Description
Fuel Conditioning ModuleTechnical information for fuel oil conditioning Inside view The FCM is part of a complete fuel treatment system from Alfa Laval. Working in conjunction with Alfa Laval Separation Units, the FCM provides operators with a one-stop fuel oil treatment chain – from bunker tank to diesel engine. 3 4 Summary The Fuel Conditioning Module System requirements System benefits Standard sizes Capacities 6 Why the Fuel Conditioning Module? Where we were Where we are Where we’re going 8 Equipment The fuel conditioning process Low-pressure stage High-pressure stage Key components Standard and optional components 16 18 20 System configurations FCM configurations Flow diagram Automation Main control functions Self-cure functions Process information 23 24 24 24 24 Remote monitoring and control Retrofitting Documentation Classification society approval Spare parts, service and support Alfa Laval Fuel Conditioning Module 2 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module Summary The Alfa Laval Fuel Conditioning Module (FCM) is a new automated two-stage pressurized fuel booster system used for diesel engines in the shipping and power station industries. A start-and-forget system, it supplies clean filtered fuel to the engine at the flow rate, pressure and viscosity specified by the engine manufacturer. The FCM is available in three sizes, in different configurations and with options for additional flexibility. FCM pumps, automatic backflush filter, mixing tube, heaters, viscosity sensor, centrally located process controller and other components are mounted on a single base plate. All components, connections and controls are pre-installed and pre-tested. For easy installation where space is limited, modules can be divided into two separate units. The FCM provides what is arguably the best control system available on the market. It has a range of flexible solutions for remote operation. Conveniently housed in a central pillar, the FCM’s new generation of process controller integrates all monitoring and control functions, including startup, diesel oil (DO) and heavy fuel oil (HFO) changeover, self-cure functions and process information. The process controller employs the same user interface as the controller for the Alfa Laval Separation Units. This enables Alfa Laval to supply a complete fuel treatment system that works in harmony and provides operators with a familiar operating environment. Alfa Laval has vast experience in the design, manufacturing and supply of modules for fuel conditioning. All modules are carefully tested and, when required, approved by leading classification societies. The purpose of this document is to provide technical information about the FCM. This includes information about the fuel conditioning process, advances in system design, the benefits of these advances, and a description of equipment with an emphasis on automation and remote monitoring and control. Benefits for the shipyard and engine builder • Easy to install. Compact, modular, flexible design saves space, reduces installation costs, and meets the precise requirements of specific engines and engine rooms. • Faster, more secure commissioning with full technical support during design, installation and startup. • A single responsible supplier. Alfa Laval designs and engineers the complete fuel conditioning system, supplying it as a convenient factory-tested module. • Complete system approach. Used in conjunction with Alfa Laval Separation Units, the FCM is part of a complete, automated fuel treatment system. Benefits for the ship or plant operator • User-friendly, easy-to-access, easy-to-operate equipment with automatic, start-and-forget systems that minimize maintenance, reduce man-hours and cut operating costs. • Proven key components provide more uptime, high reliability, consistent performance and low maintenance. • A single responsible supplier. Alfa Laval assumes full responsibility for the availability of FCM functionality, including service, spare parts and support. • Easy installation when replacing older modules or upgrading from 180 cSt to a higher viscosity fuel, which saves money. • Maximum safety for the engine when changing over HFO-DO mode. Automatic ramp function handles transition between two modes to prevent temperature shock to engine injection equipment. Alfa Laval Marine & Diesel Equipment 3 Alfa Laval Fuel Conditioning Module The Fuel Conditioning Module The FCM is part of the complete Alfa Laval fuel oil treatment chain from bunker tanks to diesel engine. It is specifically designed for marine applications and diesel power stations for conditioning of heavy fuel oils prior to injection. Alfa Laval Fuel Conditioning Module. Compact, easy to install and easy to operate, the FCM consists of carefully selected components mounted on a frame, complete with piping, valves, electrical cabling and other accessories. The FCM operates at pressures of up to 14 bar and at fuel oil temperatures of up to 160°C. Standard sizes cover flow rates to the engine from one to up to 30 cubic metres per hour. • Flow rate The maximum fuel consumption rate of the engine, multiplied by a circulation factor. Circulation factors generally fall within the range of 2.0 to 6.0, depending on the type of engine. • Pressure Depending on the type of engine, generally falls within the range of 4 to 14 bar. • Viscosity Generally falls within the range of 10–15 centiStokes (cSt). Clean fuel oil of the correct viscosity should be circulated under constant pressure at a high flow rate through the injector pump block. This ensures efficient engine operation, during changing engine output, regardless of engine type and engine manufacturer. If these requirements are not met, then the engine will not perform according to manufacturer specifications and emissions may increase due to poor combustion. System requirements Fuel conditioning is the term given to a system that treats the heavy fuel oil used in marine diesel engines and diesel power stations so that the fuel oil meets the requirements for cleanliness, flow rate, pressure and viscosity specified by the engine manufacturer. • Cleanliness The percentage of particles over a certain size that must be removed by filtration. A typical specification requires removal of 85 percent of all particles larger than 20 microns. 4 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module System benefits • Compact, modular and flexible design The small FCM footprint saves up to 20 percent of engine room space. Its modular design provides flexibility to configure the unit and the fuel conditioning system layout, according to requirements of a specific engine or engine room. A wide range of options for functionality, remote control and other features adds more flexibility. • Easy to install Simple installation of this factory-tested module makes the FCM a plug-and-play fuel conditioning system. Pipe connections located underneath the unit make the FCM easy to install in most engine rooms. Piping can run in any direction – from the front, rear or side. • Faster, more secure commissioning Pre-tested, pre-installed and pre-approved components for all functions of the FCM system make commissioning quick, easy and much less expensive than buying separate components and designing a fuel conditioning system. • Easy to operate Automation and remote control make the FCM a userfriendly, start-and-forget system. The process controller also shares the same user interface as the Alfa Laval Separation Unit controllers, facilitating ease of operation for a complete fuel treatment system. • Easy to access and maintain Built-on service areas facilitate inspection and maintenance. A central pillar houses all motor starters and the advanced process controller so that the FCM is easier to service and easier to operate than the other fuel conditioning units available today. • Robust design The module is designed with the lowest center of gravity available on the market, suitable for handling excessive external vibrations onboard ships. • More uptime Low maintenance requirements on components, automation and remote control increase operating time and decrease service disruptions. Durable components contribute to longer service intervals between inspections. • Lower installation and operating costs Thanks to pre-testing, FCM installation requires less time and money than installation of separate components. Automation and remote control reduce operating costs. • Lower maintenance costs Many components, such as the automatic backflush filter and HEATPAC® heaters, require little maintenance. • Technical support All spares, service and sales engineers are available through the Alfa Laval International Service Network. Standard sizes Standard fuel conditioning modules from Alfa Laval consist of three series of modules. Fuel Conditioning Size Module in mm FCM 1000 series 2500x1150x1900 FCM 2000 series 3000x1150x1900 FCM 3000 series 4500x1500x2200 Volume 5.5 m3 6.5 m3 14.9 m3 Weight 1650 kg 1950 kg 2700 kg Capacities Each module series can handle several different capacities, depending on the installed components. This gives a total of eight different capacities. The largest module covers a diesel engine installation with an output capacity of approximately 50–60 MW engine power. For the exact module size required for different demands, please contact Alfa Laval. Engine power. FCM 3300 FCM 3200 FCM 3100 FCM 2200 FCM 2100 FCM 1300 FCM 1200 FCM 1100 0 10 60 Hz 20 50 Hz 30 40 50 60 70 MW Based on engine consumption 200 g/kWh. Filter after supply pumps and circulation factor 3. Alfa Laval Marine & Diesel Equipment 5 Alfa Laval Fuel Conditioning Module Why the Fuel Conditioning Module? Making fuel-conditioning solutions more efficient is paramount to boosting the bottom line for ship operators as well as power station operators. The FCM from Alfa Laval helps these operators make their businesses more profitable. Alfa Laval is committed to providing fuel-conditioning systems that improve operating costs and profitability. To understand how and why the FCM contributes to this success, let’s take a brief look at fuel conditioning: where we were, where we are and where we’re going. This arrangement had two inherent problems. First, as fuel viscosity increased, there was insufficient head from the feed tank to ensure the correct flow rate of fresh oil into the system. Second, cavitation occurred in the circulation pumps due to temperatures in excess of 100°C at fuel injection. As fuel returned to the atmospheric mixing tube, the small quantities of water usually found in light fuel oils mixed with more volatile components in the fuel itself and vaporized after passing through the pressure control valve. Other factors also played a role in advancing fuel-conditioning system technology. Fuel booster systems were large, poorly designed and difficult to service and maintain, despite some minor improvements. Most of the systems delivered used fuel temperature as the primary control parameter, despite the fact that a viscometer was often installed. This was due to the fact that the accuracy of these early viscosity systems was considerably lower than today’s systems. Reduced staffing of the engine room raised demand for low maintenance, improved safety and remote control. There was also demand to improve the environmental aspects of fuel treatment and engine operation. Where we were In the 1970s, oil prices increased substantially as a result of limited supplies of crude oil used to make refined products, such as distillates like petrol and jet fuel. In addition, the increased demand for distillates led to a new refining process known as catalytic cracking. Catalytic cracking enabled refinement of significantly lighter fractions of fuel from crude oil. This caused deterioration in the quality of marine engine residuals. Fuel conditioning for light fuel oils consisted of a simple atmospheric booster system with an open mixing tube, circulation pumps, heaters, filters and a heater control system based either on temperature or on viscosity. Fuel flowed through the injector pumps at the pressure created by the engine pressure control valve. Excess fuel returned to the atmospheric mixing tube. The daily service tank and mixing tube were level so that gravity caused fresh oil to flow into the system. Atmospheric booster unit. Two-stage fuel conditioning module of Alfa Laval SBM type. 6 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module Where we are The lessons learned from the 1970s soon gave way to improvements. During the 1980s, Alfa Laval paved the way to increased use of heavy fuel oils by introducing the Alcap® type fuel oil separator. Alcap separators enabled diesel engines to use fuel oils of 700 cSt at 50°C with a maximum density of 1010 kilograms per cubic metre at 15°C. Alfa Laval then continued its research and development efforts, collaborating with a major engine manufacturer to explore ways to improve fuel conditioning. The development of the two-stage pressurized booster system is the result of these efforts. Two-stage pressurized systems, such as the FCM, eliminate the control difficulties that are frequently encountered with single-stage systems. Two-stage pressurized systems also reduce the occurrence of other problems, such as gasification, that are associated with the high fuel temperatures required for operation using heavy fuel oil. By introducing a feeder module with supply pumps and a closed pressurized mixing tube at the low-pressure stage, fresh fuel is supplied, maintained at the proper pressure and flow, and mixed with hot fuel returning from the engine. Because the closed mixing tube maintains a pressure of at least 4 bar, cavitation does not occur. Fuel is then circulated during the high-pressure stage to obtain the required viscosity for injection. Unlike single-stage systems that often use temperature as the primary control parameter, the FCM uses viscosity as the primary control parameter. Single-stage atmospheric systems are generally now used only when the required fuel injection temperatures do not exceed 110°C. This corresponds to fuel oil of approximately 180 cSt at 50°C. However, two-stage systems are also now used for light fuel oils because two- stage systems offer other benefits, such as greater flexibility for installation. Heavy fuel oils are now the fuel of choice for main diesel and auxiliary engines. Viscosity has proven to be an important factor for efficient engine operation. Diesel engine manufacturers specify the fuel injection viscosity that provides optimum combustion. Heavy fuel oils, usually between 380 and 700 cSt at 50°C, are generally heated to approximately 130° to 150°C to obtain the required injection viscosity. However, the temperature required to heat a certain grade of heavy fuel oil to a certain viscosity varies. This depends on the origin of the crude oil upon which the heavy fuel oil is based and on the refinery process used. Using viscosity as the primary control parameter therefore improves fuel efficiency, while preventing engine damage and reducing maintenance costs. Where we’re going Fuel conditioning is constantly undergoing change as fuel quality fluctuates, for better or worse, and as new ideas about how to improve fuel treatment emerge. We at Alfa Laval understand what it takes to design efficient fuelconditioning systems and we are continuously working to improve them. Our efforts are in direct response to the changing needs of the marine and power station industries. Alfa Laval fuel-conditioning solutions comply with the rules and recommendations concerning the design of heavy fuel treatment plants for diesel engines. We are actively involved in CIMAC, the International Council of Combustion Engines. The FCM also fulfils the rules and regulations of the major classification societies. We believe in more efficient and more environmentally aware fuel-conditioning solutions for marine transport and landbased power stations. We also believe in solutions that help reduce costs. We’ve been working on improving fuelconditioning solutions for more than a quarter of a century. And we plan to continue to do so, using our in-house expertise and thorough understanding of engine operation. Alfa Laval Marine & Diesel Equipment 7 The new two-stage conditioning module of Alfa Laval FCM type. Alfa Laval Fuel Conditioning Module Equipment The compact, modular and user-friendly FCM design makes the best use of available space and provides flexibility, easy access and easy operation. Centrally located, the control cabinet is surrounded by several sub-assemblies, or blocks, such as a heater block and a viscosity block. This approach to sub-assemblies reduces the overall module size. It also adds flexibility to configuration, such as the ability to place the filter either on the hot or cold side and to select the right type of heater for a particular duty. The bottom of the module houses a drip tray that collects spillage. Pipes from underneath the module make connections possible from the rear, front or side, reducing internal piping and increasing accessibility to components. This makes the module more compact and more costeffective. The modules are pre-assembled and pre-tested prior to delivery and include the necessary pipe connections for interconnection to the daily service tank, drains, power supplies, de-aeration outlet and engine. Centrally located, the control cabinet EPC 50B is surrounded by several sub-assemblies. The fuel conditioning system design The two-stage pressurized booster system typically maintains a pressure of 4 bar during the first, or lowpressure, stage. During the second, or high-pressure, stage, the pressure is within the range of 4 to 14 bar, depending upon the requirements of the engine manufacturer. Low-pressure or supply stage Heavy fuel oil from the daily service tank passes through a three-way valve. Strainers protect the supply pumps by removing large particles from the fuel. The supply pumps forward the oil into the low-pressure section. In case of supply-pump failure, the system can automatically change over to the standby pump. The automatic backflush filter cleans the oil by removing smaller particles. As the engine load changes, so will the fuel consumption. A special pressure control valve allows fuel to recycle within the low-pressure section so that the flow of fresh fuel entering via the three-way valve precisely matches the fuel consumption of the engine. The pressure transmitter measures pressure at the oil outlet and sends the value to the process controller. 8 Alfa Laval Marine & Diesel Equipment Pipe connections are in the module bottom. The flow transmitter measures fuel consumption and sends a signal to the process controller. Fresh oil then enters the mixing tube. The level switch monitors the mixing tube for the content of air or gas in the fuel and signals the need for manual de-aeration, if necessary. An automatic de-aeration valve is optional. Alfa Laval Fuel Conditioning Module High-pressure or circulation stage Fuel from the mixing tube enters the circulation pump, which increases the pressure. The pump then transfers the fuel to the heaters. Here oil is heated to the temperature required to achieve the correct fuel viscosity. A viscosity sensor sends a signal to the process controller for comparison against the viscosity set point specified by the engine manufacturer. Deviations are automatically corrected by adjusting the heating. A pressure control valve located after the injectors (usually part of the engine installation) maintains systemic pressure. Excess fuel returns to the mixing tube. Clean fuel is then supplied to the engine injectors for combustion. Key components Following is a brief description of key FCM components, which are more fully detailed later in this section: • Automatic backflush filter This high-efficiency, low-maintenance Alfa Laval filter effectively removes fuel contaminants. Compact and lightweight, it continuously backflushes clean filtered oil through robust disc-type filter elements and automatically drains sludge at regular, pre-set intervals. • HEATPAC® M6 plate heat exchanger The easy-to-maintain Alfa Laval M6 steam heater is designed for the heating of fuel prior to injection to the engine. With its flexible, modular design and narrow channels, the M6 provides extremely efficient, hightemperature heat transfer. Its small holdup volume enables quick response at changing load conditions and its durable high-temperature gaskets ensure more uptime. Alfa Laval HEATPAC® EHM electric heaters and shell-and-tube heaters for either steam or thermal oil can be supplied as alternatives. • Supply and circulation pumps Three-spindle screw pumps with shaft seals on the inlet side minimize leakage. • Viscosity sensor This compact, lightweight, maintenance-free sensor ensures the correct injection viscosity by measuring actual fuel oil viscosity against set value specified by the engine manufacturer. If the values require adjustment, the sensor signals the process controller, which automatically raises or lowers the temperature in the heater. • Process controller With automated remote control, the Alfa Laval EPC 50B process controller facilitates operation of the fuel conditioning system. Automation and remote control reduce operating and maintenance costs while increasing profitability and safety. The user-friendly EPC 50B monitors and controls FCM functions by displaying in clear text process parameters, alarms and other data. Low-pressure or supply stage. High-pressure or circulation stage. Alfa Laval Marine & Diesel Equipment 9 Alfa Laval Fuel Conditioning Module Standard and optional components This section describes the FCM components. These include those that come with the standard FCM configuration as well as the most important optional components. The FCM uses Alfa Laval products as well as best-in-class products from Alfa Laval’s business partners who are well-known manufacturers with proven reputations. All components are integrated, factory-tested and guaranteed to work together. Three-way DO/HFO changeover valve This valve controls changeover from diesel oil to heavy fuel oil after startup and, if required, from heavy fuel oil to diesel oil at low loads. Three types of valves – manual, electric and pneumatic – are available. End position limit switches on all types transmit the valve position to the process controller. Use of an electric valve enables the operator to set the changeover time in the process controller to obtain a smooth changeover between DO and HFO and between HFO and DO. Supply and circulation pumps The supply pumps, as well as the circulation pumps, are three-spindle screw type pumps. These pumps are specifically designed to transfer heavy fuel oils at higher temperatures. The pumps are housed in nodular cast iron with the shaft seal located on the suction side to minimize leakage. Durability is further enhanced with double shaft seals, a hard metal type and a lip seal. The standard FCM has two supply pumps and two circulation pumps, one of each type in operation and one on standby. Strainers are installed before each supply pump to protect any large particles from entering the pump. Non-return valves are mounted after the supply and circulation pumps to prevent fuel oil from entering the pump on standby. Three-way DO/HFO changeover valve. Supply and circulation pumps. Standard pumps are equipped with two-pole electric motors that operate at speeds of 2800/3400 rpm. Proven as the most cost-effective solution, these speeds also make the fuel form a thicker lubricating film that wears less and yields the longest possible life expectancy. Built-in safety relief valves are standard. Upon request, Alfa Laval can supply the pumps with four-pole electric motors that operate at speeds of 1400/1700 rpm. Emergency diesel oil pump The FCM can be equipped with an emergency diesel oil pump, either electric or pneumatic in type, to re-start the flow of oil after a power failure. This is often required on FCMs for auxiliary engines and on combined unifuel FCMs for main and auxiliary engines. When using an electric pump, the power supply operates independently from the power supply in the main control cabinet. The default emergency pump capacity is the same as the supply pump capacity. However, other capacities may be installed upon request. Pressure control valve This valve controls the pressure on the supply side by re-circulating fuel to the suction side of the supply pumps. Easy access from the service platform makes the valve easy to adjust manually. The valve provides nearly constant pressure under all operating conditions – from engine stop to maximum engine consumption. The air fin cooler after the pressure control valve limits the temperature increase of the oil due to internal friction in the supply pump and in the valve at engine stop or idle, when most of the fuel is re-circulated. Pressure control valve with air fin cooler. 10 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module Automatic backflush filter The Alfa Laval automatic backflush filter effectively uses clean oil as the flushing medium to prevent any particles present in the fuel from causing injector and engine damage. These Alfa Laval filters have been installed on virtually all types and brands of diesel engines. With Alfa Laval automatic filter, continuous backflushing helps prevent the adhesion of retained solids to filter surfaces. This ensures long service intervals – on average, up to one year or 6,000 hours – and drastically reduces the costs for manual cleaning, filter replacement and filter disposal. The small amounts of filter sludge are collected in the filter bottom and then automatically drained at regular pre-set intervals, for instance, three times every 24 hours. An electric motor for distributor rotation on the filter eliminates the need for compressed air that is required for some other filter brands. The robust, reliable disc-type filter elements operate at a low and constant pressure drop, providing high filtering efficiency and reducing the risk of cracking. Standard mesh sizes include absolute aperture sizes of 25, 35 and 45 µm, which correspond to nominal aperture sizes of 10, 20 and 30 µm. Nominal means that more than 85 percent of the particles larger than this value are retained. The standard filter configuration consists of: • An automatic filter with a manual standby filter installed after the supply pumps on the low-pressure, or cold, side. Although cold-side filter installation is farther from the engine, use of a manual indicator filter installed as close as possible to the engine may be recommended by some engine makers (loose supply on request). • Automatic drain valve, which drains the filter at regular, pre-set intervals, eliminates the need for manual draining. The filter is also automatically drained at high-pressure drop alarm. Drainage intervals are easily adjustable using the operator’s panel, depending on the level of oil contamination. • A differential pressure gauge and alarms for high pressure drop and stop of electric motor, which facilitate detection of system malfunction. Alternatives to this standard configuration include: • Filter installation after the heaters on the hot side. This usually requires a larger filter for a given engine because, even though the viscosity is lower on the hot side, the flow rate here is higher than on the cold side. Consideration must also be given to the increased risk of asphaltene precipitation from the fuel, due to the high temperature, which can clog the filter. • A duplex automatic/automatic filter to increase flexibility during operation. This is useful, for example, when lower grade fuels create problems that require more frequent, manual filter cleaning or when the filter in operation malfunctions for other reasons. This solution is strongly recommended where one FCM is installed to supply fuel to both the main engine and the auxiliary engines in marine installations. • A small, intermediate sludge drain tank situated under the mixing tube and a pneumatic sludge removal pump to dispose of the sludge after draining the filter. This can be used, for example, in power stations where it is not suitable to have a sludge tank directly beneath the FCM. Automatic backflush filter with manual bypass filter and built-in changeover system. Every FCM is accompanied by an air/water gun. This simple tool enables the disc elements to be cleaned quickly and easily. Alfa Laval Marine & Diesel Equipment 11 Alfa Laval Fuel Conditioning Module Flow meters These precision meters consist of two parts: the flow transmitter part in the oil line and the signal processing and display part that is integrated with the EPC 50B process controller. These meters monitor fuel consumption by measuring the flow rate of the fuel volume that passes through the system. The flow transmitters are installed on the pressure side of the supply pumps, after the strainers and after the main filter, if a cold-side filter, giving them extra protection against contaminants. Two types of meters, a positive displacement sliding vane volumetric flow meter and a mass flow meter, are available. Each comes with a bypass line with a pressure relief valve to ensure uninterrupted flow to the engine in case of blockage. Sliding vane volumetric flow meter. This flexible, compact, space-saving flow transmitter covers a range of capacities. Typically, the accuracy of this flow transmitter is high (better than 0.2%) and is not influenced by process pressure or temperature. An optional inlet temperature sensor enables the process controller to calculate mass flow, based on a reference density at 15ºC. Very few almost-frictionless moving internal parts prevent wear on this flow meter, guaranteeing uptime and increasing its life expectancy. The meter also does not have any mechanical seals, reducing maintenance and the possibility of fuel oil leakage. Mass flow meter. This unit electronically calculates and displays mass flow either on its own self-contained meter or on the FCM process controller. The amount of fuel oil mass moving through the meter is measured using the Coriolis Principle, which causes the tube of the meter to vibrate in a direction perpendicular to the flow. This meter also measures oil density, which facilitates the calculation of the CCAI value. Fuel consumption values are displayed on the FCM process controller. The process controller presents diesel oil and heavy fuel oil consumption as separate values. Also displayed are fuel consumption during the last 24 hours and accu- mulated consumption, which shows the amount of oil in cubic metres that has passed through the module since it was last reset to zero. Pressure transmitters Installed on both the supply and circulation sides, these transmitters control pump standby functions and measure pressure, sending the values to the process controller. Operators can also set low- and high-pressure alarm limits from the process controller or from a remote location. Installing pressure transmitters eliminates the need for manual adjustment of the hot pressure switches during operation. Mixing tube with de-aeration function This standard insulated, heat-traced mixing tube operates at pressures of up to 6 bar. The mixing tube acts as a system buffer to obtain stable viscosity or temperature control and, to some degree, to smooth the transition when changing over from DO to HFO, or vice versa. The mixing tube is available in six different sizes, depending on engine sizes and requirements. Standard mixing tube 65 litres 120 litres 140 litres Optional mixing tube 85 litres 140 litres 160 litres Module size FCM 1000 series FCM 2000 series FCM 3000 series The mixing tube is equipped with a level switch that presents an alarm when air or gases accumulate in the tube, indicating the need for manual de-aeration. As an option, the mixing tube may also be equipped with an automatic de-aeration valve. Upon accumulation of air and gases in the tube, the process controller then automatically activates the de-aeration valve and vents the gases back to the HFO daily service tank. In this case, the number of de-aerations is recorded in the process controller. The air venting connection that protrudes into the mixing tube creates an air cushion that dampens pressure fluctuations within the system. If required by engine manufacturer, the mixing tube can also be equipped with a connection for air injection, ensuring that air is present in the tube top. Flow transmitter. Automatic and manual de-aeration arrangement. 12 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module Heaters The FCM provides flexibility for heating fuel oil to the required temperature. It has two heaters, one in operation and one on standby. These are dimensioned to specific requirements based on flow rate, oil temperature from the mixing tube and oil temperature to the engine. Three alternatives are available: 1. the standard HEATPAC® M6 plate heat exchangers for steam as the heating media, 2. the HEATPAC® EHM heaters for electric heating and 3. the Alfa@Heat shell-and-tube exchanger models for either steam or thermal oil applications. HEATPAC® M6 plate heat exchanger. HEATPAC® M6 plate heat exchangers The compact, lightweight M6 is standard to the FCM and suitable for steam heating. Its flexible, modular design makes the M6 easy to modify by adding or removing plates, according to the specified duty. Narrow channels provide higher efficiency for heat transfer at high temperatures. Its small holdup volume enables quick response at changing load conditions. Durable, clip-on HeatSealF™ gaskets ensure maximum uptime. An electrically driven, steam-regulating valve controls the steam supply to the heater. A regulating valve with a quick-closing function at power failure is available as option. A float-type steam trap is installed after the condensate outlet. HEATPAC® EHM heater. HEATPAC® EHM heaters These electric heaters provide optimum heating for all types of fuel oils. With start-and-forget operation, they cover a wide range of capacities and provide accurate viscosity control due to their small holdup volumes. These easy-to-maintain heaters consist of several corrugated aluminum heating elements mounted on a flange to form a cartridge. This cartridge is inserted into a steel pressure vessel with an interior baffle that diverts the flow into two passages. The EHM heater includes a high-temperature safety switch in the top of the heater. A power unit continuously supplies variable power between zero and 100 percent, providing accurate control for viscosity or temperature. Alfa@Heat shell-and-tube heat exchangers. Alfa@Heat shell-and-tube heat exchangers These alternatives to the standard HEATPAC® M6 and the optional HEATPAC® EHM heaters can be used for either steam or thermal oil. Alfa Laval Marine & Diesel Equipment 13 Alfa Laval Fuel Conditioning Module Viscosity sensor This compact, lightweight sensor accurately measures actual fuel oil viscosity within ±0.5 cSt to ensure the correct injection viscosity is obtained. The sensor does not have any moving parts. This provides maintenance-free operation, which guarantees long life, maximum uptime, minimal, if any, servicing costs and efficient engine operation. Using the torsion vibration measuring principal, this factorycalibrated sensor is not affected by variations in flow or pressure. A vibrating pendulum with rotational movement collects data and the sensor sends the data to the process controller. If required, the process controller then raises or lowers fuel oil temperature in the heaters to obtain the required viscosity. This ensures efficient fuel combustion and optimum power output. Viscosity sensor. Temperature sensor This sensor alerts the operator when the temperature exceeds or falls below the pre-set alarm limits. It also provides a backup control method that uses temperature as the primary control parameter, should the viscosity sensor fail. An optional temperature sensor may be installed on the oil inlet to provide calculated mass flow (see “Flow meters” on page 12). Control cabinet The control cabinet has two parts, a lower one that contains all motor starters in separate compartments and an upper compartment that contains the EPC 50B process controller. Process controller The easy-to-operate Alfa Laval EPC 50B process controller facilitates monitoring and control of FCM functions by displaying in clear text process parameters, alarms and other data. This process controller is based on the same hardware used in the Alfa Laval Separation Unit, making it easy to use for operators who are already familiar with this process controller. However, since the EPC 50B is specifically designed for fuel conditioning applications, the controller has a new input/output board for increased capacity and custom software. With integrated remote control, the process controller eases operation of the fuel conditioning system. This reduces operation and maintenance costs while increasing profitability and safety. Control cabinet with EPC 50B process controller. 14 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module Other options The FCM is available in different alternatives and with a wide range of options to meet various engine and operator requirements. This flexibility extends to filter placement, flow meters, mixing tube capacities and heaters. In addition, a system to pump away filter drain, a pneumatic or electrical emergency diesel oil pump and different levels of remote monitoring and control are available as options. In case of high-pressure peaks from the engine’s injection system, pressure pulsation dampers should be installed in the pipes going to and from the engine. Engine manufacturers sometimes require this. Some engine makers recommend the installation of an indicator filter after the fuel conditioning system and as close as possible to the engine. Alfa Laval offers an optional manual duplex filter (delivered as loose supply) to protect the engine injection equipment from potentially harmful particles and to detect a main filter fault, should it occur. Screen mesh size meets engine manufacturer requirements. Upon request, Alfa Laval also advises customers about the best FCM solution, given their particular situation. We work closely with fuel conditioning system customers to analyze whether customization of the FCM is a feasible alternative. If so, we outline the scope of work and costs involved for customer approval. Alfa Laval Fuel Conditioning Module with automatic filter on hot side and emergency DO pump. Alfa Laval duplex inducator filter. (Optional loose supply.) Alfa Laval Marine & Diesel Equipment 15 Alfa Laval Fuel Conditioning Module System configurations In the past, when auxiliary engines ran on lighter fuel oils, marine applications generally used two independent fuel conditioning systems – one for the main engine and one for the auxiliary engines. However, today’s unifuel ships use a single fuel conditioning system for both the main engine and the auxiliary engines. Despite this trend, using a separate module for the main engine and one for the auxiliary engines provides distinct advantages. The main engine and the auxiliary engines often have different operating requirements and different values for engine oil pressure, viscosity set point, mesh size, and circulation factors. Separate modules make it possible to obtain the correct values for the specific applications of the main engine and auxiliary engines. In addition, the use of two separate modules for the main engine and the auxiliary engines eliminates problems associated with regulating the heaters since fuel consumption in port is just a fraction of that at sea. Different regulating valve sizes for the main engine and for the auxiliary engines are required in order to achieve optimal fuel consumption. HFO FCM Main engine DO FCM Auxiliary engines FCM configurations Alfa Laval offers four different FCM system configurations: Complete standard module configuration This is the standard Alfa Laval module with the filter installed on the supply or cold side. Complete alternative configuration This alternative comes with the filter installed on the conditioning or hot side. Divided standard configuration For easy installation where space is limited, the complete standard configuration with the filter installed on the cold side is divided and delivered as two separate units – a supply unit and a conditioning unit. Divided alternative configuration For easy installation where space is limited, the complete alternative configuration with the filter installed on the hot side is divided and delivered as two separate units – a supply unit and a conditioning unit. Separate Fuel Conditioning Modules for the main engine and the auxiliary engines. OP START/STOP HFO DO INFO + ENTER Other alternatives to these four system configurations are available. These include system configurations with optional heaters and/or filters. Upon request, Alfa Laval can also provide a certain degree of customization for system configurations. 16 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module Filter COLD side Filter HOT side Complete standard Fuel Conditioning Module PDS LS LS PDS FT PT PT TT VT FT PT PT TT VT Complete standard configuration with cold-side filter. Complete alternative configuration with hot-side filter. PDS LS LS PDS Divided configurations FT PT PT TT VT FT PT PT TT VT Divided standard configuration with cold-side filter. Divided alternative configuration with hot-side filter. Divided FCM configuration in ship installation Fuel Conditioning Unit (FCU). Fuel Supply Unit (FSU). Alfa Laval Marine & Diesel Equipment 17 Alfa Laval Fuel Conditioning Module Flow diagram ³ HFO and DO day tank. Stores clean heavy fuel oil or diesel oil that is supplied to the three-way valve by means of gravity. ´ Automatic backflush filter. Cleans fuel by removing smaller particles. a bypass with a pressure relief valve in case of blockage. ² Filter pressure drop switch. Indicates if pressure drop over the filter exceeds its set value. µ Pressure transmitter, supply pump. Measures the pressure in the supply side and signals the process controller to start the stand-by pump if the pressure decreases below the pre-set limit. · Three-way changeover valve. Handles changeover from diesel oil to heavy fuel oil at startup (and vice versa, if required), and connects the daily service tank to the FCM. ¶ Supply pressure control valve. Maintains constant oil pressure by diverting excess flow from the supply pump. » Pump strainers. Protect supply pumps by removing large particles from the fuel. ¸ Level switch. Signals the process controller when gases accumulate in the mixing tube for manual, or automatic, de-aeration. º Flow transmitter. Measures fuel consumption. Signals flow rate to the process controller. ¿ Supply pumps. Supply oils to the high-pressure stage. ¾ Flow transmitter bypass. Provides ¹ Automatic de-aeration valve. If installed, automatically vents ² ³ HFO » · ¿ PDS º µ FT ´ » ¾ PT ¿ ¶ ³ DO 18 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module gases when they accumulate in the mixing tube back to the daily service tank. Mixing tube. Combines fresh fuel from the supply pump with hot fuel returning from the engine. Circulation pumps. Circulate heavy fuel oil to the engine and then back to the mixing tube. Heaters. Raise the temperature of the fuel to the level required in order to achieve the viscosity value specified by the engine manufacturer. Pressure transmitter, circulation pump. Measures pressure and sends the measurement to the process controller to start the stand-by pump if the pressure decreases below the pre-set limit. Temperature sensor. Alerts operator when the temperature exceeds, or falls below, a pre-set limit and acts as a backup to provide temperature control should the viscosity sensor fail. Viscosity sensor. Measures fuel viscosity and sends the measurement to the process controller for comparison to the engine manufacturer’s set value. Engine pressure control valve (customer supply). Maintains systemic pressure. Alfa Laval duplex indicator filter to protect the engine (optional loose supply, if requested). ¹ LS ¸ PT TT VT FCM module Alfa Laval Marine & Diesel Equipment 19 Alfa Laval Fuel Conditioning Module Automation The new, fully automated Alfa Laval Fuel Conditioning Module (FCM) brings modern state-of-the-art information technology to the fuel conditioning process. Computer-based automation helps monitor and control FCM functions with high precision, reliability and performance. The exact scope of FCM functions depends upon the equipment installed and the level of automation selected. Using well-known, proven automated components from the Alfa Laval Separation Unit, the FCM reduces costs by providing operators with more information and improved functions. For example, these functions include fuel consumption displayed at an easily accessible local, or remote, location and automatic startup in case of power failure. Flexibility is also critical to automation, enabling operators to activate control functions from a remote location. Vital process information is always within easy reach. The FCM has a new generation of process controller, the EPC 50B, that provides advanced, fully automated monitoring and control. Continuous displays for temperature, viscosity and fuel consumption appear on the display. Other data, such as oil temperature inlet and outlet, pump pressure and accumulated engine consumption, are displayed upon request. In the unlikely event that the process controller is not working, manual alternatives for all critical functions are available. The FCM unit is also equipped with thermometers, pressure indicators and other visual indications as backups to the display presentations. EPC 50B process controller. Main control functions All main control functions, as well as text display for process data and alarms, can be accessed from the centrally located control panel. Start-up/stop sequence This automatically initiates operation of the supply pumps, circulation pumps and heater. This function also suspends operation of the heater, automatic drain timer and pump standby function. Pump operation must otherwise be suspended using manual switches. Pump operation The supply pump and the circulation pump in operation can easily be changed using the EPC 50B process controller. By setting regular changeover intervals on the process controller, operators can also automatically switch operation between the active pump and the pump on standby to equalize the run times. 20 Alfa Laval Marine & Diesel Equipment Intervals are usually set between one month and one year. An alarm alerts the operator of the changeover 15 minutes prior to activation. If manual changeover is preferred, operators can program a pump-changeover reminder to appear automatically on the display panel. Viscosity control Controlling viscosity is critical to engine performance. Automation ensures that the actual fuel oil viscosity meets the set point specified by the engine manufacturer. Deviations are corrected by the process controller, which automatically raises or lowers temperature in the heater. This ensures efficient fuel combustion and optimum power output. Operation in diesel oil mode or heavy fuel oil mode The process controller has two modes of operation, DO mode or HFO mode, with two sets of parameter settings, alarm limits, and other values that are suitable for each mode. The process controller handles the transition between the two modes via temperature ramps to control the change in temperature and to prevent temperature shock from damaging the engine’s fuel injection pumps. Alfa Laval Fuel Conditioning Module If an electric or pneumatic three-way changeover valve is installed, the process controller handles the transition of the changeover valve. If an electric three-way valve is installed, the transition time from DO to HFO can be set. Switch to DO at low engine loads The FCM unit can be configured to change over to DO if the engine load is so low that it is not suitable for HFO operation. This function is based on input from the engine control system which indicates whether or not HFO operation is acceptable. Automatic mixing tube de-aeration function An optional automatic de-aeration valve may be installed on the mixing tube. This is connected to the process controller, which automatically activates the de-aeration valve when gases accumulate in the mixing tube, venting the gases back to the daily service tank. Start of standby pump at low oil pressure The process controller initiates startup of the standby pump when oil pressure falls below a pre-set limit, or when the contactor of the pump in operation is released. The delay time for standby pump activation at low oil pressure can be set by the operator. Startup sequence after power failure A startup sequence is automatically initiated when power is restored after a failure. The process controller then automatically re-activates all FCM components. During the startup sequence, all alarms are temporarily suspended until the pre-set values are reached. Switch to temperature sensor at viscosity sensor failure Upon failure of the viscosity sensor, the process controller automatically switches to a temperature sensor that serves as a backup control method. Switch to diesel oil at heater fault If an electric, or pneumatic, three-way changeover valve is installed, operators can program automatic changeover from heavy fuel oil to diesel oil when a heater fault causes oil temperature to drop and remain below a pre-set limit for two minutes. Self-cure functions The process controller has several built-in self-cure functions that automatically take place to ensure continued operation should a system problem occur. Input from sensors and feedback signals. Output activation of valves and electric motors. PDS LS FT PT PT TT VT Process control and monitoring, typical electrical layout. Alfa Laval Marine & Diesel Equipment 21 Alfa Laval Fuel Conditioning Module Process information The FCM offers several alternatives for the display of key data. The display panels continuously provide operators with data on temperature, viscosity and fuel consumption. This makes the FCM easy to operate and control. For more information, the operator simply presses a button to access an instantaneous value list. This list provides the operator with a quick overview of oil temperatures, pressures and consumption. It also provides data on the position of the heater regulating valve, electric heater power, and changeover valve position. Depending on the level of automation, other display information is available by accessing the flow list, trip list, run list, viscosity list and timer list. Instantaneous values • Viscosity • Temperature • Pressures • Fuel consumption Total fuel consumption for HFO and DO The total accumulated fuel consumption for HFO and for DO is calculated and displayed separately. If an optional inlet temperature sensor is installed, calculated mass flow based on inlet temperature and set density also are calculated and displayed. Viscosity extrapolation The extrapolation of the viscosity to 50°C (or 100°C) provides an estimate at a fixed reference temperature of the current grade of fuel in the system. This is especially useful when a new bunker enters the system, bringing with it a new fuel load, and when switching from DO to HFO, or vice versa. During DO/HFO changeover, the viscosity value at 50°C is routinely displayed on the process controller’s instantaneous value list. Run times Run times in hours can be displayed for each pump, for both heaters as a single value and for the automatic filter. Other process information • Trip fuel consumption (total, average, last 24 hours) • Instantaneous consumption as percentage of a set maximum consumption • CCAI value based on measured viscosity, temperature and set density • Number of automatic filter drains and time until next drain • Number of automatic de-aerations and time since last de-aeration • Instantaneous electric heater power and total power consumption • Position indication of heating media regulating valve • Changeover valve position For more detailed information, contact your local Alfa Laval office. The EPC 50B controller provides easy access to process information. 22 Alfa Laval Marine & Diesel Equipment Alfa Laval Fuel Conditioning Module Remote monitoring and control The Fuel Conditioning Module offers a range of flexible solutions for monitoring and control from a remote location, such as the engine control room. This simplifies operation, reduces man-hours, improves working conditions and ensures accurate recording and analysis of key performance parameters. Remote monitoring and control also create the necessary conditions to fulfil the rules for periodically unmanned engine rooms as set forth by the marine classification societies. In the near future, remote monitoring via the Internet will also be available. Several alternatives make remote monitoring and control flexible, easy to configure, easy to install and easy to use. There are four different levels of operation from which to choose: Basic level The complete default FCM configuration is equipped with terminals for individual input and output signals that connect to the customer’s existing remote control system. The customer is responsible for supplying the remote hardware and cables. Extended level This includes terminals, a remote control panel with additional features, selector switches for pump control, viscosity display and alarm lamps. With this level, it is not possible to reset alarms. Advanced level This includes terminals and remote control panel for the engine control room. All controller functions are also available on the local FCM controller. The operator display panel is identical to the one located on the module and all functions handled by the controller can be accessed from the panel. Pump selector switches are included. The display panels continuously provide operators with data on temperature, viscosity and fuel consumption. They also provide easy access to all process information. With the advanced level, it is possible to accept and reset alarms. Advanced panel. Fully remote level The fully remote level provides complete coordination with the plant’s Integrated Administration and Control System (IACS). Proprietary field bus interface boards, according to Profibus DP or Modbus RTU standards, are installed in the process controller. This enables communication to external automation systems. Most local functions can be replicated with the use of the field bus interface boards. Separate remote installation of the supply and circulation pump selector switches is recommended. Engine control room console with Alfa Laval FCM panel. Please contact Alfa Laval if other protocol boards, such as CANopen, DeviceNet, or InterBus, are required. Customers assume responsibility for coordination of programming on the remote side through their automation providers. Alfa Laval provides documentation describing the protocol for the system developers. Standard input/output connections • Two selectable analog outputs, 4–20 mA (flow rate, viscosity, pressure, etc.) • A temperature output, 4–20 mA (viscometer with built-in temperature sensor) • Five individual alarm outputs: high temperature/low viscosity, low temperature/high viscosity, low oil pressure, switch to standby pump and high filter differential pressure • Common alarm output • Input for start/stop sequence • Input for DO/HFO changeover • Input for pump switches • Input for emergency stop • Input for manual steam valve control For more information, contact your local Alfa Laval office for additional technical documentation. Alfa Laval Marine & Diesel Equipment 23 Alfa Laval Fuel Conditioning Module Retrofitting The Fuel Conditioning Module is ideal for replacing older booster modules. Its compact size, which often occupies 20% less space than the existing booster module footprint, easily fits into the existing engine room. It can also be divided into two parts in order to facilitate transport of the units through small passageways and installation in tight spaces. In addition, the pipe connections for the Fuel Conditioning Module are located underneath the unit, which provides greater flexibility for the placement of the unit. Alfa Laval can also provide supply (feeder) units to upgrade older single-stage installations to run heavier fuel oils. Documentation Alfa Laval supplies each Fuel Conditioning Module with full documentation either as paper copies or as PDF (Portable Document Format) files on a CD-ROM. The instruction manual, which can also be made available in most major languages, covers: • • • • • • • • Safety System description Operating instruction Parameter list Alarms and fault finding System reference/installation instructions Spare parts catalogue Component descriptions Classification society approval Alfa Laval ensures that the FCM fulfils the requirements of all major classification societies. Upon request, Alfa Laval delivers the FCM with an individual test certificate. This includes approval by the society of the main components as well as workshop testing of the complete module. Most key components are also type approved by the leading classification societies. Spare parts, service and support Alfa Laval provides spare parts kits for all service and maintenance needs. Global technical service, training and support are available throughout the lifetime of the FCM. 24 Alfa Laval Marine & Diesel Equipment Alfa Laval reserves the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local Alfa Laval company. Published by: Alfa Laval Tumba AB Marine & Diesel Equipment SE-147 80 Tumba Sweden © Copyright Alfa Laval Tumba AB 2005. Alfa Laval in brief Alfa Laval is a leading global provider of specialized products and engineered solutions. Our equipment, systems and services are dedicated to helping customers to optimize the performance of their processes. Time and time again. We help our customers to heat, cool, separate and transport products such as oil, water, chemicals, beverages, foodstuff, starch and pharmaceuticals. Our worldwide organization works closely with customers in almost 100 countries to help them stay ahead. How to contact Alfa Laval Up-to-date Alfa Laval contact details for all countries are always available on our website at www.alfalaval.com www.fotoskrift.se EMD00008EN 0512 ALFA LAVAL is a trademark registered and owned by Alfa Laval Corporate AB. Alfa Laval reserves the right to change specifications without prior notification.
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