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No. 1000-0134-4
Rev. A: 01Jul04
Operation manual
SB200
SB300
SB400
SB600
No.
Date/sign.:
Page:
Rev. A:
1000-0134-4
Sept-2000
2 of 13
01Jul04/AGAa
CONTENTS
1
1 GENERAL DESCRIPTION
The Framo hydraulically driven submerged ballast pump consists of five main parts:
- Pump casing/ air separator
- Pump head
- Pipe stack
- Top plate/Control valves
- Evacuating system
Figures in this procedure are made general for all types of submerged ballast pumps. For further
information, see drawings for the actual ballast pump.
Pump head
The pump head includes the hydraulic motor, impeller and sealing arrangement. A cofferdam
completely segregates the hydraulic oil from the ballast water. The cofferdam is filled with
water/glycol.
Pipe stack
The pipe stack consists of a hydraulic section and an arrangement with pipe and cable for the
evacuating system.
Supports on the pipe stack prevent horizontal movement and allow for vertical expansion.
No.
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Rev. A:
1000-0134-4
Sept-2000
3 of 13
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Header tank
Evacuating control
system cable
Cofferdam connection
Pilot line
Compr. air
LP
HP
Thermal expansion
Evacuating control unit
HP service valve
Manometer
Filter/water trap
(Yard supply)
Top plate
Resilient
top plate connection
Local control valve
Bellow
Radial support
Anodes
Intermediate
support
Pipe stack
Cofferdam pipe
Anodes
Suction line
Pump head
Anode
Level switch
Discharge
line
Pump casing/
air separator
Anode
Fig. 1
No.
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Rev. A:
1000-0134-4
Sept-2000
4 of 13
01Jul04/AGAa
Evacuating system
The air separator is integrated in the
pump casing. The pump casing is
equipped with a level switch for
automatic start and stop of the
evacuating system.
When there is air in the pump casing
the level switch will be in the low level
position. The ejector will start
evacuating the pump casing and suction
piping (priming on).
When the water level again reach the
high level position, the ejector will stop.
Illuminated lamp
PLC
PRIMING
Evacuating
control unit
WBP
300
225
Filter/
water trap
150
Compr. air
75
0
BAR
ON
Ejector
Suction line
Level switch
Discharge
line
Fig. 2
-8
Vacuum (mwc)
-6
0
B4
0/
0
60
2
SB
30 0
00/
Volume 1 m3
-4
-2
20
40
60
80
Time (seconds)
100
120
140
No.
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Rev. A:
1000-0134-4
Sept-2000
5 of 13
01Jul04/AGAa
OPERATING INFORMATION
Hydr. motor
Valve, closed =
Valve, open =
Suction
WBP
Discharge
Bypass
Starting of pump
Open ballast pump suction valve.
Start the pump slowly, and let it run
with hydraulic motor pressure 50 bar
for approx. 1 minute.
Hydr. motor
PRIMING
WBP
300
Suction
WBP
Discharge
225
150
75
0
BAR
ON
Bypass
Start
Fig. 5
Hydr. motor
PRIMING
WBP
300
Suction
WBP
Discharge
Note!
Avoid running pumps against closed
discharge valve for a longer period.
225
150
75
0
BAR
Bypass
Fig. 6
ON
No.
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Rev. A:
1000-0134-4
Sept-2000
6 of 13
01Jul04/AGAa
Pumping
The ballast pump is designed
to operate with discharge
head between 20 and 30 mlc
(design head).
a)
b)
Fig. 7
Limit of operation
100% m
otor p
ress
ure
75%
Head H
50% OPERATION
RANGE
Pressure loss,
throttle discharge valve
Pressure loss
discharge system
Capacity Q
Fig. 8
Note! Performance diagram for the actual pump gives the operation range
End of deballasting
With low water level in the ballast tank the pump capacity must be reduced to avoid loss of suction.
An gradually increasing amount of air will enter the pump suction line via the vortex forming at the
suction bell mouth. Air will accumulate in the pump casing (air separator) and the evacuating system
will eventually be activated priming light in control panel switched on.
The pump capacity must be reduced to match the water inflow to the suction bell mouth area (the
inflow is depending of the tank layout, opening in stiffeners etc.). This is most critical when emptying
a ballast tank furthest away from the pump, especially when pumping from ballast tanks located aft of
the pump when the ship is in aft trim condition.
For some systems the hydraulic motor
pressure will automatically be reduced to
balance the capacity of pump against
supply to the suction line.
ON
Vortex
Stiffeners
No.
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Rev. A:
1000-0134-4
Sept-2000
7 of 13
01Jul04/AGAa
Reduced hydr.
motor pressure
PRIMING
WBP
300
225
150
75
Note!
Do not run the pump unnecessary when
the pump lose suction.
0
BAR
ON
Stop
Air
Fig. 10
PRIMING
WBP
300
Handle in
maximum
position
225
150
75
0
BAR
ON
Fig. 11
Local control
valve, OPEN
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Rev. A:
1000-0134-4
Sept-2000
8 of 13
01Jul04/AGAa
Cofferdam liquid
Open
Max level
Header
tank
Fill
glycol water
Service hole
Corrosion inhibitor:
0.9%
(Rocor NB Liquid or equal) (initial dosing)
Other types of corrosion inhibitors for cooling water
systems can also be used. The corrosion inhibitor
must be compatible with glycol. The mix ratio and
the use of the corrosion inhibitor must be according
to the suppliers data sheets, as this can vary for the
different types available.
Demineralised water:
40-50%
v. 50% glycol
v. 60% glycol
Hose
Drain tool
Volumetric
expansion : 0 - 60C ~ 63.5 x 10-5 litre/litreC
Drain
plug
Connection
to cofferdam
Topping up cofferdam:
Fig. 12
If required, top up the header tank until liquid level is at normal level (see fig. 13).
No.
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The cofferdam volume depends on pump type and pump length. The following formulas give approx.
volume (in litres) required to fill cofferdam to high level mark in header tank:
Pump type
Pump head
Pipe stack
Header tank
SB200
2,5
L x 0,5
2,5
SB300
80
L x 3,5
12
SB400
95
L x 3,5
12
SB600
125
L x 3,5
12
L = Pump length in metres. (See Framo specification)
Total
5 + (L x 0,5)
92 + (L x 3,5)
107 + (L x 3,5)
137 + (L x 3,5)
Max.
Normal
level variations
Min.
Refill and
log volume
Fig. 13
When pump is running the normal leakage rate for mechanical seals can be up to 2-5 ml per hour,
but leakage up to 20 ml per hour is acceptable.
Enclosed (page 13) is a log form that can be used as a help to monitor the condition of the seal
system.
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Sept-2000
10 of 13
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Draining of cofferdam
Draining of cofferdam shall be done by
using special draining tools from Framo
toolbox:
Draining of pipe stack:
Pump head
Fig. 14
Connect a hose
from drain tool to
a recovery tank.
Connect pressurized
air to pump head.
Air
Fig. 15
3 MAINTENANCE INFORMATION
Prior to entering a ballast tank for doing service it is essential to become familiar with the ship's
safety rules and requirements regarding cargo-handling equipment. Do not enter a ballast tank
before the tank is confirmed gas free.
Before doing service on pump, always close and lock the HP service valve.
Close the ballast valves (suction line and discharge line). Ensure that the valves are in closed
position until the work/service is finished (info sign to be placed on the control panel/computer).
Before starting to dismantle impeller, wear rings etc.,make sure that pipe stack/ pump head is
secured properly in order not to drop down when work is in progress.
Note! To prevent contamination and hazardous situations it is important to avoid oil spill during
maintenance and repair work. Drain in accordance with procedures ( Instruction for
maintenance and repair for actual pump).
The operator should be confident that all flange connections are in satisfactory condition so as to
prevent hydraulic oil and cargo spills.
After any work has been carried out in the ballast tank, always check that the tank is free for foreign
objects.
No.
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Rev. A:
1000-0134-4
Sept-2000
11 of 13
01Jul04/AGAa
TROUBLE SHOOTING
Symptom:
Possible reason:
Remedy: *)
General
Symptom:
Dropping level in header
tank. (See also chapt. 2.2)
Possible reason:
General
Note!
Always pressure test pump
prior to and after
dismantling. This is required
to locate possible leakage
and to confirm no leakage
upon completion of repair.
No.
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Rev. A:
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12 of 13
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Remedy: *)
Pressure test pump cofferdam system at approx.
3 bar.
Check for leakage if required spray with soapy
water to locate the leakage.
Note!
For inspection of pump head / shaft seal it is
required to lift pump out of pump casing prior to
pressure test.
c) Crack in piping
c) Crack in piping
Note!
Evaluate if changed parts as sleeves, mechanical seals etc. are possible to recondition.
Send these parts to Framo Service Station and ask for an evaluation.
No. 1000-0134-4
Page 13 of 13
LOG FORM FOR LIQUID FILLED COFFERDAM ON FRAMO SUBMERGED BALLAST PUMPS
VESSEL NAME: ____________________________________ TYPE OF LIQUID USED IN COFFERDAM: __________________________________
Header tank level to be measured in mm above low level mark on sight glass. 10 mm on sight glass is equivalent to: For SB200: 0,12 litres volume.
For SB300/400/600: 0,36 litres volume.
Pump Date and
location
year
Header
tank level
(mm)
Ballast water
temperature
(C)
Hydraulic oil
temperature
(C)
Ambient
temperature
(C)
Hours of operation
since last control
Signature / Date