Framo Submerged Ballast PumpsNo. 1000-0199-4 Rev. A 27Oct09 Operation manual SB200 SB300 SB400 SB600 .......... ........Evacuation system Figures in this procedure are made general for all types of submerged ballast pumps......................... ....... A sealing arrangement between top plate and pipe stack allows the pipe stack to expand.............. ... 5 2........... Pump head The pump head includes the hydraulic motor.......................................... impeller and sealing arrangement......................... 11 Reference to associated instructions 1000-0109-4: Interchange of pump control valve 1375-0027-4: Service manual for Speed Torque Controller (STC) 1 GENERAL DESCRIPTION The Framo hydraulically driven submerged ballast pump consists of five main parts: ...Top plate/Control valves . 5 2. ............. .....................2 Cofferdam control ...................... For further information.................................... A cofferdam completely segregates the hydraulic oil from the ballast water............. ............. 11 TROUBLE SHOOTING .........................1 Ballasting / deballasting ... 8 3 4 MAINTENANCE INFORMATION .. .... Supports on the pipe stack prevent horizontal movement and allow for vertical expansion............... Date/sign.............................Pipe stack ......: Page: Rev.................... The pump control valve STC(Speed Torque Controller) and evacuation control unit and header tank is located at the top plate.Pump head ........................ Air entering the pump through the suction line will be separated in the air separator and removed by the evacuation system. see drawings for the actual ballast pump.............. Pipe stack The pipe stack consists of a hydraulic section and an arrangement with pipe and cable for the evacuation system... ...................................... ............... 2 OPERATING INFORMATION....Pump casing/ air separator ................... Pump casing / Air Separator The pump casing is bolted to a foundation...Framo Submerged Ballast Pumps OPERATION MANUAL No.... The cofferdam is filled with water/glycol. Top plate/ Control valves The pipe stack penetrates the top plate............................................A : 1000-0199-4 20Sep07/HB 2 of 13 27Oct09/AGAa CONTENTS 1 2 GENERAL DESCRIPTION ........... A : 1000-0199-4 20Sep07/HB 3 of 13 27Oct09/AGAa Fig.: Page: Rev.Framo Submerged Ballast Pumps OPERATION MANUAL No. Date/sign. 1 . 2 The evacuating capacity for the air driven ejector is given in fig. When the water level again reaches the level switch. reduce pump capacity to obtain an improved suction performance. If there is air in the pump casing the level switch will be dry. Then the ejector will start evacuation the pump casing and suction piping (priming “on”).: Page: Rev. . No.Framo Submerged Ballast Pumps OPERATION MANUAL Evacuation system The evacuation system starts if it is air in the pump casing. the air consumption will be.9 Nm /min (49 Nl/sec) 3 3 (Nm = normal m ) 3 -4 -2 Volume 1 m3 20 40 60 80 Time (seconds) 100 120 140 Fig.1 Nm /min (18 Nl/sec) 3 For SB400 and SB600 pumps: 2. Vacuum (mwc) Priming with 7 bar air supply pressure to ejector -8 -6 S 0 B4 0 60 0/ 0 0/3 20 B S 0 With an air supply pressure of 7 bar to the ejector. the ejector will stop. Date/sign. 3. 3 Curve indicating vacuum in a 1 m 3 volume (suction line) versus priming time. Illuminated lamp on the pump control panel indicates that the evacuation system is in operation. Note! The evacuation system is only activated when pump control is switched “on”.A : 1000-0199-4 20Sep07/HB 4 of 13 27Oct09/AGAa Fig. For SB200 and SB300 pumps: 1. In this running mode. The system is automatically activated by the level switch (conductive type with intrinsically safe circuit [EExia]). . fig. motor To get maximum lifetime of the pumps. Note! HP service valve (fig. Start the pump slowly. as this may damage the hydraulic motor. Note! Avoid running pumps against closed discharge valve for a longer period.Framo Submerged Ballast Pumps OPERATION MANUAL No. 1 minute. .1 Ballasting / deballasting As the flow caused by gravitation decreases.: Page: Rev. 2. 1) should always be open except when carrying out service work on the pump. to avoid gravitation through the ballast pump (ref.Check that pressurized air for evacuation system is available. Date/sign. 5 Close bypass valve.4). Note! The ballast water must not gravitate through the pump.Check that the hydraulic system is started and enough hydraulic power is available. Starting of pump Open ballast pump suction valve. Valve. open = Valve. Fig. closed = Suction WBP Discharge Bypass Fig. the pump has to be started to increase the capacity. 6 . open discharge valve and increase hydraulic motor pressure until required capacity is achieved. 8). Keep suction valve and discharge valve closed and open by-pass valve. and let it run with hydraulic motor pressure 50 bar for approx.A : 1000-0199-4 20Sep07/HB 5 of 13 27Oct09/AGAa 2 OPERATING INFORMATION Hydr. 4 Water gravitating through the ballast piping system. the ballast water will normally gravitate through the ballast piping system. Fig. fig. When starting ballasting. operate the pumps within the operation range (ref. An gradually increasing amount of air will enter the pump suction line via the vortex forming at the suction bell mouth.A : 1000-0199-4 20Sep07/HB 6 of 13 27Oct09/AGAa Fig. 9 End of deballasting (ship in aft trim condition) . This may lead to heavy vibrations and damage to the pump. Throttle the discharge valve. No. There are two ways to bring the pump back to the operation range: a) b) Reduce speed / hydraulic motor pressure. Air will accumulate in the pump casing (air separator) and the evacuation system will eventually be activated – priming light in control panel switched on. 7 Limit of operation ress ur e Head H 1 00 % m o to r p 75% Pressure loss. opening in stiffeners etc. the pump capacity must be reduced to avoid loss of suction. This is most critical when emptying a ballast tank furthest away from the pump. 8 Note! Performance diagram for the actual pump gives the operation range End of deballasting With low water level in the ballast tank. Date/sign. throttle discharge valve b 50% OPERATION RANGE Pressure loss discharge system a Capacity Q Fig.). Fig. When running pump at low discharge head and high motor pressure.: Page: Rev. the capacity will be higher than normal.Framo Submerged Ballast Pumps OPERATION MANUAL Pumping The ballast pump is designed to operate with discharge head between 20 and 30 mlc (design head). The pump capacity must be reduced to match the water inflow to the suction bell mouth area (the inflow is depending of the tank layout. Run the pump as described for remote controlled operation. The evacuation system will be operating continuously. Date/sign. indicated by the priming lamp on the control panel. Note! Do not run the pump unnecessary when the pump loses suction. 11 . OPEN BAR ON Priming activated Fig. No. 300 225 150 75 0 Handle in maximum position Local control valve. Close the suction valve. the pump will lose suction. Set the remote control handle in the maximum position. Open local control valve by turning counter-clockwise.A : 1000-0199-4 20Sep07/HB 7 of 13 27Oct09/AGAa Fig. Start the pump by closing the local control valve by turning clockwise.: Page: Rev.Framo Submerged Ballast Pumps OPERATION MANUAL Stopping the pump When the ballast tank is empty. and stop the pump. 10 Operation of pump from local control valve The ballast pump can be operated from the local control valve at the STC valve. Close the discharge valve. ethanediol) Propylene glycol is less toxic and less corrosive than ethylene glycol. Clean and correct type of cofferdam liquid is important in Fill glycol water order to get a long lifetime of the shaft seal arrangement.2. Seal arrangement Mechanical oil seal Hydraulic return oil Pressure 3 .Remove the cap on header tank and fill the cofferdam liquid through the header tank.2 Cofferdam control The pump hydraulic section is surrounded by the liquid filled cofferdam that completely segregates the hydraulic oil from the ballast.2.: Page: Rev.-35°C * Propylene glycol. Date/sign.2 ethanediol.5) 87 + (L x 3. When filling pump head.Framo Submerged Ballast Pumps OPERATION MANUAL No. Framo recommend propylene glycol to be used. Static overpressure in the cofferdam gives clean cofferdam liquid to the seal faces and lubrication of these.5) L = Pump length in metres. The following formulas give approx.Glycol * Freezing point 40 60 -40°C - 50 % 50 % . Note! Think safety and health.A : 1000-0199-4 20Sep07/HB 8 of 13 27Oct09/AGAa 2. . Therefore. .5 + (L x 0. 12 The cofferdam volume depends on pump type and pump length. Condition monitoring of the shaft seal arrangement is carried out by surveillance of the liquid level in the header tank. the cofferdam can be filled with demineralized water without glycol. Glycol is added to prevent freezing.5 bar static head Mechanical sea water seal Filling sequence: .5) 102 + (L x 3.5 80 95 125 Pipe stack L x 0. 1. C2H6O2 (monoethylene glycol.5) 132 + (L x 3.Demineralized water: .Fill the cofferdam until liquid level stabilises at normal level on the sight glass (halfway between low and high level mark).10 bar Cofferdam Chamber Water/glycol Pressure 1 .5 bar Ballast Pressure 0 . Note! Never use other anti-freeze solutions. 1. Lower bleed plug cofferdam (toolbox) Use only pure glycol without additives. (See Framo specification) . Read the Material Safety Data Sheet before using the different glycol. vent through the lower bleed plug (fig.5 L x 3.Air in cofferdam must be released during filling. propanediol) or ethylene glycol.2 propanediol.5 Header tank 5 7 7 7 Total 7.Hydraulic oil filling of pump must be done before cofferdam is filled. If no danger of frost. Fig. volume (in litres) required to fill cofferdam to normal level in header tank: Pump type SB200 SB300 SB400 SB600 Pump head 2. .5 L x 3.5 L x 3. Remove cap Header tank Cofferdam liquid: Upper bleed plug cofferdam . Some of the additives in anti-freeze forms deposits on seal parts and thereby causing seals to fail. C3H8O2 (monopropylene glycol. 12). Pipe stack to be ventilated through the upper bleed plug. Leakage rate (to be calculated) = (H 2 − H1 )x31 [ml/h] h .: Page: Rev. Low level Normal level variations depends on pump type and pump length. at normal operating temperature. By using the enclosed log form (page 12). The header tank level(H) to be measured in mm above low level mark on sight glass. 13 Because of level changes due to temperature variations. it is possible to establish a trend towards increasing or decreasing level. Figure indicates normal level variations with 10 oC temperature variation on cofferdam liquid. Date/sign. the level should always be monitored at the same temperature. Figure 13 indicates normal level variations for the different pump types with a temperature change of ±10°C on the cofferdam liquid for the different pump types.A : 1000-0199-4 20Sep07/HB 9 of 13 27Oct09/AGAa The liquid level in the header tank varies with the temperature of the ballast water. The filled in example below indicates how to use the log form.Framo Submerged Ballast Pumps OPERATION MANUAL Monitoring of cofferdam level We recommend regular control of the cofferdam level. High level No. i.e. hydraulic oil and ambient temperature. Fig. For a shorter periode of time. Therefore increasing or decreasing level due to leakages from mechanical seals should not be expected when pump is not in operation. Increasing level (Hydraulic oil leak into pump cofferdam) Different temperature compared to the previous measurement (temperature of the ballast water. Volume and amout of oil must be logged. hydraulic oil and ambient temperature). the leakage rate from the mechanical seals is very low (up to 0. A continous leakage rate > 20 ml/h or a sudden increasing level in header tank indicate a worn out mechanical oil seal. Different temperature compared to the previous measurement (temperature of the ballast water. hydraulic oil and ambient temperature). Bleed plug cofferdam Layer of oil High level High level Hose (toolbox) Water/ glycol Low level Refill and log volume Low level Fig. If the level drop under low level.13. refill the header tank. please contact Frank Mohn Services AS for assistance.: Page: Rev. which most likely occurs in the first period after initial water/glycol filling or complete refill after service. higher leakage peaks can occur. Trouble shooting). IN CASE OF ANY DOUBT.Framo Submerged Ballast Pumps OPERATION MANUAL No. Normal leakage rate can be up to 5 ml/h from the mechanical oil seal.A : 1000-0199-4 20Sep07/HB 10 of 13 27Oct09/AGAa EVALUATION OF CHANGES IN LIQUID LEVEL IN HEADER TANK When pump is not running. Changes in liquid level Sudden decrease Decreasing level (Leak from pump cofferdam to ballast tank) Possible reason Can indicate that it is air in the cofferdam system. This will give a increasing level in header tank of up to approx. fig. Drain off and log volume If level exceed high level.e. Refill the header tank. “Trouble shooting”. 15. Log the volume.13. 16 mm per 100 running hours. the header tank must be drained. higher leakage peaks can occur. see fig. i. 15 . 0.1 ml/h). 14 Fig. i. ref. Abnormal decreasing level over a period of time indicate a worn out mechanical sea water seal. This will give a decreasing level in header tank of up to approx.65 mm/h. Date/sign. chapter 4. ref.e 65 mm per 100 running hours.16 mm/h. When pump is running the normal leakage rate can be up to 20 ml/h from the mechanical sea water seal. see chapter 4. and overhauling may be necessary (ref. 0. fig. Empty the header tank by draining through the cofferdam bleed plug. For a shorter periode of time. (If required interchange pump control valve as described in instr. instr. for Pump control system. b) Impurities stuck in impeller or other mechanical problem. instruction for Remote control system b) Ref. Date/sign. system service manual .Trouble shooting section a) Ballast pump remote control system failure b) Pump control valve failure c) Pump impeller stuck. instr. a) Ref. After any work has been carried out in the ballast tank. Note! To prevent contamination and hazardous situations it is important to avoid oil spill during maintenance and repair work. The operator should be confident that all flange connections are in satisfactory condition so as to prevent hydraulic oil and cargo spills. or other mechanical problem *) Ref. Do not enter a ballast tank before the tank is confirmed gas free.Framo Submerged Ballast Pumps OPERATION MANUAL No. Before starting to dismantle impeller. 1000-0109-4) b) Pump head to be inspected Pump is vibrating heavily a) Control system problem b) Rotating parts out of balance. always check that the tank is free for foreign objects.. for Pump control system and instr. a) Ref. Close the ballast valves (suction line and discharge line).: Page: Rev. make sure that pipe stack/ pump head is secured properly in order not to drop down when work is in progress. Too low pumping capacity a) Control system problem b) Worn wear rings. Drain in accordance with procedures ( “Instruction for maintenance and repair” for actual pump). Ensure that the valves are in closed position until the work/service is finished (info sign to be placed on the control panel/computer). always close and lock the HP service valve. instruction for maintenance and repair for actual pump.A : 1000-0199-4 20Sep07/HB 11 of 13 27Oct09/AGAa 3 MAINTENANCE INFORMATION Prior to entering a ballast tank for doing service it is essential to become familiar with the ship's safety rules and requirements regarding cargo-handling equipment. Instruction for Pump control valve – STC c1)Pump head to be inspected. Before doing service on pump. c1)Foreign objects stuck in pump or other mechanical problem a) Ref. wear rings etc. Impurities stuck in impeller. for Pump control valve. 4 TROUBLE SHOOTING Symptom: Ballast pump operational problem (First it is necessary to verify if the problem is in the pump control system or in the pump head itself). The pump will not start Possible reason: General Remedy: *) Ref. . 2. Remedy: *) Log level in header tank for a periode of time. a) Replace mechanical seawater seal. Signal from ballast tank level Stop the pump and check level switch and switch not detected. Date/sign.2) Possible reason: General Note! Always pressure test pump prior to and after dismantling.2) General a) Leaking mechanical oil seal b) Leaking seal element in flange connection(s).2).A : 1000-0199-4 20Sep07/HB 12 of 13 27Oct09/AGAa Symptom: Decreasing level in header tank. 2. (See also chapt. a) Worn mechanical sea water seal b) Leaking seal element in flange connection c) Crack in piping Increasing level in header tank. c) Contact Framo Service Station c) Crack in piping The ejector do not start Signal from ballast tank level Stop the pump and check level switch and switch not detected. Pressurize pump return side at approx 4 bar and check for and locate the leakage. 3 bar.Framo Submerged Ballast Pumps OPERATION MANUAL No. This is required to locate possible leakage and to confirm no leakage upon completion of repair. instruction for maintenance and repair for actual pump. Note! Evaluate if changed parts as sleeves. mechanical seals etc. a) Replace mechanical oil seal (replaced seal to be reconditioned if feasible) b) Check sealing surface for possible damage – repair if damaged.: Page: Rev. Evaluate the changes (see chapt. (replaced seal to be reconditioned if feasible) b) Check for loose bolts and for pitting corrosion in seal faces – in case of corrosion repair is required. Note! For inspection of pump head / shaft seal it is required to lift pump out of pump casing prior to pressure test. related wiring to control panel. 2. related wiring to control panel. see instruction for maintenance and repair. Send these parts to Framo Service Station and ask for an evaluation . Note! For inspection of shaft seal area it is required to lift pump out of pump casing prior to pressure test.2). Evaluate the changes (see chapt. Pressure test pump cofferdam system at approx. The ejector do not stop *) Ref. Check for leakage – if required spray with soapy water to locate the leakage. (See also chapt. Assemble using new seal element. see instruction for maintenance and repair. c) Contact a Framo Service Station Log level in header tank for a periode of time. 2. Assemble using new seal element. are possible to recondition. chapter 2. Pump location (P or S) Date Header tank level (H) (mm) Ballast water temperature (°C) Hydraulic oil temperature (°C) Ambient temperature (°C) Hours of operation since last control (h) Leakage rate (ml/h )* Comments / Remarks (Action taken) Signature / Date *Leakage rate (to be calculated) = (H 2 − H1 )x31 h [ml/h] Also ref.2. 1000-0199-4 Page 13 of 13 Rev. 1 mm on sight glass is equivalent to 31 ml volume. A 27Oct09/AGAa LOG FORM FOR LIQUID FILLED COFFERDAM ON FRAMO SUBMERGED BALLAST PUMPS VESSEL NAME: ____________________________________ TYPE OF LIQUID USED IN COFFERDAM: __________________________________ Header tank level(H) to be measured in mm above low level mark on sight glass.No. “Monitoring of cofferdam level” .