1000-0121-401

Framo Cargo Pumps

No. 1000-0121-401Rev.C 14Oct10/AGAa

Operation manual

SD100 SD125 SD150 SD200 SD250 SD300 SD350

Framo Cargo Pumps OPERATION MANUAL

No. Date/Sign.: Page: Rev. C:

1000-0121-401 08Jun98/AGAa 2 of 20 14Oct10/AGAa

CONTENTS

1 GENERAL DESCRIPTION ....................................................................................................... 2 1.1 Top plate ........................................................................................................................ 2 1.2 Pipe stack ...................................................................................................................... 2 1.3 Pump head .................................................................................................................... 2

2 OPERATING INFORMATION .................................................................................................. 4 2.1 Discharging .................................................................................................................... 4 2.2 Running of pumps in parallel ......................................................................................... 6 2.3 Stripping ........................................................................................................................ 8 2.4 Purging of cofferdam ................................................................................................... 11 2.5 Precautions to be taken when handling special types of cargoes ............................... 14 2.6 Tank cleaning / cleaning of pump ................................................................................ 15 2.7 Precautions if using cargo pumps in sea water ........................................................... 16 2.8 Loading of cargo tank .................................................................................................. 17

3 MAINTENANCE INFORMATION ........................................................................................... 18

4 TROUBLE SHOOTING ........................................................................................................... 18

Reference to associated instructions 1000-0109-4: Interchange of pump control valve 1375-0027-4: Service manual for Pump control valve (STC)

1 GENERAL DESCRIPTION The Framo cargo pump is a hydraulically driven single stage centrifugal pump – with parts exposed to cargo in stainless steel as standard material. The pump is installed in the cargo tank with suction inlet at the bottom of the tank.

1.1 Top plate The cargo pump is supported by a deck trunk welded to the deck. All the connections are at the top cover plate, to which the pump control valve STC (Speed Torque Controller) is also mounted. This control valve for remote and local operation of the cargo pump regulates the inlet pressure to the hydraulic motor. Thereby the pump speed can be regulated step less from 0 – to max. speed.

1.2 Pipe stack The pipe stack connects the pump head to the top plate by a cargo pipe and a hydraulic section. In addition the stripping pipe, the check pipe and eventually temp. sensor pocket and vacuum drain pipe are integrated in the pipe stack.

1.3 Pump head The pump head is welded or flanged to the pipe stack/casing and supported by the bottom support. The hydr. motor is located inside the pump head and surrounded by low pressure hydraulic oil. The short shaft, supported by bearings lubricated by hydraulic oil, is connected to a single-stage impeller. The hydraulic section is surrounded by a cofferdam that completely segregates the hydraulic oil from the cargo. Leakages to the cofferdam chamber will be purged through the cofferdam check pipe and collected in the exhaust trap when cofferdam is purged. The seal arrangement consists of a mechanical oil seal, single cofferdam lip seal and a cargo seal. The cargo seal is only exposed to static head from the cargo. The backstop unit installed on the shaft enables the pump to be used as a drop line. Wear rings are fitted between the impeller and the volute casing.




Impeller

Bearings

Mechanicaloil seal

Cargo seal set

Wear rings

Volute casing

Back stop unit

Hydraulic motor

Cofferdamsurroundinghydraulic section

Cofferdam check pipe

Hydraulic Pipestack

Cofferdam pipe

Hydraulic pressure pipe

Hydraulic return pipe

Cargo stripping pipe

Cargo pipe

Flexible suspension

Exhaust trap

Cargopurging valve

Local control valve

Manometer

Pump control valve (STC)

Cofferdam purging connection Stripping valve

CargoDischarge valve

Deck trunk

Top plate

Fig. 1




300

225

150

75

0BAR

1P

ON

Manifoldpressure

Dischargepressure

OPEN

300

225

150

75

0BAR

1P

ON

Reduced capacity

300

225

150

75

0BAR

1P

ON

Reduced capacity

2 OPERATING INFORMATION This procedure describes the normal operation of the cargo pumps. Certain cargoes require special handling procedures for safe handling. In addition to this operation procedure charters instruction, Material Safety Data sheet and any ATC instructions shall be taken into consideration during cargo operation and handling.

2.1 Discharging

To get maximum lifetime of the pumps, operate the pumps within the operation range.

100%

60% dp

Hea

d H

25%0

50%

075%50%

100%

125%

Flow Q

100% dp75%

25%

80% dp

40% dp20% dp

125%

OPERATIONRANGE OPTIMUM

OPERATIONRANGE

Check that the hydraulic system is started and enough hydraulic power is available. Operation of pump from cargo control panel:

1) Local control valve and cargo discharge valve must be in closed position.

HP service valve, OPENOnly to be closed when carryingout service work on the pump.

Stripping valve, CLOSED

Cargo discharge valve, CLOSED

Local controlvalve, CLOSED

Cargo purging valveCLOSED(Purging hose disconnected)

2) Start the pump and let it run

with hydraulic motor pressure at approx 50 bar for 1 minute.

3) Increase hydraulic

motor pressure until the cargo discharge pressure is above cargo manifold pressure.

4) Open cargo

discharge valve.

Note! Avoid running pumps against closed cargo valve with high discharge pressure for a longer period. 5) Increase hydraulic

motor pressure until required discharge pressure or capacity is achieved.

Note! Check that the system pressure is about 20 bar above the motor pressure of the highest consumer. 6) End of discharging

When the tank is close to empty reduce pumping capacity to avoid loss of suction. This is indicated by a hunting hydraulic pressure, and should be avoided. Empty the cargo tank at reduced hydraulic motor pressure.

7) When the cargo tank is empty the hydraulic

motor pressure will drop. Close cargo discharge valve and stop the pump (handle in minimum position).

8) If the pump is to be restarted, relieve the

vacuum in pump cargo pipe as described in chapter 2.3, Stripping (page 9).

300

225

150

75

0BAR

1P

ONStart

300

225

150

75

0BAR

1P

ON

Manifoldpressure

Dischargepressure




OPEN

Operation of pump from local control valve:

1) Open local control valve (by turning counter clockwise). Cargo discharge valve must be in closed position.




Local controlvalve, OPENED


2) Set the remote control

handle in maximum position. (Remote control closed)

3) Start the pump by

closing the local control valve (turn clockwise) and let it run with hydraulic motor pressure 50 bar for approx. 1 minute.

4) Increase hydraulic motor pressure (turn the

local control valve clockwise) until the cargo discharge pressure is above cargo manifold pressure.

Manifold pressure Discharge pressure

5) Open cargo

discharge valve

6) Increase hydraulic motor pressure until

required discharge pressure or capacity is achieved.

7) End of discharging When the tank is close to empty reduce pumping capacity to avoid loss of suction. This is indicated by a hunting hydraulic pressure, and should be avoided. Empty the cargo tank at reduced hydraulic motor pressure.

bar0

100

200

300

400

Reduced capacity

8) When the cargo tank is empty the hydraulic

motor pressure will drop. Close cargo discharge valve and stop the pump by opening the local control valve (by turning counter clockwise).

Open localcontrol valve

CLOSE

9) Reset for remote control

operation: Set the remote control handle in minimum position (remote control open) and close the local control valve.

10) If the pump is to be restarted, relieve the vacuum in pump cargo pipe as described in chapter 2.3, Stripping (page 9).

bar0

100

200

300

400

300

225

150

75

0BAR

1P

ON




300

225

150

75

0BAR

1P

ON

Manifoldpressure

Dischargepressure

2.2 Running of pumps in parallel This is a general description for running pumps in parallel. 1) Local control valve and cargo discharge valve

must be in closed position.

Local controlvalve, CLOSED





2) Start the hydraulic

system and set the system pressure to about 100-150 bar. (Depending on piping system, cargo sp.gr., visc. etc.)

Also see performance diagram for actual pump. 3) Start the first pump and

let it run with hydraulic motor pressure at approx. 50 bar for 1 minute.

4) Increase hydraulic

motor pressure until the cargo discharge pressure is above cargo manifold pressure. (Ref. fig. 31 pos. A)

5) Open cargo discharge valve. (Ref. fig 31, pos. A-B)

6) Start offloading and raise the hydraulic

motor pressure command to maximum (fig.31, pos C).

300

225

150

75

0BAR

1P

ON

Manifold pressure

Discharge pressureNote!Handle inmaximumposition.

7) Start the second

cargo pump against closed cargo discharge valve as described in step 3.

8) Check that pump discharge pressure is

higher than manifold pressure. If necessary adjust the motor pressure until the cargo discharge pressure is just above cargo manifold pressure and then open cargo discharge valve.

300

225

150

75

0BAR

2P

ON

Manifold pressure Dischargepressure

Note!Handle inmaximumposition.

9) Start offloading and raise the hydraulic motor

pressure command to maximum (the handle in maximum position).

Verify that the ullage in the tank is increasing.

SYSTEM PRESSURE

0

100 300 200

400 bar

PRESSURE SET

300

225

150

75

0BAR

1P

ON

Start

OPEN

300

225

150

75

0BAR

2P

ON

Start




Pressure lossdischarge system

100%25%0 75%50% 125%

Flow Q

Hea

d H

50%

0

100%

75%

25%

125%

20% dp

40% dp

60% dp

80% dp100% dp

A

B C

A)

A-B)

C)

D)

E)

F)

G-I)

Increase hydraulic motor pressure.Cargo discharge valve closed.

Open cargo discharge valve.

Increase hydraulic motor pressure.

Open cargo discharge valve - 2 pumps.



Increase hydraulic system pressure(4 pumps running).

100%25%0 75%50% 125%

Flow Q

Hea

d H

50%

0

100%

75%

25%

125%

A

B C D EF

G

H

I

Pressure lossdischarge system

Typical capacity/head diagramfor cargo pump runningone

Typical capacity/head diagram for cargo pumps runningfour

Fig. 31

10) Start the next pumps, one by one, following the same procedure, ref. fig. 31 pos. E-F. Ensure that enough hydraulic power is available for the pumps to be run in parallel.

11) Increase the hydraulic system pressure until

required discharge pressure or capacity is achieved, ref. fig. 31 pos G-H-I.

12) During parallel pumping with differences in

tank ullage and pressure losses in deck piping – it is sometimes required to readjust the hydraulic motor pressure on some of the cargo pumps to adjust individual capacities.

Discharge pressure

SYSTEM PRESSURE

0

100 300 200

400 bar

300

225

150

75

0BAR

4P

ON

300

225

150

75

0BAR

3P

ON

300

225

150

75

0BAR

2P

ON

300

225

150

75

0BAR

1P

ON

Manifold pressure

13) When a cargo tank becomes empty, close the cargo discharge valve and stop the pump (handle in minimum position).

300

225

150

75

0BAR

1P

ON

Stop 14) If the pump is to be restarted, relieve the

vacuum in pump cargo pipe as described in chapter 2.3, Stripping (page 9).




2.3 Stripping Stripping is to remove remaining cargo in pump cargo pipe upon completion of the discharge operation. The stripping is done by running the pump locally at reduced hydraulic motor pressure against closed discharge valve while purging the pump cargo pipe. The remaining cargo is then purged into the deck line through the stripping valve. The pump impeller acts as a non-return valve, preventing cargo from returning to tank. If the pump speed (hydraulic motor pressure) is too low, cargo will flow through the impeller back to the tank. The arrangement of deck piping must be taken into consideration when stripping. Optimal procedure for tank stripping to be based on experience on board.

The best stripping result is obtained when stripping against lowest possible backpressure. At increased back pressure cargo flow is reduced, and stripping time is increased. High cargo viscosity will also increase stripping time. Examples: Purging press. - Static head - Back press. = Available purging pressure I 7 bar - 2 bar - 0 bar = 5 bar II 7 bar - 2 bar - 3 bar = 2 bar

0

1

2

3

4

5

6

7

8Pressure (bar)

Flow

Purgingmediumpressure

Reduced stripping flow atincreased back pressure

Stripping flow atmin. back pressure

Static headStatic head

Backpressure

Availablepurgingpressure Available

purgingpressure

Fig. 33

Estimated time to empty the pump cargo pipe (Backpressure 0 bar(g), 1cSt, spgr. 1.0) *

SD100 / SD125 / SD150 2 – 4 min.

SD200 / SD300 4 – 7 min

SD350 8 – 9 min * Time will be influenced by pump length, back pressure, piping system, type of suction well, cargo, purging medium pressure etc.

Minimum required hydraulic pressure to prevent backflow through impeller

0

2

4

6

8

60 80 100 120Hydr. motor pressure (bar)

Pur

gin

g m

ediu

m p

ress

ure

in c

arg

o p

ipe

(ba

r g

)

Fig. 32

Statichead

Stripping pipe

Pumpcargo pipe

Strippingvalve (C)

Cargo dischargevalve (D)

Cargo deck lineback pressure

Purging mediumpressure

Localcontrol valve

Cargo purging valve/connection (B)

Purgingmediumsupply (A)

Fig. 34




Stripping procedure

Relieving vacuum in pump cargo pipe

Stripping

Note!

Open stripping valve (C)

Open cargo purging valve (B) to start the stripping.

Continue stripping until pump cargo pipe is empty, identified by frequent speed variationsof pump.

Close stripping valve (C) and valve at cargo purging connection (B).

Stop the cargo pump.

If necessary, purge the cargo deck line and repeat the stripping sequence.

Close valve (A) and disconnect purging medium hose.

Do not run the pump unnecessary during stripping.

8)

9)

10)

11)

12)

13)

14)

Purging of cargo deck linePurgingmediumsupplyOPEN

OPEN

CLOSED

CLOSED

Purge the cargodeck line eitherto terminal line,slop tank orother cargo tankin accordance withships procedure.Close the manifoldvalve.

5)

Relieving deck line pressure

CLOSED

CLOSED

C OPEN/CLOSE

B CLOSED

CLOSED

Relieve the deckline pressure intothe tank by openand closestripping valve (C).

6)

Note!

Start the pump by using the local control valve, andincrease hydraulic pump pressure to 90-120 bar.

Optimum hydraulic pressure depends on cargo specificgravity and viscosity, purging medium pressure, statichead etc., and must be based on experience on board.

7)

Alternatively the pump can be stripped into a slop tank through a dedicated deck line.It is also possible to strip to a cargo deck line at low manifold pressure, howeverstripping time will increase with increased cargo pressure.

A

Pump running

Purgingmediumsupply

CLOSED

CLOSED

CLOSED

C OPEN

A

B

Purgingmediumsupply

D CLOSED

A

B

Pumpstopped

Connect purging hoseto the purging mediumsupply (A) and cargopurging valve (B).

Relieve vacuum inpump cargo pipe byopening valves atpurging medium supply(valve A and B).

Close the cargo purgingvalve (B).

Note!Purging mediumpressure in the hosemust always behigher than thepressure in thecargo pipe.

2)

3)

4)

Preparations

When the tank isempty, close cargodischarge valve(D)and stop the pump.

1)

Fig. 35




Water test procedure according to Marpol Annex II Ensure that the cargo tank to be tested and its associated piping have been cleaned and that the cargo tank is safe for entry. Provide 100kPa (1 atmosphere) back pressure at the cargo tank’s unloading manifold, see fig. 36. - Fill the cargo tank with water to a depth necessary to carry out normal end of discharge operation.

Water test with sea water must be followed by a thoroughly rinse with fresh water to remove chlorides.

- Purge and relieve pressure in cargo piping according to “Stripping procedure” step 1 to 6. - Follow the normal stripping procedure.

Start timing when cargo purging valve is opened, ref. step 9. Stop timing when stripping valve is closed, ref. step 11.

- The time taken to be recorded. - Residues to be collected and measured.

Note! Residues in cargo deck line to be measured separately.

Log the results

Tank noResidues (liter)

In suction well On tank topDuration (sec)

Water residuesin tank afterwater test.

Fig. 37

10m

Cargo piping

Manifoldvalve

Test hoseMin. Ø75mm

Fig. 36 Suggested back pressure manifold arrangement




2.4 Purging of cofferdam

This procedure describes purging of submerged cargo pumps with «dry» cofferdam. (For submerged cargo pumps with liquid filled cofferdam, refer to instruction 1000-0102-4.)

The cargo pump cofferdam is essential for segregation of the pump hydraulic section from the cargo – and for seal monitoring. Purging to be carried out at regular intervals for the purpose of:

- Leakage rate detection - Condition monitoring of the shaft seal system - Avoid that leakages are blocking the cofferdam How to purge the cofferdam CAUTION: Exhaust gas and liquid may be hazardous. Wear safety gear and avoid contact with drain from exhaust trap and venting line. Preparation: 1) Place a suitable container underneath the exhaust trap to

collect the leakage.

2) Check that drain valve at bottom of exhaust trap is not blocked.

3) Drain the purging medium supply line for condensed water.

4) Connect purging hose (max. supply pressure 7 bar).

Purging:

5) Start the purging by opening the valve at purging medium supply line.

Note! A relief valve is fitted at cofferdam purging connection. This is set at 3-3,5 bar to limit the purging pressure for protection of the pump seals. A small leakage from the relief valve is normal when liquid is purged from cofferdam. The valve will also open if the cofferdam is blocked.

6) Check that exhaust gas is coming out of the exhaust trap vent line (to verify that cofferdam is open).

CAUTION! Exhaust gas and liquid – watch out ! 7) Purge cofferdam in several sequences if required.

Drain exhaust trap between each sequence.

8) Disconnect purging hose.

9) Close exhaust trap drain valve.

10) Log the amount of leakage, -evaluate the result.

Note! For handling special cargoes, ref. chapter 2.5.

Cofferdam purging connection

Purging medium supply

Exhaust gas

Cofferdamcheck pipe

Container tocollect the leakage

Relief valve

Exhaust trap

CLOSED

CLOSED

Purgingmedium

Flexible hose withsnap-on coupling

Vent. line

Drain valve

CLOSED

CLOSED

Fig. 38




Purging intervals, - logging of purging result

LOADING VOYAGE DISCHARGE

1. Shortly before loading.

1. 1-2 days after loading. 1. Shortly before discharging.

2. If no leakage at step 1, purge every fortnight. 2. Shortly after discharging.

3. If leakage is detected at step 1, or at a later stage during the voyage, purge this pump every day.

4. If pumps are used for cargo circulation during the voyage, the cofferdam must be purged before start and after stop.

Note! Neglecting of purging can result in a blocked cofferdam and lack of leakage control. The purging form should be filled in with the results from every purging operation. Each horizontal line in the form represents one cargo in one tank from loading till discharging. If a ship loads and discharges some tanks more frequently than other, an extra form should be filled in for those tanks.

PURGING ROUTINE FOR FRAMO SUBMERGED CARGO PUMPS

SHIP NAME:__________________________________ VOYAGE NO.: __________________________________

Electronic copy: [email protected] paper copy: Frank Mohn Services AS Ship owner: Electronic/ Paper copy

A B C D

NOTE:

In "Result" column: H = hydr. oil C = cargo W= water condensate In "Open cofferdam" column: Yes = air or liquid coming through No = Blocked cofferdam

Shortly

before loading

1-2 days

after loading

If no leakage at A go to C.

If leakage at A purge this pump every day

Shortly

before unloading

Shortly

after unloading

Tank No.

Cargo Date Result Open coffer-dam

Date Result Open coffer-dam


Average result



State action taken, new parts installed, etc.

Signed by: Chief Officer Chief Engineer Pumpman

For long voyages with "no leakage at A"

purge at least every fortnight.

Tank no. Type ofcargo

Date ofpurging

Open cofferdam:Yes= air or liquid coming throughNo = blocked cofferdam

Note action taken -new parts installed etc.

RESULT:If no leakage, write OK.If leakage, write amount of leakage in litres andtype of leakage.(Example: 1H= 1 litre hydraulic oil, 1C= 1 litre cargo,1 H/C= 1 litre mixture of hydraulic oil and cargo).

Fig. 39 Example of FRAMO purging form

Filled in purging form to be sent to Ship owner and to Framo ([email protected]). (Green copy for the ship, red copy for the Ship owner and white copy for Framo.) Ship’s crew to evaluate the purging results and to take necessary action – however in case the ship’s crew needs advice, contact a Framo Service Station.




Evaluation of the purging result Cargo leakage

A small leakage rate of up to about 0.5 l/day (and higher with light cargoes) during pump operation is normal. Acceptable leakage rate depends on the type of cargo and possible consequences in case of leakage. - Risk for clogging of pump cofferdam

Cargoes like naphtha, condensate etc. penetrates the shaft seals more easily than lubricating oils, vegetable oils and other viscous cargoes. It is therefore recommended to carefully monitor the leakage rate over a period of time, preferable with different type of cargoes. For critical cargoes, when the leakage rate is about 2 litres/day or higher, the pump must be purged a couple of times daily and service (pressure test-repair) carried out at first opportunity. Intensify the purging if the leakage rate is exceeding acceptable limits. If this is not sufficient to keep the leakage under control it must, depending on the nature of the cargo, be considered to discharge the tank using the portable pump. Cargo leakage to cofferdam normally indicates shaft seal leakage. But the leakage might come from flange connections or damage (cracks/pin holes) in pump/pipe stack (ref. chapter 4, Trouble shooting). The development of a cargo leakage can be monitored if purging is done according to instructions. Thereby maintenance work can be planned, and unexpected shut down due to leakage can be avoided.

Hydraulic oil leakage

Hydraulic oil in the cofferdam normally indicates shaft seal leakage, but might come from flange face seals in pipe stack/ pump head or damage in the pipe stack/pump head. A small leakage rate into the cofferdam up to about 10 ml/h (0.25 l/day) from the mechanical oil seal or lip seal during pump operation is normal. For short periods of time, higher leakage peaks can occur. If the leakage rate is increasing above acceptable level, the pump must be purged a couple of times daily and inspected as soon as possible to find the reason for the leakage. Intensify the purging if the leakage rate is increasing above the acceptable level. If this is not keeping the leakage under control, close the hydraulic service valve. Depending of the nature of the cargo consider to use the portable pump to discharge the cargo. Blocked cofferdam

In general we do not recommend operating the cargo pump with blocked cofferdam. For advice, depending of type of cargo etc., contact a Framo Service Station.

Note! Always remember to pressure test the cofferdam with 3 bar to locate the leakage prior to any

dismantling of the cargo pump.




Liquidsupply

Liquidreturn

CLOSED

CLOSEDCLOSED

Valve forregulation of flow

OPEN

Flexible hose withsnap-on coupling Fig. 41

2.5 Precautions to be taken when handling special types of cargoes The main rule is to have the cofferdam clean, dry and vented to atmosphere through the exhaust trap vent line, in order to detect leakages easily. However, 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 solidifying cargo blocking the cofferdam. Recommended type of liquid to be filled into the cofferdam for some groups of cargoes is given below. This is a general advice, only experience can define which liquid gives the best result for the great number of different types of cargoes.

Filling To fill liquid in the cofferdam, disconnect the exhaust trap piping from the pump top plate. Using a suitable adapter, fill the liquid through the cofferdam check pipe. Open the purging connection to ventilate the cofferdam during filling. (Connect an open female coupling or similar). Circulation A circulation of liquid through the cofferdam can be arranged in the following way: - Connect liquid supply to the purging connection. The supply line must also be equipped with a valve to regulate the liquid flow. - Open drain valve on the exhaust trap, and collect the return liquid here. Note! When filling or circulating liquid in the cofferdam, it is important that the hydraulic oil return pressure always is higher than the pressure in the cofferdam. This is especially important on hydraulic systems with non-pressurised return line.

Solidifying cargoes (in cargo tanks with heating coils) To prevent the cargo to get solid (freeze) inside the suction well, circulate the cargo at intervals by starting the cargo pump.

Acid cargoes After discharging and purging is finished, it may be an advantage to circulate fresh water through the cofferdam to remove all residues after a leakage.

Phenol, caustic soda etc. A circulation of hot water through the cofferdam can avoid clogging. Note! Remember that some of these types of cargoes are very hazardous.

Polymerising cargoes. (TDI, MDI) Fill cofferdam with dioctyl phthalate(DOP) to limit the risk of blocking the cofferdam.

Heated oil products (fuel oil, crude oil) Fill cofferdam with diesel oil/white spirit to keep any leakage into cofferdam in liquid form. (This is especially important after stripping and during tank cleaning.)

Crystallizing cargoes (molasses, etc.) Fill cofferdam with fresh water. The cofferdam may also be arranged with a small water circulation.

CLOSED

Vent. line

CLOSED

CLOSED

Open purgingconnection

Fig. 40




2.6 Tank cleaning / cleaning of pump

For viscous/solidifying cargoes During tank cleaning the pump should be run at approximately the same flow rate as cleaning water / liquid supply. Halfway the tank cleaning time close the cargo discharge valve, open the stripping valve and operate pump for a short period in order to get a good cleaning of wear rings, seal rings, pumps parts and stripping pipe. Then open the cargo discharge valve and run the pump to complete the tank cleaning operation. Cleaning water left in pump's cargo pipe is to be stripped as described in chapter 2.3. For corrosive cargoes Tanks to be cleaned should be filled with a large amount of cleaning water to dilute the corrosive cargo. After tank flushing the same cleaning procedure as for viscous / solidifying cargoes should be followed.

Note! Remains of cleaning water in suction well to be removed to avoid galvanic corrosion.

Galvaniccell

Suction wellempty

Fig. 42 Note! If steam is used to clean the pump, the steaming out period must not exceed 10 minutes, to avoid damage of seals or hydraulic motor. Always purge the cofferdam before tank washing with steam. Note! If using sea water or brackish water for tank cleaning, see chapter 2.7.




2.7 Precautions if using cargo pumps in sea water

Seawater tank cleaning (Continuous circulation)

The nominal corrosion rate for stainless steel in sea water is low. However, under certain circumstances, local corrosive attack can take place and the corrosion rate might be severe. High chloride concentrations and low pH increase the probability of pitting and crevice corrosion as do high temperatures and stagnant solutions. Tank cleaning using sea water must therefore be carried out according to qualified procedure. - In general the tank cleaning should be carried out

within limited time frame at temperature below 60C. Higher temperature up to 80C can be used for a shorter period. (Fig. 43, for guidance only.)

- Avoid pH values below 6,5. Check carefully if the ship has been carrying acids.

- If hot seawater is used, cool immediately with cold seawater until surface temp. is below 40C before fresh water rinse. This to avoid concentration of chlorides from evaporation on hot steel surfaces.

- Tank cleaning with seawater must be followed by a thoroughly rinse with fresh water to remove chlorides.

Sea water for heavy ballast

- When possible, take clean seawater in open sea and avoid contaminated harbour water.

- Empty the tanks as soon as possible when the ballast is no longer required or when the testing is finished.

- Carefully clean the tank and the pump to ensure no chlorides remain on surfaces.

Max. exposure time, hours

Se

awat

er t

emp

. C

o

2 4

40

50

60

80

70

Tank cleaning

Fig. 43

2 4 6

10

20

30

40

8 10 12

Max. exposure time, days

Ballast

Se

awat

er te

mp.

Co

Fig. 44




2.8 Loading of cargo tank In general it is recommended to start the loading slowly to avoid pressure surges in the cargo pipe line and the pump. Correct operation of valves is important. Open / close valves slowly !

If a separate drop line is installed, it is recommended to load through the drop line only. If required to load through the pump, use following procedure: Note! For sampling procedures, ref. charterer's requirements. - Keep manifold valve closed until the cargo reach the manifold. - Open manifold valve partly to fill cargo line on deck. - Open cargo pump discharge valve and drop line valve slowly. - Open manifold valve slowly until required pressure/capacity is reached. Note! Maximum acceptable loading pressure when loading through the pump is 8 bar at the pump top plate.

Cargo line

Cargo discharge valveCLOSED

Drop line

OPEN valve

Loading pressureMax. 8 bar

Fig. 45 Arrangement with separate drop line




3 MAINTENANCE INFORMATION

Prior to entering a cargo 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 cargo tank before the tank is confirmed gas free and safe. Before doing service on pump, always close and lock the hydraulic pressure inlet valve and purge the cofferdam. Purge cofferdam according to chapt.2.4. Close the cargo discharge valve. Ensure that the valve is in closed position until the work/service is finished (info sign to be placed at the control panel/computer).

Caution: Venting gas and liquid may be hazardous. To prevent skidding and minimize the risk of fire it is important to remove oil spill during maintenance and servicing work. The operator should be confident that all flange connections are in satisfactory condition so as to prevent hydraulic oil and cargo spills.

4 TROUBLE SHOOTING

Warning: To prevent damage from hazardous cargoes, take necessary precautions, wear safety gear and avoid contact with spray/gases.

Symptom: Possible reason: Remedy: *)

COP operational problem (First it is necessary to verify if the problem is in the pump control system or in the pump unit itself).

General Ref. system service manual - Trouble shooting section

The pump will not start a) Cargo pump remote control system failure

b) Pump control valve failure

c) Pump impeller stuck.

c1)Frozen /solidified cargo

c2)Foreign objects stuck in pump or other mechanical problem

a) Ref. instruction for Pump remote control

b) Ref. Instruction for Pump control valve (STC)

c1) Heat the cargo in the pump suction well.

c2) Pump unit to be inspected.

Pump is vibrating heavily a) Control system problem

b) Rotating parts out of balance.

a) Ref. instr. for Pump control system.

b) Impurities stuck in impeller or other mechanical problem.

Too low pumping capacity a) Control system problem

b) Worn wear rings. Impurities stuck in impeller, or other mechanical problem

a) Ref. instr. for Pump control system and instr. for Pump control valve. (If required interchange pump control valve as described in instr. 1000-0109-4)

b) Pump unit to be inspected

*) Ref. instruction for maintenance and repair for actual pump.





Noise(non return valve) and vibration when loading through the pump.

Damaged back stop unit

Check hydraulic motor inlet pressure – pressure above 15-20 bar indicates malfunctioning back stop unit.

Change back stop unit.

Contact a Framo Service Station.

Not possible to purge the cofferdam (no air, inert gas or liquid coming out of the check pipe when purging)

(See also chapter 2.4)

a) No or insufficient purging medium supply

b) Blocked cofferdam system

Note! In case steam is used in attempt to clear a blockage in pump cofferdam system pay special attention not to over pressurize the pump/pipe stack

a) Check valves, hose connections and purging medium relief valve (open at approx. 3 bar).

b) Check the exhaust trap and the piping on deck for blockage. Open if possible.

b1) Disconnect check pipe from pump unit (lower seal house) – watch out for possible pressurized liquid in cofferdam!! By carefully purging check if the blockage is located in the check pipe or in the pump/ pipe stack cofferdam. Depending on the nature of the medium blocking the cofferdam system use steam or solvent to dissolve the blockage. Dismantling of pump might be required.

Note! Pressure test pump after assembly.

Cargo leakage to pump cofferdam.


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. a) Worn cargo seal

Note; If no leakage is detected by pressure test it is likely that the cargo leakage to cofferdam is caused by worn cargo seal. (the upper seal lip is sealing when pressurizing cofferdam).

b) Leaking seal element in

flange connection c) Crack/pinhole in piping

Pressure test pump cofferdam system at approx. 3 bar. Check for leakage – if required spray with soapy water to locate the leakage. a) Replace cargo seal set.

Also, carefully check ceramic sleeve for possible damage-wear.

b) Check for loose bolts and for pitting corrosion

in seal faces – in case of corrosion repair is required. When assemble, renew damaged seal element.

c) Contact a Framo Service Station.

*) Ref. instruction for maintenance and repair for actual pump.





Hydraulic oil leakage to pump cofferdam.


General

a) Leaking shaft seal

b) Leaking seal element in flange connection.

c)Crack/pinhole in piping

Drain the pump return side prior to dismantling. Disconnect pump head/unit from pipe stack/casing. Pressurize pump unit return side at approx 4 bar and check for leakage to cofferdam side. Pressure test pump pipe stack / casing at max 7 bar on cofferdam side and check for leakage to return side.

a)Replace shaft seal (replaced seal to be reconditioned if feasible)

b) Check sealing surface for possible damage – repair if damaged. When assemble, renew damaged seal element.

c) Contact a Framo Service Station.

*) Ref. instruction for maintenance and repair for actual pump. Note! Evaluate if changed parts as sleeves, mechanical seals etc. are possible to recondition. Send these parts to a Framo Service Station and ask for an evaluation.

Documents

1000-0121-401