Académique Documents
Professionnel Documents
Culture Documents
No.: 49564-10E
2) Pump Specification
3) Performance curve
5) Instruction manual
7) Special Tools
8) Motor Specification
9)
CUSTOMER:
PUMP
Acceptance tolerances for pump performance as per ISO 9906-2
Application ............................................. : Cargo pumps
Type ....................................................... : DL 132d/100
Capacity ................................................. : 300 m3/h
Total head ............................................... : 120 m l.c.
Closing pressure ..................................... : 135 m l.c.
Speed ...................................................... : 2920 r.p.m.
Efficiency ............................................... : 73%
Power required ....................................... : 108 kW
Liquid ..................................................... : Chemicals, oil products
Specific gravity ...................................... : 0.8
Viscosity ................................................ : 1 cSt.
Speed, max. ............................................ : 3000 r.p.m.
Flange norm ........................................... : DIN 2632
Pressure stage ......................................... : 16
Weight .................................................... : 820 kgs
Pump length ........................................... : 8388 mm
Shaft dia. ................................................ : 40 mm
Serial No. ............................................... : 46435, 46436, 46437, 46438 (004740-WC-50)
Serial No. ............................................... : 46439, 46440, 46441, 46442, 46443 (004741-WC-50)
Serial No.............................................: 46458(Spare pump head)
Impeller drawing No. ............................. : 12248-01
Impeller dia. actual / max. ...................... : 320 / 320 mm
Paint ....................................................... : Svanehøj standard RAL 3009
ELECTRIC MOTOR
Make / type ............................................ : Client supply, Loher / DNSW 315 MB04
PUMP DOCUMENTS
Dimensional drawing ............................. : 36452-00/01, 49128-15/25, 36464-10/11
Dimensional drawing ............................. : 32695-55
Curve ...................................................... : 100241-00/01/02
Sectional drawing ................................... : 12174-20, 24047-63, 12208-44, 24048-91
Sectional drawing ................................... : 35259-23 (sect. 7)
Parts list .................................................. : 004740-WC-50, 004741-WC-50
Parts list .................................................. : 351932
Instruction .............................................. : 49564-10E
Class certificate ...................................... : LR
Hamworthy Svanehøj A/S
PO Box 30, Fabriksparken 6
DK-9230 Svenstrup J, Denmark
Tel +45 96 37 22 00
Fax +45 98 38 31 56
Email svanehoj@hamworthy.dk
DOCUMENTS, LANGUAGE/QTY.
Documents for approval by client .......... : E/4 incl. pdf
Final instruction manuals for client ....... : E/4 incl. pdf
Final instruction manuals for Svanehøj .. : E/1 incl. pdf
Final instruction manuals for ................. : Hamworthy BV, E/1 incl. pdf
Final instruction manuals for ................. : Hamworthy FE, E/1 incl. pdf
CLASS INFO
Name of vessel ....................................... : Nordic Marianne
Pressure testing base flange ................... : 1 bar
Pressure testing discharge flange/pipe ... : 16 bar
Pressure testing stripping flange ............ : 10 bar
Pressure testing pump cylinder .............. : 16 bar
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Note: Lifting instruction, if any, is attached to the pipe stack near the base and included in section 6.
Figure 1 Horizontal lift of standard pump, e.g. from truck to storage at yard.
Lifting:
Crane No. 1 must start lifting 50-300 mm
before crane No. 2 Travelling trolley
Lowering:
Crane No. 2 must lower down to support
at base before crane No. 1
Figure 3
For transportation on telescopic trailer the supports are adjusted to the construction of the trailer.
Storage:
In general it is recommended that all the equipment is stored in-door. Activities such as welding, grinding,
sandblasting or painting must not take place in the same area.
The minimum requirement for storage of equipment is stated below.
Warehouse storage
Dry and clean
No corroding or aggressive atmosphere
No dripping water
The components are typically electric motors, power pack units, portable pumps, flexible hoses, mild steel
domes, partial pumps with remaining parts, mounting parts supplied in a box, and box with special tools.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Outdoor storage
Protected with tarpaulin from rain and dust.
The components are typically cargo pumps, submerged ballast pumps, stainless steel pipes, stainless
domes and pump supports.
Note: Stainless steel may corrode if surface is polluted with dust or particles from welding, grinding,
salt water etc.
If the above is observed, the pumps can be stored for 6 months. For longer time storage, contact
Hamworthy Svanehøj A/S for instruction.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Alignment
Before installing the pump in the tank it is to be ensured that the support devices (guide plates) at the
pump well (sump) are aligned in relation to the dome flange.
1) A circular object e.g. a wooden plate, with the same diameter ØD (+0.5 to +1.0 mm) as the pump
head and with markings of the brackets outside the pump volute, is placed in the sump. Centre of
the plate identical with the pump. Drawing of the pump housing, viewed from above, can be
supplied in scale 1:1.
2) The supports for the guide plates are spot welded on the tank top in relation to centre point stated in
1) and according to installation drawing, see SEC. 6. Concerning dimension and placing of brackets
on the outside of the pump volute, see also figure 49241-20 and 49421-00, examples of placing the
pump head in the sump.
3) An alignment flange supplied by Hamworthy Svanehøj A/S is placed on the dome flange. The
alignment flange is centre by 4 pins Ø16 placed in the holes, see figure 49241-20. An optical
instrument or a laser is placed in the alignment flange.
4) The dome flange is placed on top of the tank and centred in proportion to the centre point stated in
1) by means of an optical instrument/laser or plumb line. See SEC. 4, page 7.
5) The distance between the bottom of the sump and the dome flange is measured and, if necessary
adjusted according to installation drawing, see SEC. 6.
6) The dome flange is spot welded, and the alignment is checked. The centre of the dome flange may
max. deviate 10 mm from the centre of the guide plates, and it must be possible to move the
guide plates min. 10 mm to each side in the slits.
7) The length is checked again. If this is correct, the dome flange can be full-welded. During welding
the optical instrument or laser is still to be in alignment flange for check of alignment.
8) Before exact alignment takes place, it is examined by means of a feeler, with the alignment flange
placed on the dome, that planeness of the dome is within 0.4 mm.
ATTENTION
If planeness of dome is not within the tolerance, the planeness of the alignment flange should be
checked before further action is taken.
9) Exact alignment can hereafter be made in the following way:
To maintain the guarantee the alignment must be checked by Hamworthy Svanehøj A/S before
the pump is mounted.
The guide plates are attached, bolts and nuts are temporary tightened.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The alignment sheet (see page 6) is placed with its centre in the centre of the guide plates, by means of
a circular object, e.g. a wooden plate.
The alignment flange with optical instrument or laser is turned 90o, and centre is marked again on the
circular object of the guide plates. This is repeated until four points are marked. The points are
connected diagonally.
The intersection marks the centre of the dome flange compensated for inaccuracies, if any, in the
alignment equipment and is to be within the tolerances indicated on alignment sheet.
The supports for the guide plates are now fully welded and the guide plates are finally mounted, bolts
and nuts are secured with lock plates.
ATTENTION
In order to secure the guide plates from coming loose and to ensure that the guide plates can be
placed again in correct alignment after dismantling, min. 1 pc. 10 mm hole is drilled through
the guide plates and support for guide plates. Then bolt is mounted, use two nuts as counter
locking.
ATTENTION
All alignment sheets must be handed over to Hamworthy Svanehøj A/S for filing.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Drawing for A B C
Pump Type
alignment, scale [mm] [mm] [mm]
1:1
DL 100 12328-01 53 20 60
DL 125 12328-02 57 24 70
DL 132 12328-03 59 27 70
DL 150 12328-04 24 65 70
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Alignment Sheet
Yard : ………………………………………… Date : ……………………..
If planeness of dome is not within the tolerance, the alignment flange should be
checked for planeness.
ATTENTION
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Mounting of Pump
To maintain the guarantee the alignment must be checked by Hamworthy Svanehøj A/S before the
pump is mounted.
Welding, sandblasting and grinding must be finished and the tank cleaned before mounting the pump.
If the tank is to be coated, this must also be finished.
Forces from the piping on deck must not influence the discharge flange of the pump.
If the intermediate support(s) are not aligned exactly, make sure that:
The bolts and nuts for intermediate guide ring(s) (if any) are loose enabling the guide ring to move
within its slits.
1) The pump is to be installed without motor. Two cranes are used to lift the pump from horizontal to
vertical position. Mount the two eye bolts at the base arrangement. The crane at base lifts the pump
up to vertical. The other crane at the pump head must keep the lower part clear from the ground.
Crane No. 2
is lifting the
pump.
1) 2) 3)
Crane No. 2
is lifting the
pump.
Crane No. 1
starts lifting.
Both cranes
are lifting.
Use 2 eye bolts.
Crane (Special tool box)
No. 2
1) 2) 3)
2) Lift the pump above the dome. Lower the pump carefully guiding the pump through the dome and
intermediate guide ring(s). After installation check the distance between the bottom of the sump
and the suction branch of the pump. It must comply with the dimensions stated on the installation
drawing.
4) The protection cover at the base and elements for fixing the coupling are removed.
5) The motor is mounted by guiding the motor shaft into the coupling hub. Before assembly the
shaft/hub are greased with Molykote or similar.
6) The direction of rotation of the motor is checked through the hole for oil refilling. See arrow on the
motor stool.
7) Lubrication oil is filled into the pipe stack through the fitting on the pump head by using the hand
pump. See instruction, section 5.5, point 3-8.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Page
5.3: Maintenance 14
ATTENTION
During pump operation, the oil level can rise above normal level, marked on the sight glass,
because of the increasing temperature in the lubrication oil.
The discharge valve is only slight open (almost closed). Now the cargo pump is started, and the
discharge valve is adjusted until the requested working pressure is attained.
CAUTION
It is not recommendable that the cargo pump is running for more than 1 minute at empty tank
after unloading. If the cargo pump is running with decreased lubrication for a longer period the
wear of the mechanical seal will increase.
Complete dry-running of the cargo pump will wear the mechanical seal severely.
If the cargo pump is used as drop line, the pressure drop through the pump unit must be taken in
consideration.
Max. loading pressure 7 bar.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Operation Diagram
Frequency Converter
or
Soft Starter
or
DOL Start
Pump is ready
for pumping
No.49906-00
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Purging System
ATTENTION
CAUTION
Principle of operation:
While the cargo pump is not running the following are carried out, referring to example of principle
below:
1. Loading
1.1 Immediately before loading.
2. Voyage
2.1 1 – 2 days after loading.
2.2 If no leakage at stage 1, purge every fortnight.
2.3 If a leakage is observed at stage 1, or later during the voyage, purge this pump every 24
hours.
3. Discharge
3.1 Immediately before discharge.
3.2 Immediately after discharge.
The purging rapport, drawing no. 49505-00E, are to be filled in with the result from every purging
operation, as described above.
This rapport is handed over to Shipowner and to Hamworthy Svanehøj A/S for filing.
Sending by email, please use: purging@hamworthy.com
ATTENTION
The ship’s staff on board has the primary responsibility for purging of the pumps and the
necessary action to be taken. In case of any doubt, please contact Hamworthy Svanehøj A/S for
further information/advice.
Cargo leakage into the cofferdam can occur from the mechanical shaft seal, flange connections at
cartridge/pump casing and purging pipe/pump casing.
Lubrication oil leakage into the cofferdam can occur from the mechanical shaft seal and the sealing
between cartridge/pump casing.
A small leakage of either cargo or oil from the mechanical shaft seal into the cofferdam up to 5 ml/h
(0,12 l/day) during operation is normal and acceptable. For short periods, higher leakage peak can
occur. The leakage rate is depending of the type of cargo pumped.
If the leakage rate is increasing above 0,5 l/day the pump must be purged more often and inspected as
soon as possible to find the reason for the leakage.
Intensify the purging routine if the leakage rate is increasing above normal level. If this is not keeping
the leakage under control, stop operating with the pump.
CAUTION
When handling certain groups of cargoes it may be an advantage to fill the cofferdam with liquid to
improve the seal lifetime and to avoid cargo blocking the cofferdam.
Acid cargoes
Flush fresh water through the cofferdam. Purge the cofferdam with air/nitrogen subsequently.
Polymerising cargoes
Fill the cofferdam with 1 - 2 litres of DOP (di-octyl phthalate) to avoid blocking of cofferdam. Purge
the cofferdam with air/nitrogen subsequently.
Crystallizing cargoes
Fill the cofferdam with 1 - 2 litres of fresh water. Purge the cofferdam with air/nitrogen subsequently.
Stripping System
Principle of operation:
Main rule:
To obtain the best stripping result, perform
always stripping against the lowest possible discharge head.
Operation:
After the cargo pump is stopped at empty tank, cargo located on the tank top and walls will slowly seep
to the suction well. Accordingly, it may be necessary to restart the cargo pump against throttled
discharge valve for a short period to minimize cargo residue in suction well.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
When discharge of tank has taken place, the following procedure of stripping the cargo residue is
recommended - see principle sketch shown on page 10.
Discharge at starboard side.
2) Stripping the residue from the tank into the discharge pipe by running the cargo pump.
Valve position:
No. 1: Closed
- 2: Closed
- 3: Open
- 5: 3-way valve - connection from stripping pipe (cargo pump) to the discharge pipe.
- 6: Closed
- 7: Open
- 10: Closed
- 11: Closed
- 12: Closed
- 13: Closed
Operation:
Relieve the discharge pipe pressure. The cargo pump is started and compressed air/N2 is connected to
the valve no. 4. The cargo in the intermediate pipe is now purged through the stripping pipe into the
discharge pipe. When the stripping pressure drops to almost zero, the cargo pump has to be stopped.
4) Alternative, stripping of residue in the tank is performed directly from the cargo pump to the
manifold.
Valve position:
No. 1: Closed
- 2: Closed
- 3: Open
- 5: 3-way valve - connection from stripping pipe (cargo pump) to the manifold.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
- 6: Closed
- 7: Open
- 10: Closed
- 11: Open
- 12: Closed
- 13: Closed
Operation:
When the cargo pump has stopped, all cargo residues is flushed through the discharge pipe and cargo
pump into the tank.
The cargo pump is started and compressed air/N2 is connected to the valve no. 4. The cargo in the
intermediate pipe is now purged through the stripping pipe into the discharge pipe. When the stripping
pressure drops to almost zero, the cargo pump has to be stopped.
If there is still cargo left in the tank, enough to restart the cargo pump, the above procedures can be
repeated.
ATTENTION
It is not recommendable that the cargo pump is running for more than 1 minute at empty tank
after stripping.
Air/nitrogen pressure: App. 1 – 2 bar above the pressure in the stripping pipe.
Air/nitrogen consumption: Depending on pump size, piping design and characteristics of cargo.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
SECTION 5.1
STARTING UP AND
PUMP OPERATION Page 11
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Tank Cleaning
Start
1) Start the tank cleaning pump and supply washing water to cargo tank.
3) Start the cargo pump, when the washing water level in suction sump and pump head is sufficient to
ensure liquid in cargo pump. The discharge pressure should increase shortly after starting the pump.
4) Adjust the discharge valve or the speed of rotation of cargo pump if possible, to match the capacity
of the cargo pump to the quantity of washing water supplied.
The pump should have a discharge pressure of 0.5 bar or more to ensure efficient and stabile pump
operation.
Stop
5) When the tank washing machine is stopped, the cargo pump should be stopped immediately after
the sump is empty. The pressure and power consumption drops, when the sump is empty.
ATTENTION
The table below provides a summary of the most common problems and malfunctions that could arise.
For any other specific problems not covered by this list, please contact Hamworthy Svanehøj A/S.
Inspection
During pump operation, the oil level can rise above normal
level, marked on the sight glass, because of the increasing
ATTENTION temperature in the lubrication oil.
Lubrication
Bearings in the electric motor are lubricated with the grease type recommended by the motor
manufacturer. Amount and time intervals according to the directions of the motor manufacturer.
The drive shaft supported by guide bearings and ball bearings in the pump head are oil-lubricated.
Dimension of pipe/shaft:
Ø89/40: L * 3.6 [litre/m]
Ø102/50: L * 4.4 [litre/m]
L = Length of pump.
The oil should meet the requirements in DIN 51 524 part 2 HLP. Kinematic viscosity at 40º C: 32 cSt.
As an example the following types of oils could be used:
BP Bartram HV 32 Fina Hydran HV 32
ESSO Nuto HP 32 Texaco Rando Oil HDZ 32
Mobil DTE 13M Castrol Hyspin AWH 32
Shell Tellus Oil 32 Kuwait Haydn 32
or similar.
The oil should meet the requirements in DIN 51 524 part 2 HLP. Kinematic viscosity at 40º C: 68 cSt.
As an example the following types of oils could be used:
BP Bartram HV 68 Fina Hydran HV 68
ESSO Nuto HP 68 Texaco Rando Oil HDZ 68
Mobil DTE 16M Castrol Hyspin AWH 68
Shell Tellus Oil 68 Kuwait Haydn 68
or similar.
Note. The oil is yard supply, and must be available at the time when the pump is being mounted.
Oil Samples
An optionally procedure to a regular time-based exchange of lubrication oil surrounding the transmission
shaft, could be performed as a preventive condition-based maintenance.
The exchange of lubrication oil is then based on the actual condition and if oil analyses are to be used as
basis, the frequency of taken oil samples should be increased to every 6 months.
Contamination of the lubrication oil could be devastating to the bearings, both in the pump housing and in
the intermediate pipe. If the oil sample is contaminated, immediately action has to be taken in order to
prevent bearing failure.
If condition-based maintenance is used as an optionally procedure, do not forget that only purging and
necessary action taken about evaluate the purging result can secure trouble-free operation of the cargo
pumping system.
Procedure:
Immediately after the cargo pump is stopped, the oil sample is taken.
(All necessary parts to be used are stored in the special-tool box except bottles).
Hamworthy Svanehøj A/S is offering the option to co-ordinate performance of oil analyses. Please forward
the oil samples to the address above, marked Service Department.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Before mounting the pump head on the intermediate pipe section, it must be controlled that the shaft
seal, cofferdam and the purging pipes are impervious.
1) The pressure testing equipment is mounted on the pump head, as shown on figure 4. Mount the
reciprocal coupled flanges to the purging connections.
2) Insert the manometer arrangement into the quick coupling.
3) Close the shut-off valve. Connect the compressed air supply at the quick coupling *.
4) Open the shut-off valve slowly until the pressure on the manometer is showing 2 bar, then close the
shut-off valve and disconnect the compressed air supply.
5) Now check all flanges and fittings by using soap water.
6) Leave the pressure in the cofferdam at least 30 min. and observe that the pressure level is stable.
7) Open the ventilation valve and release the pressure.
*
Alternative, use liquid as medium, such as petroleum, light oil or similar. Testing pressure shall then
be 10 bar.
Figure 4
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The below procedure describes how to detect a leakage in the purging pipe system i.e. from the flange
connection at the pump head to the in- and outlet at the base.
It is necessary to carry out this, if any modifications have been made on the purging pipe system.
Figure 5
*
Alternative, use liquid as medium, such as petroleum, light oil or similar. Testing pressure shall then
be 10 bar.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Flexible hose
Figure 6
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The following operation can be done without drainage of oil from the intermediate pipe.
1) Dismount the E-motor by removing the bolts, item 100, and lift the motor from the base.
2) Unscrew the securing bolt, item 103, and subsequently the adjustment bolt, item 104. The coupling,
item 102/122, including ball bearing, item 110, is now pulled of the shaft, if necessary, two M8 treads
at the top of the coupling can be used as pulling holes.
3) If the key has to be dismounted, be careful not to drop it into the inner driving pipe stack.
4) For renewing ball bearing, item 110, first remove the circlip, item 108, and then pull off the bearing.
5) For pump type DL 150 base, item 101, can be dismounted from the flange, item 180, by removing
bolts, item 169 (only for pump type DL 150 attached to sectional drawing no. 12308-XX).
1) The O-ring, item 107, is renewed before mounting the coupling including ball bearing in the base. It
can be necessary to drain out a small amount of oil to get access to fit the O-ring.
2) If base, item 101, has been dismounted from flange, item 180, we recommend renewing gasket, item
164 (only for pump type DL 150 attached to sectional
drawing no. 12308-XX). Coupling is split in two pieces, item 102
and 122, for newer pump versions.
Adjustment of shaft
5) If the oil level inside the base has decreased, refilling can bee done by removing the plug, item 112,
and filling through the hole.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
ATTENTION
Before starting to dismount the pump head, information about products, which might be inside
the pump head, must be available and the necessary precautions must be taken.
If the pump head has to be send ashore for servicing, information about products must be
forwarded.
Item nos. refers to sectional drawing of pump head and drawing for special tools stated in section 6.
All parts are cleaned so that they are free of dust, grains of sand etc.
All gaskets are renewed.
All screw connections are lubricated with Molykote or similar high pressure and chemical-resistant
grease.
It is recommended to exchange ball bearings.
It is also recommended to exchange mechanical shaft seals, as it is often difficult to get "old" seals
tight.
All screws not fitted with lock washers are to be tightened with Loctite.
Originally, there is a clearance of 0.15-0.20 mm between the wear ring and the collar of the impeller.
If this clearance exceeds 0.60 mm, new wear ring is to be fitted. Otherwise, the pump capacity will
be reduced.
Shaft is checked for misalignment, max. deviation 0.05 mm.
Burrs and other sharp edges are removed so that gaskets and O-rings are not damaged.
7) Key, item 354, is mounted, and then the impeller, item 350, is pushed in over the shaft end.
8) Lock plate, item 353, is placed at the shaft end and the screw, item 355, is then screwed on to the
shaft, the key shown in figure 10 can be used. Now the lock plate is bent to secure the screw.
9) Finally, the suction branch, item 360, is fitted.
ATTENTION
It is checked that the pump can be turned freely by hand.
10) It is recommended to carry out a pressure test of the cofferdam and shaft seals before mounting the
Pump Head. See “Pressure test of complete Pump Head” section 5.3, page 17.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
1) Gaskets, item 213 and 218, are placed on the top of the pump head.
2) The pump head is led in under the intermediate pipe section, and the spline connection is pushed
together. Be careful when fixing the spline teeth not to lift the transmission shaft, use the special
tool for rotating the outer spline into the right position.
3) The screws are tightened. Use special tools for lifting the pump head. See figure 15, below.
4) Oil filling is done by connecting the hose from the hand pump to the fitting on the side of the pump
head. See figure 15, below.
5) First remove the plug, item 306, and then fit the quick coupling supplied with the hand pump.
6) Connect the discharge hose to the quick coupling and the suction hose is submerged into the drum
containing lubrication oil. Be careful NOT to contaminate the oil.
7) Start operating the hand pump and the oil is pumped into the pipe stack. Observe lubrication oil
level on the sight glass at the base. Stop filling at the marking: NORM. Regarding oil type and
amount see section 5.2.
8) Disconnect the hose and remove the quick coupling. A nonreturn-valve in the fitting is preventing
lubrication oil from running out.
9) The plug, item 306, is mounted in the fitting, item 308. Remember always to renew the gasket,
item 304.
Figure 15
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The pump can be disassembled after either the whole pump has been dismounted from the tank or piece
by piece e.g. if head is not available for lifting the whole pump out of the tank in full length.
2) Supports, if any, from the tank wall to the intermediate pipes are loosened and removed.
3) All pipes are disconnected, and bolts/nuts holding base arrangement on the dome flange are
dismounted. Then the whole pump is lifted out be means of two eyebolts mounted in the motor
frame in threaded holes for motor bolts. The pump is placed with supports as shown in section 4,
page 1. Please note the lifting places.
6) The bolts, item 216 and 217, holding the intermediate pipes on the base are removed (do not
forget to support the base), and base is drawn out above the shaft, item 252.
Adjustment flange, item 206, is removed, please note the serial number on the flange.
7) The pump head is dismounted as described in section 5.4, page 14. The two intermediate pipes are
now separate.
8) If the intermediate pipe consist of two or more pipe sections, the flange connections are
dismounted by removing the bolts, item 230/291/293. After having loosened setscrew, item 243,
the sleeve coupling, item 240, can be pushed into the transmission shaft, item 252. Now the
transmission shaft can be turned to unscrew the connection to the lower shaft. The sleeve coupling
and the keys, item 241/242 are removed and the transmission shafts can be taken out of the
intermediate pipes. Be careful not to damage the surface of the transmission shaft.
9) The guide bearing housings, item 205, with bearing, item 204, and O-rings, item 207, can be
pushed out of the intermediate pipe. Max. clearance for the guide bearings is +0.8 - +1.0 mm
related to the diameter in proportion to the transmission shaft.
Besides we refer to section 5.4-5.5 for assembly of base arrangement and pump head.
Do not forget to mount new dome gasket before the pump is mounted in the tank.
The below instruction is for an intermediate pipe section with two or more flange connections.
2) Supports, if any, from the tank wall to the intermediate pipes are loosened and removed.
3) All pipe connections are dismounted. Bolts holding base arrangement on dome flange are
dismounted.
4) The pump is lifted in two eyebolts mounted in the motor frame in threaded holes for motor (neck
iron can be placed around the upper intermediate pipe). The pump is lowered down so that the neck
iron carries the pump on the dome flange.
5) Bolts, item 216/217, holding the intermediate pipes on the base are removed, disconnect all pipes at
lower side of base, and base arrangement is lifted off.
6) A lifting device is fixed on the flanges of the upper intermediate pipes, item 260/265. The pump is
lifted, the neck iron is dismounted and fixed on the next intermediate pipe, item 201/202, and the
pump is lowered so that the neck iron rests on the dome.
7) Bolts, item 235 and 230, and nuts, item 231/238, are dismounted, and the upper intermediate pipe,
item 260/265, is drawn up over the transmission shaft, item 252, until the sleeve coupling, item 240,
is free, app. 200 mm. Setscrew, item 243, is dismounted and the sleeve coupling can now be lifted.
The transmission shaft is turned to unscrew the connection to the lower transmission shaft. The
sleeve coupling and the keys, item 241/242, are removed. This procedure is repeated if there is
another flange connection.
9) The guide bearing housings, item 204, with bearing, item 205, and O-rings, item 207, can be
pushed out of the intermediate pipe. Max. clearance for the guide bearings is +0.8 - +1.0 mm in
proportion to the transmission shaft.
10) The pump is assembled as stated under the previous section, about dismantling with the pump
dismounted from the tank.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
When pumping of liquids with a high content of impurities, e.g. phosphoric acid/ gypsum, crude oil/sand
etc. the following are to be observed;
1) At empty tank it is to be observed that the pump stops max. 10 sec. after the tank is empty, as the
life of the mechanical seal at the cargo-side and wear rings will be considerable reduced at dry
running together with the presence of impurities.
2) It is important that there is an optimum cycles for circulation of the pump medium through the
circulation nozzle arrangement or the like so that sedimentation of impurities is avoided in the
bottom of the tank.
If the concentration of impurities in the bottom of the tank is extensive, this will also reduce the life
of the mechanical seal at the cargo-side and wear ring, when the pump is started.
3) During tank washing it is required that sediments of impurities are loosened from the tank bottom
and mixed with water, so that the wear, on the mechanical seal, at the cargo side and wear ring, not
will be more than at normal pumping of liquids with impurities.
During tank washing it is to be observed that the pump stops at empty tank (see point 1).
It is important to avoid too many re-starts after the first stop, as this will increase the possibility of
dry running.
5) Wear caused by pumping of sediments as mentioned above is not covered by the guarantee.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The shaft sealing system consists of an upper and a lower mechanical Level sight
seal with a cofferdam in between. The upper seal seals against the oil- glass
lubricated driving shaft, which is embedded in an oil-filled pipe. The
lower seal is placed on the back of the impeller and seals against the
cargo.
From deck to the cofferdam there are two pipe connections, one from
a header tank, and one from a quick coupling used for filling. By
monitoring the level in the header tank the condition of the seals can
be detected.
The volume of the cofferdam is 0.23 litres x length of pump (in metres) + 2 litres in header tank.
1
The cargo is not considered being contaminated if smaller quantities of sealing liquid are mixed with the cargo.
As an example crude oil mixed with hydraulic oil is acceptable.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Condition control
Max level
Check the level in header tank before discharge Drain off and
operation. log volume
Normal level
Note: The level varies with the temperature of the cargo due
to thermal expansion of the liquid. To get the optimum
1 mm: 16 ml
monitoring it should always take place at the same
temperature and condition, e.g. before operating.
Min level
Example on level variations Refill and
A pump with a length of 30 m contains 30x0.23 litres + 2 log volume
litres = 9 litres. If the temperature of the oil in the pump
increases 10° C the level in the header tank will increase
approximately 5 mm.
Having filled the sealing system at 20° and later loading cargo
at 70° into the tank the level will increase approximately 25
mm.
Figure 18
To monitor the condition of the system it is recommended to
log the level and cargo temperature regularly e.g. each month.
Remove plug
Figure 19
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The table below provides a summary of the most common problems and malfunctions that could arise.
If the level has been logged regularly, it is possible to see the trend in average fluid consumption.
#) Before any dismantling is started the system should be pressure tested to find out where there is a
problem. See “Pressure testing the purge system” Section 5.6.
¤) The direction of leakage depends on whether the static pressure of the sealing liquid or the static
pressure of cargo plus inert gas pressure is the largest.
For any other specific problems not covered by this list, please contact Hamworthy Svanehøj A/S.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Amount
Amount
Amount
Amount
Amount
Result
Result
Result
Result
Result
Remarks
Date
Date
Date
Date
Date
Signed by:
________________________________________________________________________________________________________________________________________
Chief Officer Chief Engineer Pump Man
Hamworthy Svanehøj A/S
P.O. Box 30, Fabriksparken 6
DK-9230 Svenstrup J., Denmark
telephone
+45 96 37 22 00 main
Parts List No . . . . . . . . . . . :004740-WC-50 +45 40 26 39 74 service
Pump type . . . . . . . . . . . . . :DL 132D/150, STRIPPING RIGHT
facsimile
+45 98 38 31 56 main
Drawing number . . . . . . . :36452-00 +45 98 38 16 97 service
e-mail
Page . . . . . . . . . . . . . . . . . . . :1 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Parts List No . . . . . . . . . . . :004740-WC-50 +45 40 26 39 74 service
Pump type . . . . . . . . . . . . . :DL 132D/150, STRIPPING RIGHT
facsimile
+45 98 38 31 56 main
Drawing number . . . . . . . :36452-00 +45 98 38 16 97 service
e-mail
Page . . . . . . . . . . . . . . . . . . . :2 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Parts List No . . . . . . . . . . . :004740-WC-50 +45 40 26 39 74 service
Pump type . . . . . . . . . . . . . :DL 132D/150, STRIPPING RIGHT
facsimile
+45 98 38 31 56 main
Drawing number . . . . . . . :36452-00 +45 98 38 16 97 service
e-mail
Page . . . . . . . . . . . . . . . . . . . :3 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Parts List No . . . . . . . . . . . :004741-WC-50 +45 40 26 39 74 service
Pump type . . . . . . . . . . . . . :DL 132D/150, STRIPPING LEFT
facsimile
+45 98 38 31 56 main
Drawing number . . . . . . . :36452-01 +45 98 38 16 97 service
e-mail
Page . . . . . . . . . . . . . . . . . . . :1 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Parts List No . . . . . . . . . . . :004741-WC-50 +45 40 26 39 74 service
Pump type . . . . . . . . . . . . . :DL 132D/150, STRIPPING LEFT
facsimile
+45 98 38 31 56 main
Drawing number . . . . . . . :36452-01 +45 98 38 16 97 service
e-mail
Page . . . . . . . . . . . . . . . . . . . :2 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Parts List No . . . . . . . . . . . :004741-WC-50 +45 40 26 39 74 service
Pump type . . . . . . . . . . . . . :DL 132D/150, STRIPPING LEFT
facsimile
+45 98 38 31 56 main
Drawing number . . . . . . . :36452-01 +45 98 38 16 97 service
e-mail
Page . . . . . . . . . . . . . . . . . . . :3 Svanehoj@hamworthy.com
2) Pump Specification
3) Performance curve
5) Instruction manual
7) Special Tools
8) Motor Specification
9)
CUSTOMER:
172082 Plate 6
351618 Plate 4
351620 Plate 2
685873 Set screw 12
690505 Nut 12
701567 Lock washer 12
685835 Set screw 6
690502 Nut 12
Note: Lifting instruction, if any, is attached to the pipe stack near the base and included in section 6.
Figure 1 Horizontal lift of standard pump, e.g. from truck to storage at yard.
Lifting:
Crane No. 1 must start lifting 50-300 mm
before crane No. 2 Travelling trolley
Lowering:
Crane No. 2 must lower down to support
at base before crane No. 1
Figure 3
For transportation on telescopic trailer the supports are adjusted to the construction of the trailer.
Storage:
In general it is recommended that all the equipment is stored in-door. Activities such as welding, grinding,
sandblasting or painting must not take place in the same area.
The minimum requirement for storage of equipment is stated below.
Warehouse storage
Dry and clean
No corroding or aggressive atmosphere
No dripping water
The components are typically electric motors, power pack units, portable pumps, flexible hoses, mild steel
domes, partial pumps with remaining parts, mounting parts supplied in a box, and box with special tools.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Outdoor storage
Protected with tarpaulin from rain and dust.
The components are typically cargo pumps, submerged ballast pumps, stainless steel pipes, stainless
domes and pump supports.
Note: Stainless steel may corrode if surface is polluted with dust or particles from welding, grinding,
salt water etc.
If the above is observed, the pumps can be stored for 6 months. For longer time storage, contact
Hamworthy Svanehøj A/S for instruction.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Alignment
Before installing the pump in the tank it is to be ensured that the support devices (guide plates) at the
pump well (sump) are aligned in relation to the dome flange.
1) A circular object e.g. a wooden plate, with the same diameter ØD (+0.5 to +1.0 mm) as the pump
head and with markings of the brackets outside the pump volute, is placed in the sump. Centre of
the plate identical with the pump. Drawing of the pump housing, viewed from above, can be
supplied in scale 1:1.
2) The supports for the guide plates are spot welded on the tank top in relation to centre point stated in
1) and according to installation drawing, see SEC. 6. Concerning dimension and placing of brackets
on the outside of the pump volute, see also figure 49241-20 and 49421-00, examples of placing the
pump head in the sump.
3) An alignment flange supplied by Hamworthy Svanehøj A/S is placed on the dome flange. The
alignment flange is centre by 4 pins Ø16 placed in the holes, see figure 49241-20. An optical
instrument or a laser is placed in the alignment flange.
4) The dome flange is placed on top of the tank and centred in proportion to the centre point stated in
1) by means of an optical instrument/laser or plumb line. See SEC. 4, page 7.
5) The distance between the bottom of the sump and the dome flange is measured and, if necessary
adjusted according to installation drawing, see SEC. 6.
6) The dome flange is spot welded, and the alignment is checked. The centre of the dome flange may
max. deviate 10 mm from the centre of the guide plates, and it must be possible to move the
guide plates min. 10 mm to each side in the slits.
7) The length is checked again. If this is correct, the dome flange can be full-welded. During welding
the optical instrument or laser is still to be in alignment flange for check of alignment.
8) Before exact alignment takes place, it is examined by means of a feeler, with the alignment flange
placed on the dome, that planeness of the dome is within 0.4 mm.
ATTENTION
If planeness of dome is not within the tolerance, the planeness of the alignment flange should be
checked before further action is taken.
9) Exact alignment can hereafter be made in the following way:
To maintain the guarantee the alignment must be checked by Hamworthy Svanehøj A/S before
the pump is mounted.
The guide plates are attached, bolts and nuts are temporary tightened.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The alignment sheet (see page 6) is placed with its centre in the centre of the guide plates, by means of
a circular object, e.g. a wooden plate.
The alignment flange with optical instrument or laser is turned 90o, and centre is marked again on the
circular object of the guide plates. This is repeated until four points are marked. The points are
connected diagonally.
The intersection marks the centre of the dome flange compensated for inaccuracies, if any, in the
alignment equipment and is to be within the tolerances indicated on alignment sheet.
The supports for the guide plates are now fully welded and the guide plates are finally mounted, bolts
and nuts are secured with lock plates.
ATTENTION
In order to secure the guide plates from coming loose and to ensure that the guide plates can be
placed again in correct alignment after dismantling, min. 1 pc. 10 mm hole is drilled through
the guide plates and support for guide plates. Then bolt is mounted, use two nuts as counter
locking.
ATTENTION
All alignment sheets must be handed over to Hamworthy Svanehøj A/S for filing.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Drawing for A B C
Pump Type
alignment, scale [mm] [mm] [mm]
1:1
DL 100 12328-01 53 20 60
DL 125 12328-02 57 24 70
DL 132 12328-03 59 27 70
DL 150 12328-04 24 65 70
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Alignment Sheet
Yard : ………………………………………… Date : ……………………..
If planeness of dome is not within the tolerance, the alignment flange should be
checked for planeness.
ATTENTION
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Mounting of Pump
To maintain the guarantee the alignment must be checked by Hamworthy Svanehøj A/S before the
pump is mounted.
Welding, sandblasting and grinding must be finished and the tank cleaned before mounting the pump.
If the tank is to be coated, this must also be finished.
Forces from the piping on deck must not influence the discharge flange of the pump.
If the intermediate support(s) are not aligned exactly, make sure that:
The bolts and nuts for intermediate guide ring(s) (if any) are loose enabling the guide ring to move
within its slits.
1) The pump is to be installed without motor. Two cranes are used to lift the pump from horizontal to
vertical position. Mount the two eye bolts at the base arrangement. The crane at base lifts the pump
up to vertical. The other crane at the pump head must keep the lower part clear from the ground.
Crane No. 2
is lifting the
pump.
1) 2) 3)
Crane No. 2
is lifting the
pump.
Crane No. 1
starts lifting.
Both cranes
are lifting.
Use 2 eye bolts.
Crane (Special tool box)
No. 2
1) 2) 3)
2) Lift the pump above the dome. Lower the pump carefully guiding the pump through the dome and
intermediate guide ring(s). After installation check the distance between the bottom of the sump
and the suction branch of the pump. It must comply with the dimensions stated on the installation
drawing.
4) The protection cover at the base and elements for fixing the coupling are removed.
5) The motor is mounted by guiding the motor shaft into the coupling hub. Before assembly the
shaft/hub are greased with Molykote or similar.
6) The direction of rotation of the motor is checked through the hole for oil refilling. See arrow on the
motor stool.
7) Lubrication oil is filled into the pipe stack through the fitting on the pump head by using the hand
pump. See instruction, section 5.5, point 3-8.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Page
5.3: Maintenance 14
ATTENTION
During pump operation, the oil level can rise above normal level, marked on the sight glass,
because of the increasing temperature in the lubrication oil.
The discharge valve is only slight open (almost closed). Now the cargo pump is started, and the
discharge valve is adjusted until the requested working pressure is attained.
CAUTION
It is not recommendable that the cargo pump is running for more than 1 minute at empty tank
after unloading. If the cargo pump is running with decreased lubrication for a longer period the
wear of the mechanical seal will increase.
Complete dry-running of the cargo pump will wear the mechanical seal severely.
If the cargo pump is used as drop line, the pressure drop through the pump unit must be taken in
consideration.
Max. loading pressure 7 bar.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Operation Diagram
Frequency Converter
or
Soft Starter
or
DOL Start
Pump is ready
for pumping
No.49906-00
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Purging System
ATTENTION
CAUTION
Principle of operation:
While the cargo pump is not running the following are carried out, referring to example of principle
below:
1. Loading
1.1 Immediately before loading.
2. Voyage
2.1 1 – 2 days after loading.
2.2 If no leakage at stage 1, purge every fortnight.
2.3 If a leakage is observed at stage 1, or later during the voyage, purge this pump every 24
hours.
3. Discharge
3.1 Immediately before discharge.
3.2 Immediately after discharge.
The purging rapport, drawing no. 49505-00E, are to be filled in with the result from every purging
operation, as described above.
This rapport is handed over to Shipowner and to Hamworthy Svanehøj A/S for filing.
Sending by email, please use: purging@hamworthy.com
ATTENTION
The ship’s staff on board has the primary responsibility for purging of the pumps and the
necessary action to be taken. In case of any doubt, please contact Hamworthy Svanehøj A/S for
further information/advice.
Cargo leakage into the cofferdam can occur from the mechanical shaft seal, flange connections at
cartridge/pump casing and purging pipe/pump casing.
Lubrication oil leakage into the cofferdam can occur from the mechanical shaft seal and the sealing
between cartridge/pump casing.
A small leakage of either cargo or oil from the mechanical shaft seal into the cofferdam up to 5 ml/h
(0,12 l/day) during operation is normal and acceptable. For short periods, higher leakage peak can
occur. The leakage rate is depending of the type of cargo pumped.
If the leakage rate is increasing above 0,5 l/day the pump must be purged more often and inspected as
soon as possible to find the reason for the leakage.
Intensify the purging routine if the leakage rate is increasing above normal level. If this is not keeping
the leakage under control, stop operating with the pump.
CAUTION
When handling certain groups of cargoes it may be an advantage to fill the cofferdam with liquid to
improve the seal lifetime and to avoid cargo blocking the cofferdam.
Acid cargoes
Flush fresh water through the cofferdam. Purge the cofferdam with air/nitrogen subsequently.
Polymerising cargoes
Fill the cofferdam with 1 - 2 litres of DOP (di-octyl phthalate) to avoid blocking of cofferdam. Purge
the cofferdam with air/nitrogen subsequently.
Crystallizing cargoes
Fill the cofferdam with 1 - 2 litres of fresh water. Purge the cofferdam with air/nitrogen subsequently.
Stripping System
Principle of operation:
Main rule:
To obtain the best stripping result, perform
always stripping against the lowest possible discharge head.
Operation:
After the cargo pump is stopped at empty tank, cargo located on the tank top and walls will slowly seep
to the suction well. Accordingly, it may be necessary to restart the cargo pump against throttled
discharge valve for a short period to minimize cargo residue in suction well.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
When discharge of tank has taken place, the following procedure of stripping the cargo residue is
recommended - see principle sketch shown on page 10.
Discharge at starboard side.
2) Stripping the residue from the tank into the discharge pipe by running the cargo pump.
Valve position:
No. 1: Closed
- 2: Closed
- 3: Open
- 5: 3-way valve - connection from stripping pipe (cargo pump) to the discharge pipe.
- 6: Closed
- 7: Open
- 10: Closed
- 11: Closed
- 12: Closed
- 13: Closed
Operation:
Relieve the discharge pipe pressure. The cargo pump is started and compressed air/N2 is connected to
the valve no. 4. The cargo in the intermediate pipe is now purged through the stripping pipe into the
discharge pipe. When the stripping pressure drops to almost zero, the cargo pump has to be stopped.
4) Alternative, stripping of residue in the tank is performed directly from the cargo pump to the
manifold.
Valve position:
No. 1: Closed
- 2: Closed
- 3: Open
- 5: 3-way valve - connection from stripping pipe (cargo pump) to the manifold.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
- 6: Closed
- 7: Open
- 10: Closed
- 11: Open
- 12: Closed
- 13: Closed
Operation:
When the cargo pump has stopped, all cargo residues is flushed through the discharge pipe and cargo
pump into the tank.
The cargo pump is started and compressed air/N2 is connected to the valve no. 4. The cargo in the
intermediate pipe is now purged through the stripping pipe into the discharge pipe. When the stripping
pressure drops to almost zero, the cargo pump has to be stopped.
If there is still cargo left in the tank, enough to restart the cargo pump, the above procedures can be
repeated.
ATTENTION
It is not recommendable that the cargo pump is running for more than 1 minute at empty tank
after stripping.
Air/nitrogen pressure: App. 1 – 2 bar above the pressure in the stripping pipe.
Air/nitrogen consumption: Depending on pump size, piping design and characteristics of cargo.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
SECTION 5.1
STARTING UP AND
PUMP OPERATION Page 11
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Tank Cleaning
Start
1) Start the tank cleaning pump and supply washing water to cargo tank.
3) Start the cargo pump, when the washing water level in suction sump and pump head is sufficient to
ensure liquid in cargo pump. The discharge pressure should increase shortly after starting the pump.
4) Adjust the discharge valve or the speed of rotation of cargo pump if possible, to match the capacity
of the cargo pump to the quantity of washing water supplied.
The pump should have a discharge pressure of 0.5 bar or more to ensure efficient and stabile pump
operation.
Stop
5) When the tank washing machine is stopped, the cargo pump should be stopped immediately after
the sump is empty. The pressure and power consumption drops, when the sump is empty.
ATTENTION
The table below provides a summary of the most common problems and malfunctions that could arise.
For any other specific problems not covered by this list, please contact Hamworthy Svanehøj A/S.
Inspection
During pump operation, the oil level can rise above normal
level, marked on the sight glass, because of the increasing
ATTENTION temperature in the lubrication oil.
Lubrication
Bearings in the electric motor are lubricated with the grease type recommended by the motor
manufacturer. Amount and time intervals according to the directions of the motor manufacturer.
The drive shaft supported by guide bearings and ball bearings in the pump head are oil-lubricated.
Dimension of pipe/shaft:
Ø89/40: L * 3.6 [litre/m]
Ø102/50: L * 4.4 [litre/m]
L = Length of pump.
The oil should meet the requirements in DIN 51 524 part 2 HLP. Kinematic viscosity at 40º C: 32 cSt.
As an example the following types of oils could be used:
BP Bartram HV 32 Fina Hydran HV 32
ESSO Nuto HP 32 Texaco Rando Oil HDZ 32
Mobil DTE 13M Castrol Hyspin AWH 32
Shell Tellus Oil 32 Kuwait Haydn 32
or similar.
The oil should meet the requirements in DIN 51 524 part 2 HLP. Kinematic viscosity at 40º C: 68 cSt.
As an example the following types of oils could be used:
BP Bartram HV 68 Fina Hydran HV 68
ESSO Nuto HP 68 Texaco Rando Oil HDZ 68
Mobil DTE 16M Castrol Hyspin AWH 68
Shell Tellus Oil 68 Kuwait Haydn 68
or similar.
Note. The oil is yard supply, and must be available at the time when the pump is being mounted.
Oil Samples
An optionally procedure to a regular time-based exchange of lubrication oil surrounding the transmission
shaft, could be performed as a preventive condition-based maintenance.
The exchange of lubrication oil is then based on the actual condition and if oil analyses are to be used as
basis, the frequency of taken oil samples should be increased to every 6 months.
Contamination of the lubrication oil could be devastating to the bearings, both in the pump housing and in
the intermediate pipe. If the oil sample is contaminated, immediately action has to be taken in order to
prevent bearing failure.
If condition-based maintenance is used as an optionally procedure, do not forget that only purging and
necessary action taken about evaluate the purging result can secure trouble-free operation of the cargo
pumping system.
Procedure:
Immediately after the cargo pump is stopped, the oil sample is taken.
(All necessary parts to be used are stored in the special-tool box except bottles).
Hamworthy Svanehøj A/S is offering the option to co-ordinate performance of oil analyses. Please forward
the oil samples to the address above, marked Service Department.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Before mounting the pump head on the intermediate pipe section, it must be controlled that the shaft
seal, cofferdam and the purging pipes are impervious.
1) The pressure testing equipment is mounted on the pump head, as shown on figure 4. Mount the
reciprocal coupled flanges to the purging connections.
2) Insert the manometer arrangement into the quick coupling.
3) Close the shut-off valve. Connect the compressed air supply at the quick coupling *.
4) Open the shut-off valve slowly until the pressure on the manometer is showing 2 bar, then close the
shut-off valve and disconnect the compressed air supply.
5) Now check all flanges and fittings by using soap water.
6) Leave the pressure in the cofferdam at least 30 min. and observe that the pressure level is stable.
7) Open the ventilation valve and release the pressure.
*
Alternative, use liquid as medium, such as petroleum, light oil or similar. Testing pressure shall then
be 10 bar.
Figure 4
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The below procedure describes how to detect a leakage in the purging pipe system i.e. from the flange
connection at the pump head to the in- and outlet at the base.
It is necessary to carry out this, if any modifications have been made on the purging pipe system.
Figure 5
*
Alternative, use liquid as medium, such as petroleum, light oil or similar. Testing pressure shall then
be 10 bar.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Flexible hose
Figure 6
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The following operation can be done without drainage of oil from the intermediate pipe.
1) Dismount the E-motor by removing the bolts, item 100, and lift the motor from the base.
2) Unscrew the securing bolt, item 103, and subsequently the adjustment bolt, item 104. The coupling,
item 102/122, including ball bearing, item 110, is now pulled of the shaft, if necessary, two M8 treads
at the top of the coupling can be used as pulling holes.
3) If the key has to be dismounted, be careful not to drop it into the inner driving pipe stack.
4) For renewing ball bearing, item 110, first remove the circlip, item 108, and then pull off the bearing.
5) For pump type DL 150 base, item 101, can be dismounted from the flange, item 180, by removing
bolts, item 169 (only for pump type DL 150 attached to sectional drawing no. 12308-XX).
1) The O-ring, item 107, is renewed before mounting the coupling including ball bearing in the base. It
can be necessary to drain out a small amount of oil to get access to fit the O-ring.
2) If base, item 101, has been dismounted from flange, item 180, we recommend renewing gasket, item
164 (only for pump type DL 150 attached to sectional
drawing no. 12308-XX). Coupling is split in two pieces, item 102
and 122, for newer pump versions.
Adjustment of shaft
5) If the oil level inside the base has decreased, refilling can bee done by removing the plug, item 112,
and filling through the hole.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
ATTENTION
Before starting to dismount the pump head, information about products, which might be inside
the pump head, must be available and the necessary precautions must be taken.
If the pump head has to be send ashore for servicing, information about products must be
forwarded.
Item nos. refers to sectional drawing of pump head and drawing for special tools stated in section 6.
All parts are cleaned so that they are free of dust, grains of sand etc.
All gaskets are renewed.
All screw connections are lubricated with Molykote or similar high pressure and chemical-resistant
grease.
It is recommended to exchange ball bearings.
It is also recommended to exchange mechanical shaft seals, as it is often difficult to get "old" seals
tight.
All screws not fitted with lock washers are to be tightened with Loctite.
Originally, there is a clearance of 0.15-0.20 mm between the wear ring and the collar of the impeller.
If this clearance exceeds 0.60 mm, new wear ring is to be fitted. Otherwise, the pump capacity will
be reduced.
Shaft is checked for misalignment, max. deviation 0.05 mm.
Burrs and other sharp edges are removed so that gaskets and O-rings are not damaged.
7) Key, item 354, is mounted, and then the impeller, item 350, is pushed in over the shaft end.
8) Lock plate, item 353, is placed at the shaft end and the screw, item 355, is then screwed on to the
shaft, the key shown in figure 10 can be used. Now the lock plate is bent to secure the screw.
9) Finally, the suction branch, item 360, is fitted.
ATTENTION
It is checked that the pump can be turned freely by hand.
10) It is recommended to carry out a pressure test of the cofferdam and shaft seals before mounting the
Pump Head. See “Pressure test of complete Pump Head” section 5.3, page 17.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
1) Gaskets, item 213 and 218, are placed on the top of the pump head.
2) The pump head is led in under the intermediate pipe section, and the spline connection is pushed
together. Be careful when fixing the spline teeth not to lift the transmission shaft, use the special
tool for rotating the outer spline into the right position.
3) The screws are tightened. Use special tools for lifting the pump head. See figure 15, below.
4) Oil filling is done by connecting the hose from the hand pump to the fitting on the side of the pump
head. See figure 15, below.
5) First remove the plug, item 306, and then fit the quick coupling supplied with the hand pump.
6) Connect the discharge hose to the quick coupling and the suction hose is submerged into the drum
containing lubrication oil. Be careful NOT to contaminate the oil.
7) Start operating the hand pump and the oil is pumped into the pipe stack. Observe lubrication oil
level on the sight glass at the base. Stop filling at the marking: NORM. Regarding oil type and
amount see section 5.2.
8) Disconnect the hose and remove the quick coupling. A nonreturn-valve in the fitting is preventing
lubrication oil from running out.
9) The plug, item 306, is mounted in the fitting, item 308. Remember always to renew the gasket,
item 304.
Figure 15
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The pump can be disassembled after either the whole pump has been dismounted from the tank or piece
by piece e.g. if head is not available for lifting the whole pump out of the tank in full length.
2) Supports, if any, from the tank wall to the intermediate pipes are loosened and removed.
3) All pipes are disconnected, and bolts/nuts holding base arrangement on the dome flange are
dismounted. Then the whole pump is lifted out be means of two eyebolts mounted in the motor
frame in threaded holes for motor bolts. The pump is placed with supports as shown in section 4,
page 1. Please note the lifting places.
6) The bolts, item 216 and 217, holding the intermediate pipes on the base are removed (do not
forget to support the base), and base is drawn out above the shaft, item 252.
Adjustment flange, item 206, is removed, please note the serial number on the flange.
7) The pump head is dismounted as described in section 5.4, page 14. The two intermediate pipes are
now separate.
8) If the intermediate pipe consist of two or more pipe sections, the flange connections are
dismounted by removing the bolts, item 230/291/293. After having loosened setscrew, item 243,
the sleeve coupling, item 240, can be pushed into the transmission shaft, item 252. Now the
transmission shaft can be turned to unscrew the connection to the lower shaft. The sleeve coupling
and the keys, item 241/242 are removed and the transmission shafts can be taken out of the
intermediate pipes. Be careful not to damage the surface of the transmission shaft.
9) The guide bearing housings, item 205, with bearing, item 204, and O-rings, item 207, can be
pushed out of the intermediate pipe. Max. clearance for the guide bearings is +0.8 - +1.0 mm
related to the diameter in proportion to the transmission shaft.
Besides we refer to section 5.4-5.5 for assembly of base arrangement and pump head.
Do not forget to mount new dome gasket before the pump is mounted in the tank.
The below instruction is for an intermediate pipe section with two or more flange connections.
2) Supports, if any, from the tank wall to the intermediate pipes are loosened and removed.
3) All pipe connections are dismounted. Bolts holding base arrangement on dome flange are
dismounted.
4) The pump is lifted in two eyebolts mounted in the motor frame in threaded holes for motor (neck
iron can be placed around the upper intermediate pipe). The pump is lowered down so that the neck
iron carries the pump on the dome flange.
5) Bolts, item 216/217, holding the intermediate pipes on the base are removed, disconnect all pipes at
lower side of base, and base arrangement is lifted off.
6) A lifting device is fixed on the flanges of the upper intermediate pipes, item 260/265. The pump is
lifted, the neck iron is dismounted and fixed on the next intermediate pipe, item 201/202, and the
pump is lowered so that the neck iron rests on the dome.
7) Bolts, item 235 and 230, and nuts, item 231/238, are dismounted, and the upper intermediate pipe,
item 260/265, is drawn up over the transmission shaft, item 252, until the sleeve coupling, item 240,
is free, app. 200 mm. Setscrew, item 243, is dismounted and the sleeve coupling can now be lifted.
The transmission shaft is turned to unscrew the connection to the lower transmission shaft. The
sleeve coupling and the keys, item 241/242, are removed. This procedure is repeated if there is
another flange connection.
9) The guide bearing housings, item 204, with bearing, item 205, and O-rings, item 207, can be
pushed out of the intermediate pipe. Max. clearance for the guide bearings is +0.8 - +1.0 mm in
proportion to the transmission shaft.
10) The pump is assembled as stated under the previous section, about dismantling with the pump
dismounted from the tank.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
When pumping of liquids with a high content of impurities, e.g. phosphoric acid/ gypsum, crude oil/sand
etc. the following are to be observed;
1) At empty tank it is to be observed that the pump stops max. 10 sec. after the tank is empty, as the
life of the mechanical seal at the cargo-side and wear rings will be considerable reduced at dry
running together with the presence of impurities.
2) It is important that there is an optimum cycles for circulation of the pump medium through the
circulation nozzle arrangement or the like so that sedimentation of impurities is avoided in the
bottom of the tank.
If the concentration of impurities in the bottom of the tank is extensive, this will also reduce the life
of the mechanical seal at the cargo-side and wear ring, when the pump is started.
3) During tank washing it is required that sediments of impurities are loosened from the tank bottom
and mixed with water, so that the wear, on the mechanical seal, at the cargo side and wear ring, not
will be more than at normal pumping of liquids with impurities.
During tank washing it is to be observed that the pump stops at empty tank (see point 1).
It is important to avoid too many re-starts after the first stop, as this will increase the possibility of
dry running.
5) Wear caused by pumping of sediments as mentioned above is not covered by the guarantee.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The shaft sealing system consists of an upper and a lower mechanical Level sight
seal with a cofferdam in between. The upper seal seals against the oil- glass
lubricated driving shaft, which is embedded in an oil-filled pipe. The
lower seal is placed on the back of the impeller and seals against the
cargo.
From deck to the cofferdam there are two pipe connections, one from
a header tank, and one from a quick coupling used for filling. By
monitoring the level in the header tank the condition of the seals can
be detected.
The volume of the cofferdam is 0.23 litres x length of pump (in metres) + 2 litres in header tank.
1
The cargo is not considered being contaminated if smaller quantities of sealing liquid are mixed with the cargo.
As an example crude oil mixed with hydraulic oil is acceptable.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Condition control
Max level
Check the level in header tank before discharge Drain off and
operation. log volume
Normal level
Note: The level varies with the temperature of the cargo due
to thermal expansion of the liquid. To get the optimum
1 mm: 16 ml
monitoring it should always take place at the same
temperature and condition, e.g. before operating.
Min level
Example on level variations Refill and
A pump with a length of 30 m contains 30x0.23 litres + 2 log volume
litres = 9 litres. If the temperature of the oil in the pump
increases 10° C the level in the header tank will increase
approximately 5 mm.
Having filled the sealing system at 20° and later loading cargo
at 70° into the tank the level will increase approximately 25
mm.
Figure 18
To monitor the condition of the system it is recommended to
log the level and cargo temperature regularly e.g. each month.
Remove plug
Figure 19
DL 100 - 150 with liquid barrier stripping No. 49564-10E
The table below provides a summary of the most common problems and malfunctions that could arise.
If the level has been logged regularly, it is possible to see the trend in average fluid consumption.
#) Before any dismantling is started the system should be pressure tested to find out where there is a
problem. See “Pressure testing the purge system” Section 5.6.
¤) The direction of leakage depends on whether the static pressure of the sealing liquid or the static
pressure of cargo plus inert gas pressure is the largest.
For any other specific problems not covered by this list, please contact Hamworthy Svanehøj A/S.
DL 100 - 150 with liquid barrier stripping No. 49564-10E
Amount
Amount
Amount
Amount
Amount
Result
Result
Result
Result
Result
Remarks
Date
Date
Date
Date
Date
Signed by:
________________________________________________________________________________________________________________________________________
Chief Officer Chief Engineer Pump Man
Hamworthy Svanehøj A/S
P.O. Box 30, Fabriksparken 6
DK-9230 Svenstrup J., Denmark
telephone
+45 96 37 22 00 main
Stykliste Nr . . . . . . . . . . . . :004742-SA-50 +45 40 26 39 74 service
Pumpetype . . . . . . . . . . . . :DL 100D/100, STRIPPING RIGHT
facsimile
+45 98 38 31 56 main
Tegningsnummer . . . . . . :36453-01 +45 98 38 16 97 service
e-mail
Side . . . . . . . . . . . . . . . . . . . . :1 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Stykliste Nr . . . . . . . . . . . . :004742-SA-50 +45 40 26 39 74 service
Pumpetype . . . . . . . . . . . . :DL 100D/100, STRIPPING RIGHT
facsimile
+45 98 38 31 56 main
Tegningsnummer . . . . . . :36453-01 +45 98 38 16 97 service
e-mail
Side . . . . . . . . . . . . . . . . . . . . :2 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Stykliste Nr . . . . . . . . . . . . :004742-SA-50 +45 40 26 39 74 service
Pumpetype . . . . . . . . . . . . :DL 100D/100, STRIPPING RIGHT
facsimile
+45 98 38 31 56 main
Tegningsnummer . . . . . . :36453-01 +45 98 38 16 97 service
e-mail
Side . . . . . . . . . . . . . . . . . . . . :3 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Stykliste Nr . . . . . . . . . . . . :004743-SA-50 +45 40 26 39 74 service
Pumpetype . . . . . . . . . . . . :DL 100D/100, STRIPPING LEFT
facsimile
+45 98 38 31 56 main
Tegningsnummer . . . . . . :36453-00 +45 98 38 16 97 service
e-mail
Side . . . . . . . . . . . . . . . . . . . . :1 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Stykliste Nr . . . . . . . . . . . . :004743-SA-50 +45 40 26 39 74 service
Pumpetype . . . . . . . . . . . . :DL 100D/100, STRIPPING LEFT
facsimile
+45 98 38 31 56 main
Tegningsnummer . . . . . . :36453-00 +45 98 38 16 97 service
e-mail
Side . . . . . . . . . . . . . . . . . . . . :2 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Stykliste Nr . . . . . . . . . . . . :004743-SA-50 +45 40 26 39 74 service
Pumpetype . . . . . . . . . . . . :DL 100D/100, STRIPPING LEFT
facsimile
+45 98 38 31 56 main
Tegningsnummer . . . . . . :36453-00 +45 98 38 16 97 service
e-mail
Side . . . . . . . . . . . . . . . . . . . . :3 Svanehoj@hamworthy.com
telephone
+45 96 37 22 00 main
Parts List No . . . . . . . . . . . :351932 +45 40 26 39 74 service
Pump type . . . . . . . . . . . . . :SPECIAL TOOLS DL
facsimile
+45 98 38 31 56 main
Drawing number . . . . . . . :35259-23 +45 98 38 16 97 service
e-mail
Page . . . . . . . . . . . . . . . . . . . :1 Svanehoj@hamworthy.com