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Main contents
1 2 3 4 5 6 8 9 10 Yard equipment 12 Installation of deck mounted cargo heat exchangers 14 Installation of submerged tank cleaning pumps 17 Hydraulic piping 18 Cargo piping 19 Hydraulic oils - Oil filling - Flushing 20 Framo commissioning - Testing Introduction Location on board Equipment handling - Storage at yard Installation of submerged cargo pumps Installation/Storage of portable equipment Installation of submerged ballast pumps Installation of hydraulic power unit, closed loop system Installation of electrical equipment 1401-0001-401 1401-0002-401 1401-0003-401 1401-0004-401 1401-0005-401 1401-0006-401 1401-0034-4 1401-0009-401 1401-0010-401 1401-0012-401 1401-0026-4 1401-0017-401 1401-0018-401 1401-0019-401 1401-0020-401
June 2003
No. 1401-0001-4
Feb-2000
Introduction
CONTENTS
1 Framo documentation 2 Ordering new parts - Return of parts 3 Addresses
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 cooperation 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 180-230C, 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.
Documentation for yards design and installation is supplied to the yard shortly after receiving the order, and contains the following:
General recommendations and requirements for design, handling and installation of the Framo cargo pumping system.
General Arrangement Framo specification Equipment drawings Technical data System drawings
Piping specifications Layout drawings Component drawings Supplied only if hydraulic 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.
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
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 P.O. Box 10 N-5641 FUSA, Norway Telephone: Telefax: E-Mail: (47) 55 99 96 00 (47) 55 99 97 84 project.marine@framo.no
Piping Department
FRANK MOHN FLATY A/S Flaty N-5918 FREKHAUG, Norway Telephone: Telefax: E-Mail: (47) 55 99 94 00 (47) 55 99 95 84 piping.marine@framo.no
Service Department
FRANK MOHN SERVICES AS P.O. Box 44 Sltthaug N-5851 BERGEN, Norway Telephone: After 1600 hrs.: Telefax: E-Mail: (47) 55 99 92 00 (47) 90 99 00 06 (47) 55 99 93 82 service@framo.no
No. 1401-0002-4
Rev. B Dec-2001
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
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
Flexible clamp Cargo valve Stripping pipe Stripping valve Exhaust trap
Cargo pipe
Service valves Local control valve Drop line High pressure pipe Low pressure pipe Valve for drop line
C pipestack L
e Bu lkh
ad
Pipestack parallel to bulkhead
Pumps with 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.
Suction well Cargo tanks should be designed with suction wells for optimal : - Cargo pumping - Stripping - Service access For further information see section 4.
Fig. 2
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.
Generally, HPU room location is recommended as shown below. For further information, see section 8.
No. 1401-0003-4
Feb-2000
CONTENTS
1 Goods receival 2 Preservation, packing and marking 3 Handling of Framo equipment
3.1 3.2 3.3 3.4 Handling of power units Handling of submerged cargo- and ballast pumps Handling of heat exchanger Handling of portable equipment
4 Storage at yard
4.1 Storage in dry and clean conditions 4.2 Warehouse storage 4.3 Outdoor storage
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.
Address and dispatch information in addition to the listed items Case- and pallet number 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 Item details
See Framo specification * Package no., Identification no., quantity, description etc.
* Every component is marked with an item number according to the packing list.
Every case or pallet is marked with packages no. 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
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.
Fig. 2
Fig. 3
Note! Damage to pump due to incorrect lifting and handling will not be covered by Framos guarantee.
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
Max. 30
Warning !
Avoid contact
Lifting point
Softslings Length = 2m
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, sandblasting, 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.
* 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.
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.
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
No. 1401-0004-4
Feb-2000
3 Installation of deck trunk and brackets for intermediate and bottom support
3.1 3.2 3.3 3.4 3.5 Framo dummy Deck trunk Bracket for bottom support Bracket(s) for intermediate support Recommendation for welding stainless steel to carbon steel
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
(Speed Torque Controller)
The Framo hydraulically driven submerged cargo pump consists of three main parts:
Top plate
Top plate Resilient top plate connection Deck trunk
The cargo pump is supported by a deck trunk welded to the deck. A special gasket and a resilient bolt arrangement will prevent noise and 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
The pump head is welded or flanged to the pipe stack and supported by the bottom support.
The cargo tank should be designed with suction well for optimal tank emptying. It should be installed at the aft end of each tank and preferably with tank top sloping towards the suction well. Prefabricated suction well can be quoted for on request.
Suction well
Fig. 1
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 line
Drop line
C pipestack L
e Bu lkh
ad
Intermediate support
C L C L Centerline (C ) to be parallel to bulkhead where L the bracket for intermediate support is welded
Fig. 2
Min. 500
Min. 1500
Fig. 3
($&+ 12==/( )
6'
6'
6'
6'
6'
) ) 0 0 0
Too high nozzle loads will give leakage, and noise will be generated by mechanical contact between top plate and deck trunk. Nozzle loads on cargo pumps have no influence on rotating parts of the pumps.
Z MZ Y FZ MX X MY FY FX
Fig. 4
F2
F1
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.
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: L = TB + S - C
S H
Deck trunk
Approx.50-100 mm
$ N [ / $ N [ / L= S= C= A1 = A2 = H= TB =
N N
"
"
Pump length [mm] Gasket, approx. 2 mm. Pump clearance, see page 12 Intermediate support height [mm] Intermediate support height [mm] Deck trunk height [mm] * Height from bottom of suction well to top of deck trunk [mm]
L
Intermediate support
TB A2
* Standard deck trunk height, 500 mm. (High deck trunks complicate cleaning work.)
A1
Fig. 7
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.
The dummy equipment package and assembling of measuring pipe are shown on fig. 8a and 8b. For length of dummy (LD), see Framo specification.
Brackets for location of flange connections Adjustment screws for deck trunk height Support dummy
LD
Pipe no.2 (Marked with two white tape rings) Tape rings to be of equal color
Support dummy
Pipe no.1 (Marked with one white tape ring)
Distance plate
Measuring tape
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. 16. - Turn the laser on. Mark the spot where the centre of the beam hits the suction well. - 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 =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.
Mark the spots
OFF ON
Adjustment screws
Laser
Laser flange
Fig. 10
b) Position of cargo and hydraulic flange connections for the pump, see pumps dimensional drawing.
Y X
Fig. 13
Y
Suction well
Fig. 11
X
Edge parallel to bulkhead where the intermediate support bracket shall be welded Adjustment screws Position for laser Holes for measuring pipe
When connecting the top plate dummy to the deck trunk, please note: a)
Sealing surface has to be protected in order to avoid scratches.
Trunk
Deck trunk Welding seam must not be orientated in ship's transverse direction Fig. 12 Fig. 14
Adjustment nuts
Pump center
Laser beam 20
Approx. 0,5mmMeasuring pipe not to touch distance plate
Fig. 16
6 Welding
7 Checking
Ruler
Laser
After finishing the installation of the first trunk, measure the distance TB in 0O, 90O, 180O, 270O at a distance R from the center line with the supplied calibrated measuring tape.
TB PUMP SD 100 SD 125 SD 150 SD 200 SD 300 SD 350 R 115 115 115 150 175 200
90 0
180
00
Check for correct height and straightness, by using the measuring pipe and laser.
270
Fig. 17
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'
6'
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7% LV WKH PLQLPXP YDOXH RI 7% / LV WKH VSHFLILHG OHQJWK RI WKH FDUJR SXPS Gasket Ruler Approx. 2 mm
(L)
Important:
R
Install the deck trunk in correct height relative to the suction well.
L
TB
Too low clearance: - Service impossible Too high clearance: - Unacceptable cargo residue.
Fig. 18
2a SD125/150
Support dummy
Brackets
Laser beam
2b SD100/200/300/350
Support dummy
Pump center
3a SD125/150
Laser beam
Blue tape
3b SD100/200/300/350
Laser beam
Mirror Adjust brackets before welding
0O Blue tape
0O Mirror
Mark
Mark
a
90
Bolts
Bolts
90
Fig. 19
Laser beam
Measuring pipe
Bolts
Mark
3
C L C L
Pump center
Centerline C must be parallel to the bulkhead L where the intermediate support shall be welded. Fig. 20
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.
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.
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.
Connection pipe
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.
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. 23
Cargo stripping pipe -bolts -washers -nuts -seal ring Bracket Cofferdam check pipe -socket bolts -seal ring Option temp. sensor -bolts -washers -nuts -seal ring Hydraulic pipes -bolts -washers -nuts -seal rings -connection pipe -circlip Option vacuum drain -bolts -washers -nuts -seal ring Cargo pipe -bolts -washers -nuts -seal ring
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 9.2 Nm M8 22.3 Nm M10 44.2 Nm M12 76.2 Nm M16 190 Nm M20 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.
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.
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.
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 manufacturers 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 pumps 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.
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 before the pump. Tighten upper nuts and lock nuts to 174 Nm (Fig. 26). If coated surfaces on bracket for support: 1) Assemble upper nut, use 174Nm torque. 2) Retighten to specified torque. 3) Assemble lock nut, use 174Nm torque.
Support ring Framo supply Fasteners : Yard supply Material : Stainless Quality: A4-80 Flat washer Support bracket Yard supply Coating touch up Flat washer Upper nut (Torque 174 Nm) Lock nut (Torque 174 Nm)
Deck trunk
Remove the flange protection and inspect the sealing surface on the deck trunk flange. Required surface roughness is Ra 1,6 m. If the sealing surface has been damaged (scratches, grooves) during transport or installation, the damages must be removed by careful grinding/ polishing by abrasive paper.
Fig. 28
Snatch block
Lower part
Upper part
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. 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.
Gasket
Rubber bushing
Snatch block
Lower part
Upper part
Fig. 32
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. Remember: Dont remove any blank flanges.
Fig. 34
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 pumps 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.
Filling of cofferdam
- Fill the cofferdam through the headertank until the 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)
Header tank
No. 1401-0005-4
Rev. A Mar-2003
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.
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
No. 1401-0006-4
Rev.B Jan-2003
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
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 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.
Fig. 1
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.
SB300 10"
Suction
SB400 14"
Suction
SB600 18"
Suction
12"
Discharge
16"
Discharge
20"
Discharge
24"
Suction
Fig. 3
F1 [kN] 7 7 11 11
F2 [kN] 12 12 18 18
Fig. 4
Fig. 5
Supports for all ballast pumps may enter the ballast tank through standard manhole openings.
To find the pump length (L) and location of the bracket(s), following calculations have to be done:
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]
Fig. 6
Fig. 7
Fig. 8
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.
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
LD
AD1- = Intermediate support height. AD3Height from top of pump casing to lower edge of intermediate support dummy.
Fig. 11
Fig. 12
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 =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.
Fig. 13
2 Pump casing
- Place the pump casing in the center marked. - Fasten the laser to the pump casing dummy and place it on top of the pump casing. - Turn the pump casing dummy in steps of 90 until a full circle is completed as described on page 12. The collection of spots should be within a circle of = 20 mm. - 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.
- Mark the center of the pump casing. - Measure the distances from this center to the bulkhead/frames (x,y). - Use these distances (x,y) to find the center of the deck trunk in the deck. - Cut a pilot hole 250 for the deck trunk. - Calibrate the laser according page 12.
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
5 Adjustment
- Move the laser to the top plate dummy and calibrate the laser (ref. page 12). - Trunk alignment - Height adjustment - 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.
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.
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 9.2 Nm M8 22.3 Nm M10 44.2 Nm M12 76.2 Nm M16 190 Nm M20 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.
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.
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 manufacturers 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 vessels 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). Locate the sealant joint on the deck trunk flange (ref. fig. 32b).
Fig. 26
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
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
- 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.
- 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
Install the installation tool on the deck trunk (see actual tool drawing). Continue lowering until the pumps 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 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.
Fig. 35
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: Freezing point Freezing point ~ - 35C < - 40C 40-50% v. 50% glycol v. 60% glycol
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 hydraulic oil.
Fig. 37
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 SB200 SB300 SB400 SB600 Pump head 2,5 80 95 125 Pipe stack L x 0,5 L x 3,5 L x 3,5 L x 3,5 Header tank 2,5 10 10 10 Total 5 + (L x 0,5) 90 + (L x 3,5) 105 + (L x 3,5) 135+ (L x 3,5)
* Other names for ethyleneglycol: monoethyleneglycol, 1.2 ethanediol, ethanediol. Other names for propyleneglycol: monopropyleneglycol, 1.2 propanediol, propanediol.
CONTENTS 1 2 3 4 5 6 7 8 9 General Arrangement Service space and lifting arrangement Ventilation and heat dissipation Foundation and mounting Cooling arrangement Cable/starter cabinet for electric equipment Starting system for diesel engines Fuel system
10 Exhaust
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.
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.
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.
Please note that the required dimensions for service space shown in the dimensional drawings are absolutely minimum.
Fig. 4 Service space
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: Diesel engine: 2000 kg 2500 kg Hydraulic pump (single): 400 kg Hydraulic oil cooler:1400 kg
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 = 10C.
Example: 3 x Diesel engines 400 kW 2 x Electric motors 400 kW Total 1200 kW Total 800 kW Total : 9 m3/s : 4 m3/s : 13 m3/s
Electric motors
Diesel engines with water cooled manifold. Cooling and combustion air
10
15
20
25
Fig. 7
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.
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. 12
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.
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.
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.
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.
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.
Fig. 17
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
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.
No. 1401-0009-4
Apr-2000
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 vessels integrated control system 6 Preservation
No.1401-0009-4
Apr-2000
Page 2 of 6
View A-A
Deck
No.1401-0009-4
Apr-2000
Page 3 of 6
When operators panels are delivered for installation in yards 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 sufficient rating and breaking capacity for protection of the motor circuit. Effort should be made to obtain optimal setting of the short circuit protection. The setting shall be as low as possible without interfering with the starting current.
No.1401-0009-4
Apr-2000
Page 4 of 6
K3
K2
K3
~M
K1
~M
K2
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.
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.
No.1401-0009-4
Apr-2000
Page 5 of 6
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.
El. connector P R P R
To return line
No.1401-0009-4
Apr-2000
Page 6 of 6
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. 1
Fig. 2
No. 1401-0010-4
Rev.B Nov-2002
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.
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.
Fig. 1 Hydraulic oil storage tank and clean oil drain tank
Storage volume depends on the ships operating trade area (easy or difficult supply of hydraulic oil) and owners 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 suppliers 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.
Cargo pipe diameter (mm) 100 150 151 200 201 250 251 400 > 400
No. 1401-0012-4
Rev.C May-2003
CONTENTS
1 General 2 Arrangement
2.1 Nozzle loads 2.2 Service space and lifting arrangement
3 Installation
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
Relief valve
Flat gasket
Channel section
Fig. 1
The heater must be protective covered against weld spatter, sandblasting during installation/ building period. 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 manufacturers procedure for pickling before starting the work.
Fig. 2
2 ARRANGEMENT
The cargo heater should be located close to the drop line. The following figures give examples of optimal piping layout.
HE 225/ 750 HE 500/ 1000
Cargo line Cargo valve Bend for expansion Fixed clamps Service spool
Service spool
HE 400/ 1000
Cargo valve
Service valves Drain Relief valve Thermostatic valveNotice the following to get a proper installation: - 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. Service spools Cargo valve Drop line
- 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. - The Framo cargo heater should be installed where it is protected from sea that breaks over the ship.
Fig. 3
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
HE500/ 400/10001000
Fig. 4
HE
HE500/ 400/10001000
FX [N] FY[N] HE500 Condensate outlet, F1 HE400/500 Cargo inlet/outlet, F2 HE400 steam inlet, F3 HE500 steam inlet, F4 HE225/400 Condensate outlet, F5 HE225 Cargo inlet/outlet, F6 HE225 steam inlet, F7 350 2500 525 900 220 1400 350 450 3000 650 1100 280 1800 450
Forces and moments FR[N] MX[Nm] MY[Nm] 650 4350 950 1600 400 2500 650 75 2300 225 700 50 1300 75 50 1200 225 350 30 700 50
HE400/1000
FZ MZ MY FY
F2
MX
FX
FZ
FZ MZ MY
F1
MZ MY MX FY
HE500/1000
FY
F2 F3
FZ MZ MX FX MY FY
FX
HE250/750
MX FX
FZ MZ MY FY FY FZ MZ MY FY MY MX FY
FZ
MZ FX MX FZ
FZ MZ MY
F5
FY
F6
MZ
FZ MX
MX FX
FX
F2
F4 F1
F2
MZ
FZ MX FX MZ MY FY MX FX
FZ MZ MY MX
FX
F7 F6
MY FY
FX
MY
FY
MX
FX
Fig. 6
4000
Sloping dec
Max. 500
2100
2500
Fig. 7
If other lifting equipment is to be used, note the weigths of the heater components in table below:
HE225/750 55 kg 175 kg
HE400/1000 70 kg 340 kg
3 INSTALLATION
1
Install the heater on the foundation.
Bolts and nuts in stainless steel Not Framo supply Relief valve Foundation Yard supply
Gasket
Thermostatic valve
Fig. 8 Note! The cargo flanges on the HE500/1000 is marked with Cargo inlet and Cargo outlet. It is important to check the labelling on the flanges for correct installation. Fig. 9
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 Pipes to be supported to avoid excessive load transferred to the heater connection. Adjust during intallation
Fig. 10
No. 1401-0026-4
Feb-2003
CONTENTS
1 General 2 Arrangement and orientation in tank
2.1 2.2 2.3 Arrangement on top plate Nozzle loads Location of brackets for intermediate support(s)
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).
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
Fig. 2
EACH NOZZLE
Fx Fy Fz Mx My Mz
FORCES/MOMENT (approx. 2 x API 610) SD100-W5 SD125-W5 SD150-W5 2,94,05,0 3,6 2,4 2,7 2,0 1,4 4,9 3,3 3,7 2,8 1,9 Fig. 4 6,3 4,1 4,6 3,6 2,4
MX X FY
Nozzle forces and moments on the tank cleaning pump have 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.
F1 (kN) 11 14 17
F2(kN) 20 23 26
Fig. 5
Fig. 6
All welding of deck trunk has to be finished before installation of the brackets.
L = TB + S
L = Pump length [mm] S = Gasket, approx. 2 mm. P = Bottom support height [mm]. (See dimensional drawing) A1 = Intermediate support height [mm] A2 = Intermediate support height [mm] H = Deck trunk height [mm] * TB = Height from lower point of flexible bellow to top of deck trunk [mm] * Standard deck trunk height, 500 mm.
Two intermediate supports Height [mm] A1= k2 x L A2= k3 x L Factors k2 k3 0.25 k2 0.3 0.55 k3 0.6 Final figures (A1, A2 and L) to be sent to Framo as soon as possible.
Fig. 7
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.
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 =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.
Fig. 11
Fig. 14
Fig. 12
Fig. 13
Fig. 15
Fig. 16
Fig. 17
Fig. 18
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.
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.
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! 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. 21
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 9.2 Nm M8 22.3 Nm M10 44.2 Nm M12 76.2 Nm M16 190 Nm M20 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.
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.
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.
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 manufacturers 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 vessels piping systems. By then the piping system has to be inspected for foreign bodies and cleaned. The blank flange/protection cover on the pumps 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 m. If the sealing surface has been damaged (scratches, grooves) during transport or installation, the damages must be removed by careful grinding/polishing by abrasive paper.
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 pumps 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 remaining rubber bushings and bolts. Tighten bolts to 44 Nm.
Fig. 28
Gasket
Note! Dont remove any blank flanges on the top plate and flexible bellow before final piping connections.
Rubber bushing
Fig. 29
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 lifting tool.
Fig. 30
Fig. 31
Lift the assembled section and remove the securing tool. Lower the pump as described in chapter 6.1.
Fig. 32
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 Freezing point ~ - 35C Freezing point < - 40C Volumetric expansion : : 40-50% v. 50% glycol v. 60% glycol
- 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:
Fig. 33
* Other names for ethyleneglycol: monoethyleneglycol, 1.2 ethanediol, ethanediol. Other names for propyleneglycol: monopropyleneglycol, 1.2 propanediol, propanediol.
No. 1401-0017-4
Rev. A Sep-2002
CONTENTS
1 Design
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 Optimum hydraulic pipe layout General requirements Detail design Branch lines Critical length of branch lines Service spools Optimal layout between engine room and deck Noise reduction Pipe qualities and sizes Flanges and connections Expansion loops Venting of pipes Pilot pipes
Installation onboard
3.1 General requirements 3.2 Tightening torques for bolts
Fig. 1
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
Documentation: All material used must comply with classification society rules, regarding material certificates and production documentation.
ACCEPTABLE Fig. 4
Fig .7 Example: Pipe OD65 with branch length approx. 5m. L-U must be minimum 1.2 m. Note! If required, flexibility- and stress analysis must be provided.
OD 100, L=15 m
300
OD 54-65, L=15 m
150
OD 38-45, L=15 m
100
<OD100, L=5m
50 0.5
1.5
2.5
3.5
4.5
1.2
L-U (m)
0 350
Duplex
Fig. 8
Fig. 9
300
300
200
200
150
OD 38-45, L=15 m
150
OD 54-60,
L=15 m L=15 m
100
OD 35-45,
100
1.5
2.5
3.5
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=50C (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 (-)
Critical pipe length for H.P. branch lines for KRITISKE SD (SB) pumps.FramoSTIKKRRSLENGDER FOR FRAMO SD(SB) PUMPER , BASERT P
SIMULERING
40
35
SD125-150 SB200-300
30
SD200 + SB400
Example: SD 100, pump length 18 m. Max. length of branch line = 13 m. Note ! If branch line exceeds limitations given in this table, pipe size to be increased by 2 step up to service valve (ball valve). Please contact Framo for verification.
25 PUMPELENGDE I METER
15
10
Fig. 10
Fig. 11
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.
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. 3. 4. 5. Note!
Check acceptable load for resilient pipe clamps. Angle bar with resilient pipe clamp must be spot welded to pipe support. 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. Welding of bracket to be completed. 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: All hydraulic lines, except pilot lines on deck Cargo line Drop line Stripping line Cooling water (HPU) Fuel connection (HPU) Exhaust connection (HPU) Requirement: Distance between clamps, see table page 9 Minimum 2 pcs close to pump If clamp is required If clamp is required Flexible bellow Flexible hose Flexible bellow
Fig. 18
OD PIPE
F+0 (mm) - 2
OD PIPE
F+0 (mm) - 2
25,0 28,0 30,0 33,4 35,0 38,0 42,0 44,5 45,0 48,3 54,0 60,3 65,0 76,1 80,0 84,0 88,9 90,0 100,0 106,0
6 12 12 20 20 10 16 20 20 24 33 29 36 51 37 42 50 50 63 44
1.2 1.2 1.2 1.2 1.2 1.4 1.4 1.4 1.4 1.4 1.4 1.5 1.5 1.5 2.3 2.3 2.3 2.3 2.3 3.0
1.4 1.8 1.4 1.8 1.4 1.8 1.4 1.8 1.4 1.8 1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0 2.0 2.5 2.0 2.5 2.0 2.5 2.0 2.5 2.0 2.5 2.5 3.0 2.5 3.0 2.5 3.0 2.5 3.0
114,3 120,0 130,0 131,0 139,8 156,0 165,2 168,3 206,0 216,3 219,1 256,0 267,4 273,0 307,0 318,5 323,9 357,0 406,4
3.0 3.0 3.0 3.0 5.0 5.0 5.0 5.0 6.0 6.0 6.0 8.0 8.0 8.0 8.0 12.0 12.0 12.0 12.0
2.5 3.0 3.0 3.5 3.0 3.5 2.5 3.0 2.5 3.0 3.0 3.8 3.0 3.8 3.0 3.8 3.0 4.0 3.0 4.0 3.0 4.0 4.0 5.0 4.0 5.0 4.0 5.0 4.0 5.0 4.0 5.0 4.0 5.0 4.0 5.0 4.0 5.0
Guidelines for attachments to stiffeners (pipe supports) Sufficient stiffness of pipe supports must be considered.
NOT ACCEPTABLE
Fig. 19
A0-bulkhead
Fig. 20
A60-bulkhead
Fig. 21
Fig. 22
Trunk dim. OD 168,3 200 219,1 290 290 HP, DN100/110 355,6 406,4
B 58 69 69 103 123 83 84
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. 237. 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.
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.
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.
Pipes indoor
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 Framos 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 Carbon steel / Stainless steel
DN DN 15 DN 20 DN 25 DN 30 DN 35 DN 40 DN 50 DN 60 DN 70 DN 80 DN100 DN110 OD x thickness CS / SS 18 x 2,5 / 1,5 25 x 3,0 / 2,5 30 x 4,0 / 2,5 38 x 5,0 / 3,5 45 x 5,0 / 4,0 54 x 6,0 / 5,0 65 x 7,0 / 6,0 80 x 10,0 / 7,0 90 x 10,0 / 8,0 100 x 10,0 / 9,0 120 x 12,0 / 10,0 130 x 13,0 / 11,0
Low pressure:
Flat gasket O-ring Flat gasket Fillet weld
Slip-on PN16
Fig. 35
Note!
Weldoflange
Threadolet
Threaded socket
Weldoflange
Fig. 36
Fig. 37
Butt welding of pipes without access to inspect internal weld seams regarding cleanliness is not acceptable in Framo hydraulic piping system.
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
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 T L = Length of pipe = Thermal expansion coefficient T = Temperature difference in C (Max. oil temp. 60C) Material St. 52 316L Duplex
LOOP DETAILS:
Max L (mm) 14 17 22 25 20 19
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
Indoor
Deck
400 Remote control Valve block Framo supply Fixed bulkhead penetration Use flanges for pipe to pipe joint
Fig. 46
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
Fig. 48
A min
D max
+ D min
Fig. 49
= = = = = =
Minimum distance between two bends acc. to bending machine used. Minimum length after bending (tool clamping). Minimum diameter after bending. Maximum diameter after bending. Bending radius, ref. class requirements. Minimum required wall thickness after bending.
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.
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
Fig. 50
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)
Framo flanges Nom. dia.MD (m) (mm)min. 30 40 50 60 70 80 90 100 110 2.0 2.0 2.0 2.0 2.5 2.5 2.5 3.0 3.0
HP Axial gap (mm) max. 0,9 0,9 1,0 1,1 1,6 1,7 1,8 1,9 2,0
LP Axial gap (mm) max. 0,20 0,20 0,25 0,30 0,35 0,40 -
Fig. 54
Calculation is based on: 1. Minimum pipe support distance MD 2. Bolt quality grade 8,8 or A4-80 Stainless steel
X-RAY MPI/DPI FOR HIGH PRESSURE PIPES: MPI (Magnetic Particle Inspection)= Carbon steel DPI (Dye Penetrant Inspection) = Stainless steel High pressure pipes: Type of weld Butt weld Butt weld Fillet weld Fillet weld NDT x-ray x-ray MPI/DPI MPI/DPI Pipe dim. OD 76.1 > OD 76.1 OD 76.1 > OD 76.1 Extent 10 % 100 % 10 % 100 %
PRESSURE TESTING ONBOARD After installation onboard the piping system must be pressure tested according to class requirement and acceptance. Hydraulic system oil must be used.
2.7
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 sandblasting and priming pipes must be cleaned inside. Remove all blank flanges before cleaning. If required, pipe to be honed inside by grinding stone.
After honing pipe must be cleaned. Fig. 56
Cleaning medium: Fresh water with corrosion inhibitor. Proposal: Dyno PK6050 or equal. Recommended temperature: 80C 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 Bath temperature Time : 10 - 18% (by volume) : 20 - 25C : 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 - 25C for about 5 minutes.
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
Fig. 57
Use pickling paste in welding zone (or corroded areas), and follow makers instruction. Avesta Beizpasta 101 or equal.
Proposal:
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 - 80C 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.
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.
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
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.
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
6. Resilient mounting
6.1 Resilient pipe clamps
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 FSOPs and OBOs. 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 owners 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.
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.
Fig. 1
Overboard line
Sl tan op k
i ng urg P ain Dr
Oil Water
Fig. 2
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.
e lin n
Overboard line
Slo tan p k
OIM
Sl tan op k
Water
Heating coils
Oil Water
Fig. 3
MANIFOLDS BELOW DECK LINES Deck lines aft of manifold sloping toward manifold LOADING (Even keel)
+ No cargo left in forward deck line Cargo left in aft deck line Cargo left in manifolds Drain arrangement to be installed
No cargo left in deck lines Cargo left in manifolds Drain arrangement to be installed
DISCHARGE + No cargo left in deck (Afterly trim)lines + + Reduced stripping time Reduced inert gas consumption
No cargo left in forward deck line Reduced cargo colum left in aft deck line Reduced inert gas consumption Separate drain lines to be installed for cargo lines aft of manifold
Increased stripping time Increased inert gas consumption Separate drain lines to be installed for all deck lines
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.
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.
Fig. 5
For cargo deck lines sloping against the manifold, 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.
For cargo deck lines sloping toward the pump, separate drain lines and drain connections must be installed. Fig. 6
For cargo pumps forward of manifold with cargo deck lines parallel to deck, a drain connection may be installed as shown below.
Fig. 7
Purging connection
Drain
Fig. 8
2 3 1 4
1.
Cargo pipe purging connection. Supplied separately by Framo for installation by Yard. 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. Stripping valve (Yard supply). Ball valve type, manually operated. This valve must be easy to operate and located close to the purging connection item 1. Stripping pipe (Yard supply).
2.
3.
CARGO PIPE
4.
Fig. 9
5.1
Fig. 10
The cargo pumps may be supplied with vacuum drain arrangement. Ref. fig. 10 and 11. 5. 6. 7. 8. 9. 10. Vacuum drain connection Evacuating arrangement Vacuum valve (Yard supply) Drain valve (Yard supply) Purging connection 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
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
D 0xO .2
Min
Drop line
If the cargo drop line is connected close to the pump as shown in fig. 13 also the drop line must be resilient clamped. The drop line must 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 away from the pumps suction inlet as possible, especially for installations with cargo deck heaters where the pumps are used for circulation.
Fig. 13
Nominal Recommended diameterdistance (mm)(m) 100 - 1252,5 - 3,0 150 - 2003,0 - 4,0 250 - 3504,0 - 5,0
Fig. 14
No. 1401-0019-4
Rev.C Dec-2002
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
5 Flushing
5.1 Flushing procedure
Framo Mounting Instruction Hydraulic oils - Oil filling - Pressure testing - Flushing
GENERAL OIL SPECIFICATION 1. 2. 3. 4. 5. 6. DIN 51524 part 2 for antiwear hydraulic oils type HLP. Sperry Vickers 35VQ25 A11XX20 test (as described in Sperry Vickers form M-2952-S). FZG A/8,3/90 test, load stage 10 according to DIN 51354 part 2. Viscosity ISO VG 46 according to ISO 3448. Viscosity index. Minimum 95 according to ISO 3448. Pour point: Max. -26C according to DIN 51597.
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 VISGA 46 * BARTRAN 46 BARTRAN HV 46 * HYSPIN AW H-M 46 * DTE 25 DTE 15 M * RANDO OIL HD 46 RANDO OIL HD Z 46 * TELLUS 46 TELLUS T 46 *
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 40C 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 Hydraulic oils - Oil filling - Pressure testing - Flushing
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. Reduced lubrication, generating of metal particles to the system, corrosion, reduced life time for oil and components. Pressure shocks and serious damage to hydraulic pumps, motors, piping and other components, loss of oil and oil pollution.
- Water
- Air
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 Hydraulic oils - Oil filling - Pressure testing - Flushing
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 in 1 ml 320 640 12 20 40 Particle size acc. to previous code 5 micron 15 micron Particle size acc. to 1999 revision 6 micron (c) 14 micron (c)
Code 16
15 11
5 micron 15 micron
Water content
The water content must be below 300 PPM (0.03 %).
Framo Mounting Instruction Hydraulic oils - Oil filling - Pressure testing - Flushing
Fig. 1
Framo Mounting Instruction Hydraulic oils - Oil filling - Pressure testing - Flushing
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.
Framo Mounting Instruction Hydraulic oils - Oil filling - Pressure testing - Flushing
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.
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 Hydraulic oils - Oil filling - Pressure testing - Flushing
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 Hydraulic oils - Oil filling - Pressure testing - Flushing
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 Hydraulic oils - Oil filling - Pressure testing - Flushing
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 Hydraulic oils - Oil filling - Pressure testing - Flushing
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 50C. 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: - Branch lines (each): - Main lines, 2nd sequence: Approx. 6 hours Approx. 2 hours Approx. 4 hours
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 Hydraulic oils - Oil filling - Pressure testing - Flushing
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.
No. 1401-0020-4
Rev. Oct-2000
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
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 Yards 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
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.
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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.
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 ships 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:
- When possible, take fresh sea water in open sea and avoid contaminated harbour water. - Empty the tanks as soon as possible when the testing is finished. - Flush the pump with fresh water.