket groove in the top plate. Stretch the gasket
over the top plate, -take care not to damage the gasket.
The gastket has to be greased with teflon grease before
installation in the top plate. Gasket and grease are supplied by
Framo. Install the gasket carefully in gasket groove while the
pump is still lying hoizontal.

Install two guide pins in top plate (180° apart).

Install lifting tool on the top plate (supplied by Framo in the toolbox) Fig. 26

Lift the pump to a vertical position. Two cranes should be used to raise the pump to vertical position,
one crane for lifting, the other for keeping the lower part clear of the ground.
The lower part must not be allowed to slide along the ground during lifting.
For pump above 12 metres it is recommended to use a snatch block on the lower part.
Minimum length of the wire through the snatch block = 2 x length of the pump’s lower part.

Fig. 27

Lower the pump until the top plate rests on the


deck trunk. Be careful when the guiding pins
enter the deck trunk holes.

Install rubber bushings and hexagon head bolts


under the trunk flange. Use Loctite on the bolts.
Tighten bolts in a diagonal sequence to 44 Nm.
Remove the two guide pins, and install the two
Fig. 28
remaining rubber bushings and bolts.
Tighten bolts to 44 Nm. Gasket

Note! Don’t remove any blank flanges on the top Rubber


plate and flexible bellow before final piping bushing
connections.

Hexagon
head bolt
Fig. 29
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 18 of 19

7.3 Additional information during installation of pumps above 20 meter


Note! The pump has to be pressure tested after assembling and installation in tank.
This requires an arrangement in tank which give access to the flange connections
in pipe stack.

Lower part
Install the lifting tool on pipe stack.

Lift the pump head section into the tank.

Stop lowering when pipe stack flange is


approximately 0,5 m above deck trunk.

Install the securing tool on the deck trunk


(see actual tool drawing).

Continue lowering until the pipe stack is


resting on the securing tool (fig. 31).

Secure the lower part before removing the Fig. 30


lifting tool.

Upper part (top plate section)


Remove the blank flanges. Clean the
all O-ring grooves with a clean and dry
rag. Lift the upper part in position
above the deck trunk.
Continue lowering until the distance
between the flanges is 50-100 mm.
Install lifting bolts (toolbox) and lift the
lower pipe stack section by using the Fig. 31
lifting bolts. Be careful when the
connection pipe enter the high
pressure pipe. For assembling of
flanges, see page 14.

Lift the assembled section and remove


the securing tool.
Lower the pump as described in
chapter 6.1.

Pressure test the pump according to page 15.

Fig. 32
Framo Mounting Instruction No.1401-0026-4
Feb-2003
INSTALLATION OF SUBMERGED TANK CLEANING PUMPS Page 19 of 19

8 FILLING OF PUMPS COFFERDAM


- Hydraulic oil filling of pump must be done before
cofferdam filling.

- Fill the cofferdam through the header tank until


the liquid level stabilises just above low level
mark on the sight glass (filling tool included in tool
box).

Fill up cofferdam and header tank with:


Ethylene glycol or propylene glycol * : 50-60 %
Use pure glycol without additives.
Commercially available automotive anti-freeze
should never be used. Some of the additives in
anti-freeze tend to form deposits on seal parts and
thereby causing failure on the seals.
Demineralised water : 40-50%
Freezing point ~ - 35°C v. 50% glycol
Freezing point < - 40°C v. 60% glycol
Volumetric
expansion : 0 - 60°C ~ 63.5 x 10-5 litre/litre°C

- The cofferdam volume depends on pump type and


pump length. The following formulas give approx.
volume (in litres) required to fill cofferdam to
low level mark in header tank:

Pump type Volume in litres


SD100 ( L x 0,6 ) + 3
SD125/150 ( L x 0,6 ) + 12
L=Pump length in metres. (See Framo Specification)

Fig. 33

* Other names for ethyleneglycol: monoethyleneglycol, 1.2 ethanediol, ethanediol.


Other names for propyleneglycol: monopropyleneglycol, 1.2 propanediol, propanediol.
Framo
No. 1401-0017-4
Rev. A Sep-2002

Mounting Instruction

Hydraulic piping installation

CONTENTS
1 Design
1.1 Optimum hydraulic pipe layout
1.2 General requirements
1.3 Detail design
1.4 Branch lines
1.5 Critical length of branch lines
1.6 Service spools
1.7 Optimal layout between engine room and deck
1.8 Noise reduction
1.9 Pipe qualities and sizes
1.10 Flanges and connections
1.11 Expansion loops
1.12 Venting of pipes
1.13 Pilot pipes

2 Fabrication of hydraulic pipes


2.1 Degreasing of carbon steel pipes
2.2 Protection of flanges
2.3 Bending of pipes
2.4 Welding
2.5 Fabrication tolerances
2.6 Non-destructive testing (NDT)
2.7 Surface treatment / Pickling / Preservation

3 Installation onboard
3.1 General requirements
3.2 Tightening torques for bolts
No. 1401-0017-4 No. 1401-0017-4
Framo Mounting Instruction Rev. A Sep-2002 Framo Mounting Instruction Rev. A Sep-2002
2 of 26 3 of 26
HYDRAULIC PIPING INSTALLATION HYDRAULIC PIPING INSTALLATION

1 DESIGN
1.1 Optimum hydraulic pipe layout
All hydraulic lines, including expansion loops, must be routed in order to avoid air pockets.
This is applicable also for pilot lines.

Key items are:


• All pipes must be resilient mounted, except pilot pipes on deck.
• Acceptable load on resilient pipe clamps.
• All pipe supports, pipe clamps and anchor points must be welded to
rigid structure.
• Bending of pipes where possible, in order to reduce quantity of
flanges and fittings.
• Carbon steel pipes must be painted with final coating system before
installation on open deck, to avoid corrosion in clamping zone.

Fig. 1
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HYDRAULIC PIPING INSTALLATION

Optimum design
The benefits of optimum design are:
• Reduced quantity of pipe components (leakage possibilities)
• Reduced installation time
• Reduced pressure drop
• Increased life time
• Reduced maintenance cost

Fig. 2 Fig. 2A

1.2 General requirements


To obtain a long lasting and well functioning hydraulic plant, cleanliness is of great importance.
Framo’s requirement is to keep the pipes and components clean and preserved during the
whole production and installation period.

Following must be considered during layout of hydraulic pipes:


• Spool length up to 12m where practical
• Stress caused by the system pressure
• Thermal expansion caused by temperature changes in the system (max. oil temp. 60°C)
• Mechanical forces caused by deflection of ship structure

Documentation:
All material used must comply with classification society rules, regarding material certificates and
production documentation.

1.3 Detail design


Hydraulic pipe spools must be designed to ensure visual inspection for all inside weld seams,
ref. fig. 4. Use of instruments like videoscope or similar is an acceptable inspection method.

OPTIMUM DESIGN ACCEPTABLE NOT ACCEPTABLE

Fig. 3 Fig. 4 Fig. 5


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5 of 26
HYDRAULIC PIPING INSTALLATION

1.4 Branch lines


In order to reduce stress in branch lines and main lines from thermal expansion and deflection of
ship, the following tables for duplex, stainless steel and carbon steel must be used for optimum
hydraulic pipe design.

Fig. 6 Carbon steel St.52 Fig .7


St 52: FLEX ANALYSIS NOT REQUIRED?
350
Example:
OD 100, L=15 m Pipe OD65 with
300
branch length
OD 80-90, L=15 m approx. 5m.
Upper flexibility limit
250 L-U must be
minimum 1.2 m.
Pipe flex. characteristic K

200
Note!
OD 54-65, L=15 m
If required,
150 OD 38-45, L=15 m flexibility- and
stress analysis
must be provided.
100
<OD100,
L=5m

50
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

1.2 L-U (m)

Duplex Fig. 8
22Cr DUPLEX: FLEX ANALYSIS NOT REQUIRED?
Stainless steel 316L Fig. 9
AISI 316L: FLEX ANALYSIS NOT REQUIRED?
0 350 350

300 300
Upper flexibility limit OD 106, L=15 m
Pipe flex. characteristic K

Pipe flex. characteristic K

250 OD 76-90, L=15 m


250
OD 100, L=15 m
Upper flexibility limit
OD 80-90, L=15 m
200 200

OD 54-65, L=15 m
j
150
OD 38-45, L=15 m 150 OD 54-60, L=15 m

OD 35-45, L=15 m
100
100
< OD 106, L=5 m < OD 106, L=5 m
0
50
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 50
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
L-U (m) L-U (m)

Figure 7, 8 and 9 show how the required flexibility length (L-U) changes with increasing pipe dimension with
a small total piping length (one curve for all pipe dimensions) and a large total piping length (four curves
with several pipe dimensions) when assuming a maximum differential temperature ∆Tmax=50ºC (FDP).
The intersection of the above mentioned curves and the upper flexibility limit will indicate the required
flexibility length (L-U) on the axis of abscissas.
For a given pipe dimension a total piping length smaller than L=15m will also require a smaller flexibility
length (L-U) somewhere between the maximum value and the minimum required flexibility length for L=5m
(linear interpolation can be performed).
D = outside diameter of pipe (mm)
L = developed length of piping between anchors (m) (L1 + L2 + L3)
U = anchor distance, straight line between anchors (m)
K = flexibility characteristic (-)
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HYDRAULIC PIPING INSTALLATION

1.5 Critical length of HP branch lines


There is a connection between pump length and the length of HP branch lines, due to pressure
waves and pipe sizes. If HP branch line is above critical length, there will be a risk of vibration.
To avoid vibration in branch lines, table fig. 10 shows critical pipe length for branch lines to
pumps. This is in most cases only applicable for submerged ballast pumps and pumps in deck
tanks. Pipe dimensions given in Hydraulic Diagram are standard pipe sizes.

Critical pipe length for H.P. branch lines for


Framo SD (SB) pumps.
KRITISKE STIKKRØRSLENGDER FOR FRAMO SD(SB) PUMPER , BASERT PÅ SIMULERING

40

35
SD125-150
SB200-300

30
Example:
SD200 + SB400 SD 100, pump length 18 m.
Max. length of branch line = 13 m.
25
PUMPELENGDE I METER

SD300 + SB600
SD100 Note !
Pump length (m)

20
SD350
If branch line exceeds limitations
given in this table, pipe size to be
15
increased by 2 step up to service
valve (ball valve).
Please contact Framo for verification.
10

0
0 5 10 15 20 25 30 35 40
MAX. LENGDE STIKKRØR I METER
Max. length of branch lines (m)
Fig. 10
This table is applicable for H.P. only

1.6 Service spools at cargo pumps and resilient pipe clamps


Hydraulic pipes must have an angular service spool at pump in order to make lifting of pumps
possible.

Fig. 11
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Framo Mounting Instruction Rev. A Sep-2002
7 of 26
HYDRAULIC PIPING INSTALLATION

1.7 Optimal layout between engine room and deck


In order to get an optimum design and low noise, pipes to be routed from the engine room,
through cofferdam or pipe duct, and up to main deck.

Note!
• Length “L” to be as short as possible, and maximum 8m without expansion bend.
• Resilient clamps and anchor points must be welded to rigid structure.
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HYDRAULIC PIPING INSTALLATION

1.8 Noise reduction


It is of great importance to isolate hydraulically driven equipment and connected piping from ship
structure by us of:
• Resilient pipe clamps
• Resilient bulkhead penetrations
• Resilient anchor points, horizontal/vertical

1.8.1 Installation of resilient pipe clamps


Due to fabrication tolerances on pipe supports and prefabricated pipes, pipe clamps must be
possible to adjust in order to have similar compression on rubber pads.
Pipe supports must be welded to rigid structure, ref. fig. 19.

Recommended procedure :

1. In order to make adjustment more easy, resilient pipe clamp to be welded to an angle bar
or similar, prior to spot welding to pipe support.

Fig. 17

2. Check acceptable load for resilient pipe clamps.


3. Angle bar with resilient pipe clamp must be spot welded to pipe support.
4. After all pipes are in position and aligned, angular bar must be adjusted, if necessary to
similar compression on rubber pads. Clamps must not be overloaded.
5. Welding of bracket to be completed.

Note! Carbon steel pipes must be painted with complete painting system before
installation, to avoid corrosion in clamping zone.

Following pipe lines must be resiliently installed:

Pipe lines: Requirement:


All hydraulic lines, except pilot lines on deck Distance between clamps, see table page 9
Cargo line Minimum 2 pcs close to pump
Drop line If clamp is required
Stripping line If clamp is required
Cooling water (HPU) Flexible bellow
Fuel connection (HPU) Flexible hose
Exhaust connection (HPU) Flexible bellow
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Framo Mounting Instruction Rev. A Sep-2002
9 of 26
HYDRAULIC PIPING INSTALLATION

Installation requirements for resilient pipe clamps

Ensure similar compression on rubber pads. Tolerance: ± 1,5mm.

Fig. 18

OD ‘F’ +0 Max Distance OD ‘F’ +0 Max Distance


PIPE (mm) - 2 load (m) PIPE (mm) - 2 load (m)
(KN) between (KN) between
clamps clamps
25,0 6 1.2 1.4 – 1.8 114,3 55 3.0 2.5 – 3.0
28,0 12 1.2 1.4 – 1.8 120,0 63 3.0 3.0 – 3.5
30,0 12 1.2 1.4 – 1.8 130,0 78 3.0 3.0 – 3.5
33,4 20 1.2 1.4 – 1.8 131,0 78 3.0 2.5 – 3.0
35,0 20 1.2 1.4 – 1.8 139,8 62 5.0 2.5 – 3.0
38,0 10 1.4 1.5 – 2.0 156,0 86 5.0 3.0 – 3.8
42,0 16 1.4 1.5 – 2.0 165,2 99 5.0 3.0 – 3.8
44,5 20 1.4 1.5 – 2.0 168,3 103 5.0 3.0 – 3.8
45,0 20 1.4 1.5 – 2.0 206,0 96 6.0 3.0 – 4.0
48,3 24 1.4 1.5 – 2.0 216,3 112 6.0 3.0 – 4.0
54,0 33 1.4 1.5 – 2.0 219,1 112 6.0 3.0 – 4.0
60,3 29 1.5 2.0 – 2.5 256,0 98 8.0 4.0 – 5.0
65,0 36 1.5 2.0 – 2.5 267,4 98 8.0 4.0 – 5.0
76,1 51 1.5 2.0 – 2.5 273,0 98 8.0 4.0 – 5.0
80,0 37 2.3 2.0 – 2.5 307,0 98 8.0 4.0 – 5.0
84,0 42 2.3 2.0 – 2.5 318,5 98 12.0 4.0 – 5.0
88,9 50 2.3 2.5 – 3.0 323,9 98 12.0 4.0 – 5.0
90,0 50 2.3 2.5 – 3.0 357,0 98 12.0 4.0 – 5.0
100,0 63 2.3 2.5 – 3.0 406,4 118 12.0 4.0 – 5.0
106,0 44 3.0 2.5 – 3.0
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HYDRAULIC PIPING INSTALLATION

Guidelines for attachments to stiffeners (pipe supports)

Sufficient stiffness of pipe supports must be considered.

Note! Pipe supports must be welded to rigid structure.

GOOD INSTALLATION PRACTICE NOT ACCEPTABLE

Fig. 19
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HYDRAULIC PIPING INSTALLATION

1.8.2 Resilient bulkhead penetration


Framo resilient bulkhead penetrations are type approved for A0 bulkheads.
By additional insulation, the penetrations are approved for A60 bulkheads.
Materials: Stainless steel / rubber / fire protection.

A0-bulkhead
Fig. 20

A60-bulkhead
Fig. 21
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HYDRAULIC PIPING INSTALLATION

1.8.3 Installation procedure for Framo resilient bulkhead penetration

A = Hole for trunk


B = Min. distance from
bulkhead to cover
(mark in trunk)
C = Max. distance from
bulkhead to cover
(mark in trunk)
D = Total length of
bulkhead penetration
E = Diameter of cover

Fig. 22

Trunk dim. OD øA B C D øE
ø168,3 170 58 76 144 198
ø200 202 69 87 156 230
ø219,1 221 69 87 156 249
ø290 293 103 121 190 322
ø290 HP, DN100/110 293 123 141 210 322
ø355,6 359 83 101 170 386
ø406,4 410 84 102 172 438

In order to obtain a correct installation of the resilient bulkhead penetration, the following
procedure must be followed:

1. Reinforcement of bulkhead/deck by use of additional stiffeners is required due to cut out in


bulkhead plate. See fig. 23.
2. Hole in bulkhead/deck to be cut out according to actual size. See table, measure A.
3. To obtain correct distance from bulkhead to
penetration flange, temporary adjustment
pieces can be cut to reduce distance. For
increase of distance shims to be used
(Ref. measure B and C).
4. Install bulkhead penetration temporary by tack
welding.
5. Support rings to be dismantled.
6. Pipe inside to be fitted to bulkhead flange.
Fig. 23 7. Remove the adjustment pieces.
8. Check alignment: radial = ±5mm
axial = ±6mm
9. Trunk to be sequence welded to bulkhead.
Use welding consumables for carbon steel/
stainless steel (309 Mo).
10. Reinstall the support ring, and check alignment (item 8).
11. Outside pipe to be fitted after adjustment and welding.
12. After sandblasting and painting of bulkhead/deck plate, remove protection tape.
Prior to start of surface treatment bulkhead penetration must be protected by use of canvas
or simular.
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HYDRAULIC PIPING INSTALLATION

1.8.4 Resilient anchor point

Fig. 24

* Note! This length is based upon pipe OD76,1 x 2,9.


If pipe with larger wall thickness is used, length can be increased.

1.8.5 Installation of resilient anchor point

Fig. 25 Fig. 26 Fig. 27 Fig. 28

Note! Resilient anchor point must not be submerged into acid bath.
Ref. section 2.7 for pickling procedure.

1.8.6 Location of resilient anchor point


Fig. 29

Fig. 30
Vertical support
Fig. 31
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HYDRAULIC PIPING INSTALLATION

1.9 Pipe qualities and sizes


Qualities
All hydraulic pipes must be cold worked to give a smooth internal surface in order to
reduce the pressure drop and to ensure sufficient cleaning during oil flushing.

Recommended material qualities below are based upon pipe material available in the market,
and life time of pipe system:
LOCATION PIPE LINE MATERIAL QUALITY
Pipes on open deck High pressure pipes Carbon steel St. 52.4
Option: Duplex Stainless steel
Pilot pipes Duplex Stainless steel
Return pipes Stainless steel 316L
Pipes indoor All pipes Carbon steel
Option: Stainless steel 316L

Note! Longitudinal welded return pipes must be fabricated by approved mill for fabrication
of welded pipes.

Pipe dimensions
Pipe dimensions given in Framo hydraulic diagrams show the minimum internal pipe diameter.
This is based upon max. permitted pressure drop calculation for each vessel.

The wall thickness is depending upon class requirement, material quality, material treatment and
bending of the pipes actually installed.
It is yards responsibility to ensure that the wall thickness complies with the classification society
rules. The thickness given on the hydraulic diagram is for guidance only.

When the hydraulic piping system is part of Framo’s delivery, Framo will do the necessary
calculations according to classification society rules.

For further information regarding pipes, see Framo piping catalogue.

FRAMO PIPE STANDARD


Table 1 - Pressure pipes Table 2 - Return pipes
Carbon steel / Stainless steel Stainless steel (316L)
DN OD x thickness CS / SS DN OD x thickness
DN 15 18 x 2,5 / 1,5 DN 15 18,0 x 2,0
DN 20 25 x 3,0 / 2,5 DN 20 28,0 x 2,0
DN 25 30 x 4,0 / 2,5 DN 30 35,0 x 2,0
DN 30 38 x 5,0 / 3,5 DN 40 44,5 x 2,0
DN 35 45 x 5,0 / 4,0 DN 50 54,0 x 2,0
DN 40 54 x 6,0 / 5,0 DN 70 76,1 x 2,0
DN 50 65 x 7,0 / 6,0 DN 80 84,0 x 2,0
DN 60 80 x 10,0 / 7,0 DN100 106,0 x 3,0
DN 70 90 x 10,0 / 8,0 DN125 131,0 x 3,0
DN 80 100 x 10,0 / 9,0 DN150 156,0 x 3,0
DN100 120 x 12,0 / 10,0
DN110 130 x 13,0 / 11,0
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HYDRAULIC PIPING INSTALLATION

1.10 Flanges and connections

Flanges
In order to get a leakage free hydraulic system it is of great importance to use flanges with clean
and damage free “flange face”. Any damage on sealing surface may cause leakage.

Note! “Flange face” must be protected during production period in workshop.

Recommended type of flanges to be used:

High pressure: Low pressure:

O-ring Flat gasket O-ring Flat gasket

Fillet weld

Welding neck Welding neck Welding neck Slip-on


PN320 PN16 special PN16 PN16

Fig. 32 Fig. 33 Fig. 34 Fig. 35

Note! Only flanges must be used on open deck.

Recommended branch connections

High pressure: Low pressure:

“Weldoflange” “Threadolet” Threaded socket “Weldoflange”

Fig. 36 Fig. 37

Extruded T-pieces may also be used.


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HYDRAULIC PIPING INSTALLATION

Pipe fittings (less than 42mm)

• Avoid use of threaded couplings on open deck, due to corrosion and leakage.
• For indoor piping profile ring couplings and “soft seal” type may be used.
• Other types of couplings can be used, subject to approval from classification society.

Note! Makers instruction must be carefully followed for correct installation.

Socket weld fitting Butt welded pipes


Fig. 38 Fig. 39

Note!
• Socket weld fittings must not be used.
• Butt welding of pipes without access to inspect internal weld seams regarding
cleanliness is not acceptable in Framo hydraulic piping system.

1.11 Expansion loops


It is important to be sure that sufficient number of expansion loops are used in the hydraulic
piping system. Expansion loops must be horizontal mounted. For dimensions, see Framo Piping
Catalogue.
Low pressure

High pressure

Typical expansion loops


Fig. 40

Location and number of expansion loops depends on thermal expansion of the hydraulic system
and deflection of ship structure.

For accurate calculation of thermal expansion the following formula can be used:

∆L = L ⋅ α ⋅ ∆T Material α
L = Length of pipe St. 52 0,0111mm/m°C
α = Thermal expansion coefficient 316L 0,0155mm/m°C
∆T = Temperature difference in °C Duplex 0,0135mm/m°C
(Max. oil temp. 60°C)
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HYDRAULIC PIPING INSTALLATION

LOOP DETAILS: OD pipe Max ∆L Axial forces


(mm) (N)
65 14 6000
80 17 11000
90 22 11000
100 25 12000
120 20 13000
130 19 21000

Fig. 41 (Plan view)


Data is based on design
pressure limited to 320 bar.
Expansion of pipe line

Expansion of pipe line can be made by expansion loops or by off-set in pipe layout,
as shown in fig. 42.

Note! Flexibility and stress analysis must be carried out, in order to make sufficient
flexibility of pipes and correct position of resilient anchor point and clamps.

Fig. 42 (Plan view)

MD = For distance between clamps, see table on page 9.

1.12 Venting of pipes


Heating and venting valve arr. to be fitted on highest part of hydraulic pipe lines (HP/LP), in
opposite end of HPU. Air venting plugs to be fitted at all high points of pipes (HP/LP).

Fig. 43 Fig. 44 Fig. 45


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HYDRAULIC PIPING INSTALLATION

1.13 Pilot pipes and remote control valves


1. The junction box to be located close to valve blocks. Distance ‘L’ is limited by cable
lengths. Cables with el. connectors are supplied with following lengths:
• From 1 – 16 valves : 2,5m
• Next 17 – 32 valves : 4,0m
• Next 33 – 56 valves : 5,5m
2. Connect pilot pipes to a suitable valve, to get an optimum pipe routing.
3. Select a cable with suitable length and connect to dedicated terminal in Junction box.

Note! Water ballast pumps must be connected to different valve blocks. This to ensure
operation of ballast system if one valve block is out of service.

Framo supply Junction El. cable


Framo supply Indoor Deck
Box

Resilient mounted
" L"

400

400
Remote control
Valve block Use flanges for
Framo supply Fixed bulkhead
penetration pipe to pipe joint

Pilot pipes OD 12 or 18mm Fig. 46


Resilient
Resilient pipe clamps
pipe indoor
clamps indoor

Note!
• Marking of valves / pumps to be done by Yard after installation of pilot pipes and
cables.
• Pilot pipes on open deck must be of stainless steel material.

Pilot lines must be routed in order to give sufficient flexibility and a professional lay out.
Expansion loops are required, maximum distance between loops is 25m. If installed in
catwalk, expansion loops for pilot lines must correspond with expansion joint in catwalk.
For dimension of expansion loops, see fig. 46.

Pilot pipes must be installed in max. 2 layers, in order to have access to tighten bolts in flanges.
Flanges to be turned as shown in fig. 47, in order to avoid contact between flanges and pipes.

Fig. 47
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HYDRAULIC PIPING INSTALLATION

2 FABRICATION OF HYDRAULIC PIPES


In order to reduce installation time, prefabrication of hydraulic pipes can be carried out in
workshop up to possible extent (~80 - 85%). Adjustment pipe to be used at bulkhead
penetrations and between service valves and pumps only.

2.1 Degreasing of carbon steel pipes and accessories before


production
Note! Preservation oil may cause toxic gasses during welding.

2.2 Protection of flanges


The seal surface must be protected during the entire production period. Flanges must be
protected by use of blank flanges, rubber gaskets and min. 4 bolts.

Fig. 48

2.3 Bending of pipes


Bending of pipes where ever possible is preferable. Use cold bending method only.

For low pressure pipes use of «mandril» inside the pipe is required. «Mandril» material must be
plastic/teflon or similar to avoid damage of pipe surface.
«Mandril» must be cleaned prior to use.

Bent section of pipe must be free of wrinkles on inner side, and ovality max. 7%.

Regarding bending data,


see fig. 49.

Mandril
(Teflon / plastic).

Cold bending machine


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HYDRAULIC PIPING INSTALLATION

R Formula for calculation of ovality (η),


T min after bending:

A min
B min D min Limit = 7%

− Dmin ö
η = 2 ⋅ æçè DD max
÷ ⋅ 100%
max + D min ø
D max

Fig. 49

A = Minimum distance between two bends acc. to bending machine used.


B = Minimum length after bending (tool clamping).
Dmin. = Minimum diameter after bending.
Dmax. = Maximum diameter after bending.
R = Bending radius, ref. class requirements.
Tmin. = Minimum required wall thickness after bending.

Table 1 - Pressure pipes – Bending data Table 2 - Return pipes – Bending data
(Carbon steel / Stainless steel) Stainless steel (316L)
DN OD x thickness A B R DN OD x thickness A B R
DN 20 25 x 3,0 / 2,5 470 200 100 DN 20 30,0 x 2,0 505 220 120
DN 25 30 x 4,0 / 2,5 505 225 120 DN 30 35,0 x 2,0 570 225 140
DN 30 38 x 5,0 / 3,5 590 300 152 DN 40 44,5 x 2,0 465 300 178
DN 35 45 x 5,0 / 4,0 475 300 180 DN 50 54,0 x 2,0 565 300 216
DN 40 54 x 6,0 / 5,0 540 300 216 DN 70 76,1 x 2,0 790 475 305
DN 50 65 x 7,0 / 6,0 110 360 260 DN 80 84,0 x 2,0 865 490 335
DN 60 80 x 10,0 / 7,0 250 400 240 DN100 106,0 x 3,0 340 600 318
DN 70 90 x 10,0 / 8,0 285 500 270 DN125 131,0 x 3,0 300 650 393
DN 80 100 x 10,0 / 9,0 300 600 300 DN150 156,0 x 3,0 470 850 468
DN100 120 x 12,0 / 10,0 360 650 360
DN110 130 x 13,0 / 11,0 390 650 390

Option: Heat induction bending

Bending by heat induction can be used for carbon steel pipes only, provided that actual
procedure is approved by classification society.

Note! Pipes must be degreased before bending, and pickled after bending.
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HYDRAULIC PIPING INSTALLATION

2.4 Welding
Welding procedures and quality control to be carried out according to classification society
rules. TIG welding with purging gas (Argon) is recommended.
t

Max 1 + 0.1t

To be grinded if tolerances are


exceeded

Fig. 50

Welding of “weldoflanges” and “threadolets” – High and low pressure

Following procedure must be followed carefully in order to obtain a high quality branch
connection.

Fig. 51
Fig. 52

1. Hole “A” must be drilled in run pipe, corresponding to inner diameter of weldoflange.
Ref. fig. 51. Note! Flame cutting is not acceptable.
2. Weldoflange is machined for medium range run pipe. In order to meet requirements of
Welding Procedure Specification (WPS), machining must be carried out to fit actual run
pipe. Ref. fig. 52 and 53.
3. Welding according to approved welding procedure, for each material grade. TIG welding
(GTAW/141) is recommended. Pipe must be filled with purging gas (Argon) in order to
prevent oxidation of welding root.
4. 100% NDT - (DPI) Dye Penetrant (316L/Duplex)
- (MPI) Magnetic Particle Inspection (Carbon steel)

Material ”B” ”C”


Carbon st. 2.0 – 3.0 1.0
316L 2.0 – 3.0 1.0
Duplex 3.0 – 4.0 0.3

Fig. 53
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HYDRAULIC PIPING INSTALLATION

2.5 Fabrication tolerances


In order to avoid leakage, it is of greatest importance that the condition and alignment of
flanges are checked prior to installation. The flange face must be clean and free from any
damage on the sealing surface. Before tightening of flange bolts radial off-set and axial gap
should be checked.

Framo flanges HP LP
Nom. dia. MD (m) Axial gap Axial gap
(mm) min. (mm) max. (mm) max.
30 2.0 0,9 0,20
40 2.0 0,9 0,20
50 2.0 1,0 0,25
60 2.0 1,1 0,30
70 2.5 1,6 0,35
80 2.5 1,7 0,40
90 2.5 1,8 -
100 3.0 1,9 -
110 3.0 2,0 -
Fig. 54

Calculation is based on:


1. Minimum pipe support distance ‘MD’
2. Bolt quality grade 8,8 or A4-80
Stainless steel

2.6 Non destructive testing (NDT)


NDT to be executed according to Classification Society rules.

WORK SHOP PRESSURE TESTING

High pressure : 1,5 x design pressure.


Medium :
Fresh water with corrosion inhibitor.
Proposal: DYNO PK 6050 or equal.

Low pressure : Leak test, 0,5 bar air.


Use soap water on welding to discover leakage.

X-RAY MPI/DPI FOR HIGH PRESSURE PIPES:

MPI (Magnetic Particle Inspection) = Carbon steel


DPI (Dye Penetrant Inspection) = Stainless steel PRESSURE TESTING ONBOARD

High pressure pipes: After installation onboard the piping


Type of weld NDT Pipe dim. Extent system must be pressure tested
according to class requirement and
Butt weld x-ray ≤ OD 76.1 10 %
acceptance.
Butt weld x-ray > OD 76.1 100 % Hydraulic system oil must be used.
Fillet weld MPI/DPI ≤ OD 76.1 10 %
Fillet weld MPI/DPI > OD 76.1 100 %
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HYDRAULIC PIPING INSTALLATION

2.7 Surface treatment / Pickling

2.7.1 Carbon steel pipes

Sandblasting
Before priming carbon steel pipes must be sandblasted on the external surface.
Roughness to be: SA 2.5 or according to requirement in actual painting system.

Note! Internal surface must not be sandblasted.

Sandblasting
Fig. 55

Priming
External surface must be primed immediately after sandblasting/
pickling. Use primer according to actual painting system.
Proposal: Zink Rich Epoxy.

Note! Final coating of pipes must be done before installation


onboard.

Cleaning
After honing pipe must be cleaned.
After sandblasting and priming pipes must be cleaned inside.
Remove all blank flanges before cleaning. Fig. 56
If required, pipe to be honed inside by grinding stone.
Cleaning medium: Fresh water with corrosion inhibitor. Proposal: Dyno PK6050 or equal.
Recommended temperature: 80°C to obtain cleaning and fast drying.
OPTION: Pickling (carbon steel)

Note! Pickling medium can be dangerous for people and environment. Use necessary
protection outfit.

If carbon steel pipes are corroded on internal surface, pickling is necessary before priming.
Use following procedure:
• Pipes must be degreased before pickling

Pickling medium: Sulphuric acid H2 SO4 : 10 - 18% (by volume)


Bath temperature : 20 - 25°C
Time : 30 - 90 minutes
Flanges (sealing surfaces) to be inspected during process.

Cleaning of pipes after acid pickling


Immediately after acid pickling the pipe must be flushed with hot clean fresh water and
neutralised.
• Neutralisation of carbon steel: Use 2% (by volume) phosphoric acid at 20 - 25°C
for about 5 minutes.
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HYDRAULIC PIPING INSTALLATION

PRESERVATION OF CARBON STEEL PIPES (INTERNAL SURFACE)

1. Pipe to be filled completely by preservation oil.


Use 2% of Shell VSI 8235 oil mixed into clean hydraulic oil.

2. Drain pipe into drip tray.

3. All connections must be blanked off by use of rubber gaskets, blank flanges
and min. 4 bolts.

Oil pump

Barrel with
preservation
oil
Drip tray

Fig. 57

2.7.2 Stainless steel pipes

Note! Pickling medium can be dangerous for people and environment.


Use necessary protection outfit.

1. PICKLING

All stainless steel pipes must be pickled after welding.

Pickling medium: Nitric acid : 15 - 20% (by volume)


Hydrofluoric acid : 4 - 5% (by volume)
Bath temperature : 20 - 40°C
Time : 15 - 60 minutes

Alternative: Use pickling paste in welding zone (or corroded areas), and follow makers
instruction.

Proposal: “Avesta Beizpasta” 101 or equal.

2. CLEANING OF PIPES AFTER ACID PICKLING

Immediately after acid pickling the pipe must be flushed with hot clean fresh water and
neutralised.

• Neutralisation of stainless steel: Use 15 - 20% (by volume) Nitric acid at 40 - 80°C
for about 15 - 30 minutes.

Note! After cleaning all connections must be blanked off.

Note! It is of great importance to protect the surface of stainless steel pipes from impurities
caused by grinding and welding, in order to maintain a corrosion free surface. This can
be done by painting of all pipes before installation onboard, or to cover all pipes with
canvas, tape or similar.
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HYDRAULIC PIPING INSTALLATION

3 INSTALLATION ONBOARD

3.1 General requirements for installation onboard

Key items are:

• Prefabrication of hydraulic pipes in workshop up to a possible extent of (∼80-85%).

• Hydraulic pipes and components must be kept clean, preserved and blanked off during the
installation period.

• Ensure that blank flanges are fitted to all connections until final assembly on board.

Note! Open ends will lead to contamination of the hydraulic system.

Fig. 58

• Alignment of pipes must be checked, and axial gap must not exceed figures given in fig. 54.

• Alignment of pipe clamps must be checked, and adjusted if required.

• All pipe supports must be welded to rigid structure.

• Pipe supports must be designed to take forces from piping system and anchor points.

• Axial clearance in resilient bulkhead penetrations must be checked.

Note! Hemp, codille, tow and sealing compound as Permatex or similar must never be used
in a hydraulic piping system.

BLOCK (UNIT) INSTALLATION

Pre-outfitting of hydraulic pipes in blocks (units) may cause problems regarding misalignment of
pipes and pipe clamps.

To prevent misalignment and leakage following details are important:

• Pipe clamps must not be welded before assembly of blocks and alignment of pipes.
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HYDRAULIC PIPING INSTALLATION

• Adjusting spool pieces must be minimum 2 - 3 m long in order to give sufficient alignment.

• During installation of adjusting spools, pipe ends must be moved (forced) 3 - 5 mm in


longitudinal direction in order to avoid damage of o-rings.

Fig. 59

3.2 Tightening torques for bolts


In order to obtain correct pretension, the threads, plus screw heads and contact surface of nuts
against foundation, must be clean and lubricated before tightening.

The lubricating agent should be Molybdenum sulphide on screw connections of stainless steel
type (A4-80 or similar).

If pneumatic or electric hammer is used during assembling this should be used for
light tightening, followed by tightening with a torque wrench.

If no torque is specified in service instruction or on drawing, use tightening torque


according to table:

TORQUE REQUIRED (Lubricated bolts)


Thread Mild steel quality Steel quality
A4-80
dimension 8.8 12.9 Stainless steel

M8 23 Nm 40 Nm 22 Nm
M10 47 Nm 79 Nm 44 Nm

M12 81 Nm 137 Nm 76 Nm
M16 197 Nm 332 Nm 190 Nm
M20 384 Nm 648 Nm 370 Nm

M24 660 Nm 1113 Nm


M30 1337 Nm 2257 Nm

Note! The torque table is based upon use of flat washers under the screw head or the nut.
Screws and nuts must be paired, A4-80 / A4-80, 8,8 / 8 and 12,9 / 12.
No. 1401-0018-4
Framo April 2000

Mounting Instruction

CARGO PIPING

CONTENTS

1. General

2. Chemical Carriers

3. Oil Product - and Crude Oil Tankers

4. Self-draining
4.1 Cargo deck lines above manifold
4.2 Cargo deck lines below manifold
4.3 Drain arrangement for manifold

5. Cargo pump stripping arrangement


5.1 Vacuum drain arrangement. (Option)

6. Resilient mounting
6.1 Resilient pipe clamps
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 2 of 12

1 GENERAL
This document is intended as a guide with some examples for possible cargo piping on
Chemical carriers, Oil product- and Crude oil tankers. Other design criteria may apply for
FSOP’s and OBO’s.

The cargo piping arrangement will depend on type of vessel, cargoes to be carried and number
of segregations, but should always be arranged for optimal efficiency regarding loading,
discharging, draining and cleaning.

In addition to the different authorities and owner’s requirements, the following main items must
be considered during design:

- Cargo piping material.


- Segregation and a minimum risk of cargo contamination.
- Self-drainage or easy draining of piping and components.
- Optimal arrangement and number of valves.
- Valves. Type-Material-Operation (remote and/or local operation).
- Number of flanges reduced to a minimum.
- Easy access for operation and maintenance of equipment.
- Service spools for dismantling and maintenance of equipment.
- Maximum cargo pressure and equipment design pressure.
- Mechanical forces from ship structure.
- Anchor points and expansion loops.
- Resilient pipe clamps close to the Framo cargo pumps.
- Flexibility between Framo cargo pumps and cargo drop line.

From a stripping point of view, an arrangement with the manifolds (crossovers) below cargo
deck lines, and with the deck lines sloping against the manifolds is preferred. From a loading
point of view, an arrangement with the manifolds above cargo deck lines is preferred.
Plus- and minus for the different arrangements are given in page 6, and regardless of manifold
location, arrangements should be made to reduce or avoid the drawback of the selected
design.

Cargo can be loaded through the Framo submerged cargo pump, but the loading
capacity/pressure is limited by an anti-rotation brake in the pump, (preventing the impeller from
rotating during loading).
Separate cargo drop lines should always be installed to obtain a satisfactory loading rate, and
also to make it possible to by-pass the cargo pump during loading.

For cargo circulation (cargo heating with deck heaters or circulation of cargoes with high
content of sediments), the drop line outlet in tank should be as far away from the cargo pump
inlet as possible.
If limited space on deck, drop lines may be routed inside the cargo tank.

Pressure transducers for remote reading of cargo pressure should preferably be installed
between the cargo pump and the cargo valve, making it possible to read the cargo pressure
when the cargo pump is running, even with closed cargo valve.
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 3 of 12

2 CHEMICAL CARRIERS
A typical chemical carrier has normally fully segregated cargo tanks, i.e. one pump, one cargo
line and one manifold for each tank.
Cargo piping material is normally stainless steel.

Efficient stripping and cleaning of cargo pipes after discharge are normally given the highest
priority, and we therefore recommend that the cargo deck line is sloping toward the manifold as
shown in fig.1. For different arrangements, see page 6.

(R) = Remotely operated valve is recommended.

Option

nifold
to ma (R)
in
Dra Drop line
(R)

Slo
tan p
k

Slo
tan p
k

Fig. 1
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 4 of 12

3 OIL PRODUCT - AND CRUDE OIL TANKERS


Oil product and crude oil tankers usually have 2 - 6 segregations with two or more submerged
cargo pumps connected to each cargo line and manifold.
Fig. 2 shows a typical arrangement with two pumps connected to one common cargo deck line
and manifold (crossover).

Cargo pipe material may be stainless steel or coated carbon steel.


Maximum flow velocity should not exceed 6 m/s in stainless steel pipes, and 3,5 m/s in coated
pipes (or flow limits given by the coating supplier).

- Coated carbon steel pipe dimensions have to be increased compared with stainless steel to
obtain the same loading and discharge rate due to the lower flow velocity limit. Limited spool
lengths are recommended to ensure proper coating and satisfactory inspection.
- Stainless steel piping gives reduced dimensions, reduced number of flange connections,
reduced weight, and reduced volume of cargo and washing water to be drained from the
piping system. Flushing with fresh water after eventual tank cleaning with seawater is
required.

Due to the ship size and large cargo pipe- and manifold dimensions,
it is most practical to install the cargo deck lines parallel to deck.

It is recommended to install a common drain line to improve the stripping and cleaning
possibilities for the cargo lines after discharge.

Tank cleaning machine

COW/Tank cleaning line

L
/TC
C OW
Overboard line
rging
Pu
Sl
tan op
k
OIM ain
Sl Dr
tan op
k

Water
Stripping /
Heating Drain line
Oil
coils
Water

Fig. 2
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 5 of 12

An arrangement with cargo deck heaters installed is shown in fig. 3.


Cargo heaters should be located close to the drop line to reduce the heat loss.

Manifold above cargo deck lines as shown simplifies the cargo loading.
Manifold below cargo deck lines simplifies the cargo stripping, see page 6.

(R) = Remotely operated valve is recommended.

(R)
ipe
i n gp
p p
( R ) Stri
e
n lin
rai
o nd
mm
Co

Tank cleaning machine


COW/Tank cleaning line

L
TC
Overboard line W/
CO

ng
rgi
Sl Pu
tan op
k
ain
Dr
OIM Sl
tan op
k Stripping / Drain line
Water

Heating Oil
coils
Water

Fig. 3
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 6 of 12

MANIFOLDS BELOW MANIFOLDS BELOW MANIFOLDS ABOVE


DECK LINES DECK LINES DECK LINES

Deck lines aft of manifold Deck lines parallel to deck Deck lines parallel to
sloping toward manifold deck

LOADING + No cargo left in forward + No cargo left in deck + No cargo left in deck
(Even keel) deck line lines lines or
manifolds
÷ Cargo left in aft deck ÷ Cargo left in manifolds
line Drain arrangement to
be installed
÷ Cargo left in manifolds
Drain arrangement to be
installed

DISCHARGE + No cargo left in deck + No cargo left in forward ÷ Cargo left in deck
(Afterly trim) lines deck line lines

+ Reduced stripping time + Reduced cargo colum ÷ Increased stripping


left in aft deck line time
+ Reduced inert gas
consumption + Reduced inert gas ÷ Increased inert gas
consumption consumption

÷ Separate drain lines to ÷ Separate drain lines


be installed for cargo to be installed for all
lines aft of manifold deck lines
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 7 of 12

4 SELF - DRAINING
During the last years, efficient stripping of cargo tanks, pumps and its associated piping system
has been a very important part of the cargo handling operation.

General key words:


- Minimum cargo left onboard after stripping.
- Shortest possible stripping time.
- Lowest possible Air/Inert gas consumption.
- Easy cleaning.

When designing the cargo piping system, the key word is Self-Draining, both for piping and
components. Even small details may improve the drainage possibility.
The piping should be self-drained without pockets and “dead pipe ends”.
Typical examples are shown in fig.4.

Drain

Fig. 4

Separate drain lines may be used to compensate for non self-drained pipes, but this induce
more lines to be cleaned, and discharge time (time for emptying the cargo lines) will normally
increase.
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 8 of 12

Possibilities for easy draining of manifold and/or cargo deck piping to slop tanks should be
made.

Equipment such as cargo deck heaters and its piping must be self-drained to tank through the
cargo drop line as shown in fig. 3.

4.1 Cargo deck lines above manifold

For cargo deck lines sloping against the manifold,


Fig. 5 only a purging connection for blowing the cargo ashore is
required.

During discharge and stripping the ship is normally trimmed by the stern, and cargo deck lines
forward of manifold may therefore be parallel to deck.

4.2 Cargo deck lines below manifold

For cargo deck lines sloping toward the pump, separate drain
lines and drain connections must be installed.
Fig. 6
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 9 of 12

For cargo pumps forward of manifold with cargo deck lines


parallel to deck, a drain connection may be installed as shown
below.

Fig. 7

4.3 Drain arrangement for cargo manifold

To have an efficient drain of the manifold independent of the ship’s list, a separate drain line
with connection to the slop tank may be installed.

Purging connection

Purging connection

Common drain line

Drain

Fig. 8
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 10 of 12

5 CARGO PUMP STRIPPING ARRANGEMENT


Typical stripping arrangements for Framo cargo pumps are shown in fig. 9-10.

2
3
1
4
1. Cargo pipe purging connection. Supplied
separately by Framo for installation by Yard.

2. Cargo valve (Yard supply).


Butterfly or ball valve type, remotely and/or
manually operated. If the valve is manually
operated, it should have gear to control the
closing time. See section 3, chapter 4.

3. Stripping valve (Yard supply).


Ball valve type, manually operated. This valve
must be easy to operate and located close to
CARGO PIPE

the purging connection item 1.

4. Stripping pipe (Yard supply).

Fig. 9
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 11 of 12

5.1 Vacuum drain arrangement (Option)

Fig. 10

The cargo pumps may be supplied with vacuum drain


arrangement. Ref. fig. 10 and 11.

5. Vacuum drain connection


6. Evacuating arrangement
7. Vacuum valve (Yard supply)
8. Drain valve (Yard supply)
9. Purging connection
10. Vacuum pipe (Yard supply)

Valves item 7 – 9 to be manually operated ball valves.


They must be easy to operated and located close to
the purging connection item 9.

Fig. 11
Framo Mounting Instruction No. 1401-0018-4
April-2000
CARGO PIPING Page 12 of 12

6 RESILIENT MOUNTING

The Framo cargo pumps are resilient


mounted to the deck trunk, and minimum 2
of the pipe clamps close to the pump must
be of resilient type to maintain the flexibility
and to avoid vibrations being transmitted to
the deck structure. (Fig. 12).

Fig. 12

If the cargo drop line is connected close to the


OD pump as shown in fig. 13 also the drop line
. 20x must be resilient clamped. The drop line must
Min Drop line be routed to have sufficient flexibility to avoid
expansion forces being transmitted to the
pump.

The drop line outlet in tank should be as far


Cargo line
away from the pump’s suction inlet as
Resilient possible, especially for installations with cargo
pipe clamp deck heaters where the pumps are used for
circulation.

Resilient mounted

Fig. 13

Nominal Recommended 6.1 Resilient pipe clamps


diameter distance
(mm) (m) For the most common used dimensions of stainless
100 - 125 2,5 - 3,0 steel cargo pipes, recommended distance between
each flexible clamp is given in the table fig. 14.
150 - 200 3,0 - 4,0
250 - 350 4,0 - 5,0
For more details regarding installation and max.
loads, see section 17.
Fig. 14
Framo No. 1401-0019-4
Rev.C Dec-2002

Mounting Instruction

Hydraulic oils - Oil filling


Pressure testing - Flushing

CONTENTS
1 Selection of hydraulic oil
2 Cleanliness requirements
3 Leakage- and pressure testing of
piping system
3.1 Leakage testing
3.2 Safety
3.3 Pressure testing with hydraulic oil

4 Initial oil filling


4.1 Oil filling before pressure testing
4.2 Oil filling before flushing
5 Flushing
5.1 Flushing procedure
6 Oil filling of components,
circulation and venting
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 2 of 12

1 SELECTION OF HYDRAULIC OIL


Hydraulic oil is a very important part of the Framo hydraulic system and must meet the below
specification unless a different specification is received in writing from Frank Mohn AS.

GENERAL OIL SPECIFICATION


1. DIN 51524 part 2 for antiwear hydraulic oils type HLP.
2. Sperry Vickers 35VQ25 A11XX20 test (as described in Sperry Vickers form M-2952-S).
3. FZG A/8,3/90 test, load stage 10 according to DIN 51354 part 2.
4. Viscosity ISO VG 46 according to ISO 3448.
5. Viscosity index. Minimum 95 according to ISO 3448.
6. Pour point: Max. -26°C according to DIN 51597.

Note! Re-branded oil is not acceptable.

Trade names
According to present information received from the oil companies, the trade names listed below are
available world-wide and valid for ISO VG46-oils in Framo systems. Formulation of different oils is
however a continuously changing process, and it is the responsibility of each oil company to supply
hydraulic oils meeting the General Oil Specification.

COMPANY TRADE NAME

ANTAR VISGA 46 *
BARTRAN 46
BP BARTRAN HV 46 *
HYSPIN AW H-M 46 *
DTE 25
EXXONMOBIL
DTE 15 M *
RANDO OIL HD 46
FAMM
RANDO OIL HD Z 46 *
TELLUS 46
SHELL
TELLUS T 46 *

TOTAL FINA ELF VISGA 46 *

* High viscosity index oils (VI > 140) are only required for low temperature applications.

If a high V.I. oil is to be used, an oil viscosity of 50-55 cSt at 40°C must be used for initial oil filling,
if necessary by mixing with an ISO VG 68 oil. Mixing ratio to be informed by oil supplier.

If an hydraulic oil not listed above is intended to be used, Framo must be contacted for comments.

Mixing of different hydraulic oils should be avoided. If different hydraulic oils have to be mixed, the
oil companies in question must run a compatibility test and guarantee the compatibility prior to
mixing.

Note! Only hydraulic system oil must be used for flushing after installation on board.
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 3 of 12

2 CLEANLINESS REQUIREMENT
High pressure hydraulic pumps, motors and control valves have close tolerances and require clean
hydraulic oil to obtain reliability, good performance and long lifetime.

Contaminated oil will not provide satisfying lubrication and is a leading contributor to reduced
efficiency, excessive down time and increased maintenance costs.

There are three types of possible contamination in hydraulic systems:

- Solid particles Increased wear, reduced oil- and component life time, sticking valves,
unexpected system shut downs.

- Water Reduced lubrication, generating of metal particles to the


system, corrosion, reduced life time for oil and components.

- Air Pressure shocks and serious damage to hydraulic pumps, motors,


piping and other components, loss of oil and oil pollution.

The contamination may enter the system:

- During production and assembling of the system.


- During hydraulic oil filling. (New oil from supplier, refined and blended under “clean” conditions
is not clean).
- Together with the atmospheric air through air venting on the hydraulic tanks.
- By wear and tear generated within the system.
- During service.

To prevent contamination, it is important to maintain a high standard of cleanliness at all


times.

- Keep pipes and components clean and protected during the whole production- and assembling
period.
- The hydraulic oil must always be filtered by using the Framo hydraulic oil transfer unit when oil
is filled into the system from the storage tank.
- Oil filling must be done without mixing air into the oil during oil filling. It is very time-consuming
to get rid of air when it is mixed into the hydraulic oil.
- Hydraulic tanks must be vented indoor and if possible through air filters.
- Wear and tear to be prevented by checking the hydraulic oil quality and cleanliness regularly,
and by replacing filter elements when necessary.
- Keep all parts clean during service and assembling. Refill with clean oil, vent and flush carefully
after assembling.

Cleanliness level:
The required cleanliness level is based upon ISO Solid Contaminant Code ISO 4406. The code
was revised during 1999 and are now referring to 3 sizes of particles, 4 - 6 - and 14 micron(c).
(Previous code referred to 5 - and 15 micron).

A typical result according to the revised code will be 18/16/12.


Framo will only use the two last digits referring to 6- and 14 micron(c).
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 4 of 12

The highest level of particles accepted in Framo systems is code 16/12.


Recommended cleanliness level during circulation and flushing is code 15/11 or better.

When reporting a particle count, it must be reported how the particle counting has been carried out:
- According to previous ISO 4406.
- According to revised ISO 4406 (1999).
- By optical microscope.

Number of particles Particle size acc. Particle size acc.


Code
in 1 ml to previous code to 1999 revision
16 320 –640 5 micron 6 micron (c)
12 20 – 40 15 micron 14 micron (c)

15 160 – 320 5 micron 6 micron (c)


11 10 -20 15 micron 14 micron (c)

Water content
The water content must be below 300 PPM (0.03 %).

3 LEAKAGE AND PRESSURE TESTING OF PIPING SYSTEM


The hydraulic system must be pressure tested to ensure that it is correctly mounted and not
leaking.

It is recommended to carry out a leakage test of the piping system with clean nitrogen gas at low
pressure before oil filling in order to locate possible leakages in the system without causing oil spill.

For final pressure testing with hydraulic oil, Framo requires the following minimum test pressures:
- Pressure lines: According to the classification society requirement
or at least system pressure + 70 bar.
- Return lines: 11 bar

The Framo commissioning engineer must be informed in due time before pressure testing.

Note! Framo equipment is pressure tested in the factory before shipment and must be
bypassed during testing.
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 5 of 12

3.1 Leakage testing


The nitrogen gas bottles must be equipped with separate relief valves to take care of the safety.

Before testing is started, every pipe connection and fitting is to be checked, and bolts re-tightened
to assure that there are no loose connections.

Disconnected pipes and equipment must be blanked off. All blank flanges on HP pipes should have
venting plugs for air venting when pressure testing with hydraulic oil.

It is recommended to adjust and keep the nitrogen gas pressure at approximately 3 bar while every
connection on the piping system is examined by means of a soap-water mixture in order to locate
possible leakage.

Fig. 1
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 6 of 12

3.2 Safety
The hydraulic piping system is under very high pressure during testing.
Every possible action must be taken by the Yard in order to avoid damage both to man and
material.

Note! Before pressure testing is started every person not participating in the pressure
testing itself should be evacuated from exposed areas.

All access to the ship to be marked with signs, for example as shown below.

To have an overview of the hydraulic system there should be one person in charge for the pressure
testing. One person to be looking after the system in the power pack room, one in the pump room
and others on strategic places along the piping system. They must have communication equipment
enabling them to inform the person in charge if a leakage occurs.

Necessary equipment for collecting and removing of hydraulic oil must be available in case of
leakage.

Note! If hydraulic oil is leaking from the piping system during testing, the test pressure
must be set to zero. Leaking oil must be collected immediately and exposed area
cleaned.

The hydraulic oil must be drained out before any repairs are made on the piping system.

Hydraulic oil is slightly toxic, but will not cause bodily harm during normal use according to oil
companies information. However, be aware of that:
- Long lasting contact with the skin may cause skin irritation. Cover the skin or use protecting
cream when working with hydraulic oil.
- Oil into the eyes is normally not dangerous, but painful. Rinse the eye with fresh water for at
least 15 minutes.
- High concentrations of oil mist can irritate the respiratory organs.

3.3 Pressure testing with hydraulic oil


Hydraulic pipes must be pressure tested with hydraulic oil.
Water or other fluids must never be used for pressure testing.
For pressure testing of the pressure lines, a special and clean
pressure testing pump must be used.

Note! The hydraulic power unit must not be used for pressure testing.
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 7 of 12

For pressure testing of the return lines, the hydraulic oil transfer unit can be used.
Oil must not be filled into the system before the Framo commissioning engineer has inspected and
accepted the cleanliness of the piping system and the associated system- and storage tanks.
If the hydraulic oil cooler and/or main filter box have been supplied separated from the HPU, (for
closed systems only) the return line in-between must be checked very carefully before oil filling.
Initial oil filling must be carried out according to chapter 4 and in co-operation with the
Framo commissioning engineer.
It is recommended only to fill oil into the hydraulic pressure lines and start with pressure testing of
these lines. If leakages occur during the test, the oil may simply be transferred to the return side
before repair, by using the hydraulic transfer unit.

Before oil filling, check that:


- All HP service valves (ball valves) are in open position and blanked off in the open end.
- All ball valves on the snap-on coupling stations are in open position, ref. fig.1.
- The system back-up valve is closed in order to reduce the leakage over the valve to a minimum.
For pressures above 315 bar, a small leakage is normal.
- The heating and venting valve is closed. For pilot operated heating and venting valve, HP
service valve to be closed. For test pressures higher than 350 bar, HP service valve to be open
and blanked off in the open end.

After oil filling according to chapter 4, item 4.1, and proper air venting:
- Start the pressure testing pump and adjust the pressure in small steps up to approximately 70
bar. After the pressure is stabilised, hold this pressure while the complete piping system is
checked for leakage.
- Leakage control must be made by visual inspection and by monitoring irregular pressure drops.
Note that normal internal leakage in some hydraulic components might cause a certain pressure
drop during the inspection period.
- The visual inspection of the piping system should be carried out in two steps. First a quick
overview of the system to ensure that there is no major leakage, then every connection has to
be checked for leakage.
- Continue to raise the test pressure in steps up to approximately 150 bar, and check for leakage
as described above.
- Finally, the test pressure is to be adjusted in steps up to max. pressure according to the
classification society requirement or at least system pressure + 70 bar for the pressure line
(ref. page 4). Hold this pressure until the complete piping system is examined for leakage
(minimum 10 minutes or according to the classification society requirement).

When pressure testing of pressure lines is finished, continue to fill the return lines according to
item 4.1. Pressure test the return lines (ref. page 4).
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 8 of 12

4 INITIAL OIL FILLING


Oil must not be filled into the system before the Framo commissioning engineer has inspected and
accepted the cleanliness of the piping system and the associated system- and storage tanks.

Initial oil filling must be carried out in co-operation with Framo commissioning engineer.

Necessary time for oil filling and venting depends on the system size, but in spite of limited time
schedule, we must emphasise the necessity of using the time needed to fill oil and get air out of the
system by proper venting.

The oil must be filled slowly into the lowest possible connections, making it possible to fill up the
pipings gradually while the air can escape through the open venting connections on the highest
points. It is very time consuming to get rid of air when it is mixed into the hydraulic oil, and mixing
must therefore be avoided.

If possible, the ship should have aft trim if the power unit is located aft, and forward trim if it is
located forward during oil filling and venting.
Venting must be done from all the high points in components and system.
If deck machinery is connected to the system, these are normally the highest points.

Only the hydraulic oil transfer unit should be used for oil filling of the system.
Capacity is given in Technical Data.

4.1 Oil filling before pressure testing


- Fill up the storage tank.
- Prepare for pressure testing according to chapter 3.
- Open venting connections on the pressure side highest points.
- Drain off a small quantity of oil from the storage tank for visual check.
- Connect the transfer unit flexible hoses. Suction to T and supply to HP (ref. fig. 1), and
open the valves for oil filling into the HP line.
- Vent the hydraulic oil transfer unit, and check direction of rotation.
- Start the hydraulic oil transfer unit and fill oil into the high pressure line.
- Vent all pressure branch lines when the main pressure line is filled.
- When all the pressure lines are completely filled and vented, stop the transfer pump.
- Let possible air settle for at least 12 hours, then start pump for refilling and venting.
- When all air seems to be out, stop pump and disconnect flexible hoses.

Pressure test the pressure lines according to item 3.3.


When pressure lines are tested, start oil filling into the return lines.
- Open all the venting connections on the return side highest points.
- Connect the transfer unit flexible hoses. Suction to T and supply to LP (ref. fig. 1).
- Vent all return branch lines when the main return line is filled.
- When all the return lines are completely filled and vented, stop the transfer pump.
- Let possible air settle for at least 12 hours, then start pump for refilling and venting.
- When all air seems to be out, stop pump and disconnect flexible hoses.
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 9 of 12

4.2 Oil filling before flushing


All Framo components are flushed prior to shipment and need no flushing if the blanking
equipment is in good condition and kept on until final installation.

Our flushing procedure is based upon use of the Framo hydraulic power unit, and orifices must
therefore be installed in the pressure lines to ensure that the hydraulic pump pressure always is
kept above 50 bar. Required flushing flow for different return pipe dimensions are given in the
flushing diagram. The calculated flow and orifice dimensions are based upon oil viscosity
46 cSt, density 870 kg/m3, a Reynolds number of approx. 4000, orifice discharge coefficient 0,65
and pressure drop 50 bar over the orifice. For other viscosities and pipe dimensions, flow and
orifice dimensions may be calculated from the following formulas:
Required oil flow : Q = 8,7 x d x n/46 [l/min] d = Inside pipe diameter [mm]
n = Oil viscosity [cSt]
Orifice diameter : D= Q x 0,3 [mm]

Install orifices, and bypass as many components as


possible according to the flushing diagram. Orifices must
be installed so that the jet stream do not damage the
flexible hoses, refer to fig. 2.
We recommend using HP flexible hoses to avoid
collapsing due to bending. Minimum dimensions:

Fig. 2
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 10 of 12

When the pressure testing is completed and all preparations are made according to fig. 3 and the
flushing diagram, proceed as follows:

- Open the heating and venting valve and valve(s) in the main return line (Pilot operated heating
valve can be opened by plugging the pilot connection).
- Connect the transfer unit flexible hoses. Suction to T and supply to HP.
- Check storage tank oil level and start oil filling into the pressure line.
- Check storage tank oil level regularly during oil filling.
- Vent all piping and equipment not bypassed, hydraulic pumps, valves, oil cooler
and main filter box.
- Stop transfer pump when the hydraulic system tank is filled and change suction
hose from T to C for circulation.
- Circulate and vent until the oil cleanliness level is 15/11 or better.
- Stop the transfer unit and disconnect the flexible hoses. The hoses must be
disconnected when the transfer unit is not used, and the valves to be closed.

Fig. 3
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 11 of 12

5 FLUSHING
Flushing is the last and final cleaning procedure in order to remove particles that has entered the
system during installation, and to bring the cleanliness of the system oil up to an acceptable level.
All Framo components are flushed prior to shipment and need no flushing if the blanking equipment
is in good condition and kept on until final installation. Use of the Framo hydraulic power unit for
flushing has proven to be the most efficient, time saving and practical procedure to avoid
unnecessary dismantling, oil spillage and possible entrance of contamination during assembling.

It is absolutely necessary that our procedure is followed very carefully if the Framo power
unit is used for flushing. Hydraulic pumps must not run with pressure below 50 bar.

Before starting the main hydraulic pumps for flushing, the hydraulic oil in the system tank must have
cleanliness level 15/11 or better.
An oil sampling procedure is included in the Framo Service Manual.

Note! Initial oil filling and start-up of the system has to be done by the Framo service engineer.

The oil flow must be turbulent in order to remove particles from the inner surface of the pipes and
transport them to the filter. Necessary flushing capacities based upon inside pipe diameters and oil
temperatures are given in the flushing diagram.
Oil flow for each power pack is given in Technical Data for the installation.
Recommended average oil temperature during flushing is 50°C.

The flushing time depends on system size, cleanliness and piping material. Stainless steel pipes
require normally less time for flushing than mild steel pipes.
The following figures may be used as a rough estimate:
- Main lines, 1st sequence: Approx. 6 hours
- Branch lines (each): Approx. 2 hours
- Main lines, 2nd sequence: Approx. 4 hours

5.1 Flushing procedure


When all preparations have been made according to item 4.2 and initial start-up of hydraulic power
packs are finished, follow the procedure given below. System pressure to be max. 70 bar.

Main lines
- Start one power pack and run at system pressure of max. 70 bar.
- Open the heating valve (Pilot operated valve can be opened by plugging the pilot connection).
- Run for approximately 5 minutes and take oil sample.
- Stop power pack.
- If cleanliness level is above 16/12, start circulation with jockey pump (for open systems) or
feed pump (for closed systems).
- When cleanliness level is 15/11 or better, start necessary number of power packs for flushing of
main return line. System pressure max. 70 bar. Manually operated heating valve can be kept
open, but pilot operated heating to be turned off and HP service valve to be closed. Open
service valves to necessary number of branch lines to obtain sufficient oil flow.
- Check cleanliness level regularly. If level increases above 16/12, stop flushing and start
circulation to reduce number of particles.
- Fill in the Flushing report included in the Framo Commissioning Protocol.
- Flush until cleanliness level 15/11 or better.
- Check flow and temperature according to flushing diagram.
Framo Mounting Instruction No.1401-0019-4
Rev.C Dec-2002
Hydraulic oils - Oil filling - Pressure testing - Flushing Page 12 of 12

Branch lines
- Close the heating valve.
- Start necessary number of power packs for the arranged number of branch lines to be flushed
simultaneously.
- Open ball valve to the branch lines and follow the same procedure as for the main lines.
- Continue until all branch lines are flushed to cleanliness level 15/11 or better.

Main lines, 2 nd sequence


- Start necessary numbers of power packs for flushing of main return line.
- Open the heating valve and ball valve to necessary number of branch lines to obtain sufficient oil
flow.
- Flush until cleanliness level 15/11 or better.

Pilot pipes and pipes with inside diameter less than 25 mm


For these pipes turbulent flow is not obtainable due to the high pressure drop. It is therefore required
that the pipes are purged with clean nitrogen.

Other methods like “Pigging” (special plugs blown through the pipe by using a special tool) may be
used, but the results depends very much upon pipe material, quality, welding and pipe lengths.
Please contact Frank Mohn Services AS if such methods are considered to be used.

Branch pipes for dry mounted pumps and thruster motors


See separate flushing diagram.

6 OIL FILLING OF COMPONENTS, CIRCULATION AND VENTING


All by-passed components, cargo pumps etc. must be filled with oil and vented properly after
flushing to avoid air mixed into the system.

It is very important to get the air out of all components and hydraulic lines instead of having the
oil/air mixture back to hydraulic tank, hydraulic pumps etc.

Note! Oil filling has to be done slowly to let the air escape through the venting connections.

Air in the system is indicated by:


- Back flow to the hydraulic tank during stand still
- Great difference between tank level at low and high system pressure
- Foaming
- Discolorated oil

Please note that Framo is not responsible for damages caused by air in the hydraulic oil, or if the
system has been started without Framo commissioning engineer’s approval.
Framo No. 1401-0020-4
Rev. Oct-2000

Mounting Instruction

Commissioning - Testing

CONTENTS
1 General
2 Verification of design and installation procedures
3 Final Check-out and Start-up schedule
4 Final Check-out and Start-up
5 Testing
No.1401-0020-4
Framo Mounting Instruction
Rev. Oct-2000
COMMISSIONING - TESTING Page 2 of 5

1 GENERAL
The commissioning shall ensure that the delivered equipment, installation and its function are in
accordance with the Framo documentation, and to demonstrate the operational capabilities of the
system.
The time consumption for commissioning depends on ship type and size, system size, and Yard’s
progress related to other equipment and parts of the ship which will effect the various activities
related to the Framo cargo pumping system. It is also related to a correct installation according to
Framo requirements.
In general the commissioning is divided in two sequences:

1. Verification of design and installation procedures, (normally not necessary for the 2nd and the
following ships in a series if the Yard personnel responsible for the installation are the same).

2. Final check-out and start-up

2 VERIFICATION OF DESIGN AND INSTALLATION PROCEDURES


The verification part should be a coordination meeting between Yard and Framo to ensure that the
engineering and the actual installation are carried out to both parties satisfaction.
This quality assurance meeting should be held at the Yard at an early stage of the installation. The
following personnel should participate:

From Yard : Outfitting and Design personnel. (It is very important that personnel responsible for
the actual installation on board are present during this meeting).

From Framo : Project manager (Technical dept.) and Project engineer (Service dept.)

Yard and Framo should appoint suitable time for this meeting, and the verification activity should
mainly be focused on:

- Handling and storage of Framo equipment.


- Review technical documentation.
- Location and installation of Framo equipment.
- Location and installation of Yard associated equipment.
- Hydraulic- and cargo piping installation.
- Pre-inspection of installed equipment.
- Commissioning progress and schedule (to be worked out).
- Review the practical realization of the final check-out and start-up activities, requirements
for Yard assistance etc.

3 FINAL CHECK-OUT AND START-UP SCHEDULE


During check-out and start-up of the Framo Cargo Pumping System also other equipment on board
will be involved, such as auxiliary machinery and generators, cargo lines and tanks, cargo and
ballast valve systems etc.
Installation and commissioning of these systems must therefore be incorporated when planning the
various activities and time needed.
No.1401-0020-4
Framo Mounting Instruction
Rev. Oct-2000
COMMISSIONING - TESTING Page 3 of 5

Delays and waiting time caused by insufficient planning or progress of the installation leads to
additional cost for the commissioning, which again have to be covered by the buyer. An effective
verification meeting will however improve the possibilities for a smooth and effective total
commissioning within the agreed timeframe given in the Framo Acknowledgement of Order.
As a guidance for the different Framo check-out and start-up activities, a typical example of a
schedule is shown below.

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Note! If the check-out and start-up schedule made during verification meeting is revised,
Framo must be informed as soon as possible.
No.1401-0020-4
Framo Mounting Instruction
Rev. Oct-2000
COMMISSIONING - TESTING Page 4 of 5

4 FINAL CHECK-OUT AND START-UP


Please note that Frank Mohn Services AS must be informed minimum 2 weeks prior to start of the
final check-out and start-up. Also eventual revisions of the schedule must be informed.
The following assistance and services are required during the final check-out and start-up:

- Contact person at Yard responsible for the Framo Cargo Pumping System.
- Office with access to phone and fax for our service engineer.
- Labour assistance for our service engineer when required.
- Sufficient supply of electric power for running of all the installed power packs simultaneously.
- Sufficient fuel supply for running of diesel driven hydraulic power packs.
- Operational cargo lines, ballast lines and valve systems.
- Fresh water in cargo tanks.
- Compressed air or nitrogen for purging and stripping of cargo pumps.

Note! The hydraulic piping and associated hydraulic oil tanks must be approved by the
commissioning engineer prior to oil filling.
Before water is filled into the cargo tanks, the commissioning engineer must inspect
and approve the tanks related to cleanliness.

5 TESTING
Testing is to be supervised by Framo commissioning engineer and must be done according to the
classification society- and Framo requirements to fulfil the system guarantee.
It is very important that sufficient time is given for our engineer in co-operation with Yard personnel
to carry out testing, venting and adjustment of the whole system prior to official test or ship’s sea
trial.

Please note that all components delivered by Framo are pressure tested before assembly.
Hydraulic power units are tested together with the controllers, and all hydraulically driven
equipment, cargo pumps, ballast pumps and other pumps are tested and certified by the
classification society before delivery.

If possible, use fresh water for test of cargo pumps. If seawater has to be used,
see below limitations:

Recommended maximum time/temperatures - When possible, take fresh sea water in


open sea and avoid contaminated
Sea water temp. deg. C

harbour water.
40
- Empty the tanks as soon as possible
30 when the testing is finished.
- Flush the pump with fresh water.
20

10

0
0 2 4 6 8 10 12
Exposure time, days
No.1401-0020-4
Framo Mounting Instruction
Rev. Oct-2000
COMMISSIONING - TESTING Page 5 of 5

The following tests are required in order to ensure proper function of the system and to issue a
Framo Completion Certificate:

- Hydraulic piping to be pressure tested according to the classification society requirement.


Pressure piping must be tested with a minimum test pressure of “System pressure + 70
bar”. A special (and clean) pressure testing pump has to be used.
Return piping with a minimum test pressure of 11 bar. The hydraulic oil transfer unit can be
used for this test.

- Particle- and water test of the hydraulic oil.

- Acceptance test of alarms and shut down functions.

- Running of Yard equipment connected to the Framo system to ensure that no pressure
shocks are transmitted to the system.

- Running of cargo pumps, ballast pumps and other pumps.


It is recommended to do a stripping test for each cargo pump according to
Marpol 73/78 – Water test procedure.

If additional tests are required, test requirements and procedures have to be evaluated and
approved by Framo.