P-28 Cargo Pumping System (1-4) [PDF]

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Cargo pumping system IMO NO. DEP'T NO . DEP'T NAME

3851 TEL.NO.

HULL PIPING DESIGN DEP'T SHIP NO .

47K DWT PRODUCT/CHEMICAL TA 'KER. SHIP NAME

NAME OF DRAWI NG

APPROVED:

J. C. CHOI

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CHECKED:

B. D. CHOI

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DRAWN:

H. S. YU

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CA RGO PUMPING SYSTEM (1 /4)

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HYUNDAI MIPO DOCKYARD CO , LTD . ULSAN KOREA

DRAWI NG NO.

NONE CONSOLIDATED

REV.NO

5411 0TOO1

I

FIN AL P-28

II

I

ATLANTIC ATLANTI CQUEEN PEGASUS

2101

3864

: 9440136

SHIP TYP E

SERVICEMANUAL FOR CARGO PUMPING SYSTEM

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LJLJ-·

FRAMO

No: 614974 Date/Sign: 10.05.2010/PET Sect: 0 Rev.:

Contents VOLUME 1 1

INTRODUCTION

0242-0001-401

2

GENERAL DESCRIPTION OF THE INSTALLATION

0242-2576-4

3

TECHNICAL DATA

4

INITIAL START-UP

0242-0004-401

5

OPERATION

0242-2577-4

6

TROUBLESHOOTING

0242-0006-401

7

MAINTENANCE

0242-0007-401

8

INSTRUCTIONS, DRAWINGS AND PART LISTS

0242-0008-401

8.1

INSTRUCTIONS

VOLUME 2

8.2

9

DRAWINGS AND PARTS USTS

APPENDICES 9.1

TABLES FOR CORRESPONDING MATERIAL STANDARD

0113-0024-4

9.2

INSTALLATION OF MECHANICAL SEALS

0290-0036-401

10

REVISIONS LIST / MODIFICATIONS

1

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

FRAMO

1.0

INTRODUCTION

1.1

General

No.: Date: Page: Rev.G:

0242-0001-4 20JunOO

1 03Dec07

Frank Mohn AS (Framo) is the leading supplier of submerged cargo pumps to the world tanker market. The company was founded in 1938 and is located outside Bergen in Western Norway. Continuous dialogue with customers has determined the criteria for research and development activities. The result has become a cargo pumping system that satisfies requirements for safe and profitable cargo handling, efficient stripping and tank cleaning, and meets all new international rules and regulations. Our pumping systems are installed on board chemical carriers, product tankers, crude carriers, barges, OBO carriers and FPSO. A world-wide service organization takes care of training, technical services, spare parts and repairs. All of our products are manufactured in Norway. The Framo customer support organisation is located worldwide. The location, contact numbers and addresses are given in chapter 1.5. Support from this organisation is available 24 hours a day throughout the year. Spare parts and service ordered will normally be supplied from the closest location to the ship if not otherwise specified. In case of difficulties to get in contact with the local office, the duty number in Norway will give you further assistance after office hours Norwegian time.

1.2

Safety and environmental precautions The Framo cargo pumping system is designed for a long life and reliable operation. To obtain this long life it is important that the system is operated according to the instructions. Further, the specified preventive maintenance must be carried out and the cleanliness level in the hydraulic system must be kept within acceptable limits. Operation of any pump must be within its capacity range and dry running to be avoided. Only qualified personnel should operate the system, thus ensuring a safe and economic operation. Necessary training is owner's responsibility. Framo may offer several alternatives for technical training. System adjustments and service work should only be performed by a Framo service engineer, or by qualified members of ship's crew. Hydraulic connections, flexible hoses and particularly cargo hoses must be regularly checked to avoid leakage.

FRAMO

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.: Date: Page: Rev. G:

0242-0001-4 20JunOO

2 03Dec07

Hydraulic oil based on mineral oil has a flash point between 180 - 230°C. Hot surfaces must be shielded. Hydraulic oil is slightly toxic. Long lasting contact with the skin may cause skin irritation. When working with hydraulic oil, use gloves/ protection cream. Notel

Comply with the Material Safety Data sheet for the oil. Do not start any service work on hydraulic items if the hydraulic circuit is pressurized. Relieve pressure and close service valves. Never enter a cargo tank before the tank is certified gas-free and clarified as safe. The cargo discharge valve must be closed. Before opening of cargo handling equipment, precautions must be taken against the possible release of dangerous cargo or gas. Before doing service on a ballast pump close the ballast valves (suction line and discharge line). Switch off and lock the main switch before any work is carried out inside electrical control panels / starters. Be aware of foreign voltage. Electrical isolation should be implemented in accordance with applicable rules. Ensure a safe working environment during service. Use padlock or similar to lock service valves and electrical equipment. A warning sign (work in progress) should be placed on the Framo control panel/computer until the work/service is finished. Do not paint mechanical parts of valve shut-off switches. When portable equipment is used, connect the hydraulic hoses as follows: - Always connect return hose before pressure hose. - Always disconnect pressure hose before return hose. Ear protection should always be used when entering noisy areas or working with noisy machines. Hydraulic power pack rooms, pump rooms with hydraulic driven pumps and rooms with hydraulically driven bow thrusters are considered as noisy areas. Hydraulic pumps and motors are considered as noisy machines. For safety and environmental precautions, also see information in separate instruction for the actual component involved.

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

ffi FRAMO

1.3

No.: Date: Page: Rev.G:

0242-0001-4 20JunOO 3 03Dec07

Guarantee conditions To ensure a valid guarantee and a good performance of the system, we will highlight some important conditions: •

Sealed adjustment screws must not be broken.

•

Only acceptable oil quality and blends according to Framo lubrication chart to be used.

•

Oil samples to be taken on a regular basis and according to separate instruction. Particle counting and water analyses every 3 months and full oil analyses once a year.

• Debris switches to be checked according to separate instruction. • Filter change to take place according to maintenance instruction. • Any leaks must be corrected as quickly as possible. • Alarm and shutdown function to be checked once a year according to separate instruction. • After a repair, make sure that all air is vented from the system. • Re-filling of oil only to be done through the Framo filling pump/filter. • The supply voltage must be kept within +/-10%. • If override is used for operation of the system, make sure that the instructions given by Framo are followed. Override operation must be reported to Frank Mohn Services, including the reason for using override mode. • Purging of cargo pump cofferdam to be done according to separate instruction and instruction given in the purging report format. Abnormal leakage to be repaired immediately. Filled in purging reports to be sent to Frank Mohn Services. E-mail with address [email protected] will ensure quick and safe transmittal. • To ensure that the quality level of the system is kept, only genuine spare parts from a Framo office shall be used in the system. • Wear and tear parts are excluded from the guarantee. These parts include, but are not limited to the following: All filter elements in the system. All o-rings and dynamic seals, i.e. shaft seals. All wear rings. • The guarantee also excludes: Abnormal wear due to erosion from pumping cargoes with high sediment content. Corrosion caused by highly corrosive cargoes, or seawater.

ffi FRAMO

1.4

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.: Date: Page: Rev.G:

0242-0001-4 20JunOO 4 03Dec07

Ordering of spare parts Inquiries and spare part orders will normally be handled by the Framo service station closest to the vessels area of operation or required delivery address. To ensure the most efficient handling of spare parts order, the order should be placed at the same service station that issued the quotation. When ordering new parts the following information must always be included: Name of the vessel or the installation Framo id. no. and quantity Framo instruction manual ref. (Drawing! item no.) as for what part of the system the spare parts are required. For the following units in the Framo system serial no. is always required to ensure that correct parts are quoted! delivered: Diesel engines EI. motors Hydraulic pumps Oil coolers Feed pumps If parts are delivered as guarantee the replaced part should, unless Framo provide other instructions, be returned to the following address and marked with the name of the vessel and claim ref. no: Frank Mohn Services AS Hardangerveien 150 5226 NESTTUN NORWAY Fax: +4755999382 Phone: +4755999200 E-mail: [email protected]

lOB FRAMO

1.5

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.:

0242-0001-4

Date: Page:

5

Rev.G:

03Dec07

20JunOO

Contacts I names I addresses for service and spare parts FRANK MOHN SERVICES AS P.O. Box 44 Slatthaug 5851 Bergen Norway

Telephone: After office hours: Telefax: Telefax: E-mail:

+4755999200 +4790990006 +4755999382 (Marine) +4755999290 (Offshore) [email protected]

FRANK MOHN NEDERLAND BV Edisonweg 18 P.O. Box 305 3200 AH Spijkenisse The Netherlands

Telephone: Telefax: E-mail:

+31181619311 +31181611193 fm. [email protected]

FRANK MOHN HOUSTON INC 3002 East 13th Street La Porte, Texas 77571 U.S.A.

Telephone: Telefax: E-mail:

+1 281 884 4800 (24 hrfi days) +1 281 844 4888 [email protected]

FRANK MOHN SINGAPORE PTE LTD 17, Tuas View Circuit Singapore 637575

Telephone: Telefax: E-mail

+65 6210 2400 +656210 2401 [email protected]

FRANK MOHN NIPPON K.K. Kotsu Building 5F 15-5, Shinbashi 5-chome Minato-ku, Tokyo 105-0004 Japan

Telephone: Telefax: E-mail:

+81 357762405 +81 357762406 [email protected]

FRANK MOHN KOREA OFFICE Chang San Engineering Co., Ltd. Rm. 309, Yachting Center Bldg. 1393, Woo-1 Dong, Haeundai-Ku Pusan Korea

Telephone: Telefax: E-mail:

+8251 7436942 +8251 7436944 [email protected]

FRANK MOHN CHINA LTD. Building No.5 123, Lane 1165, Jin Du Road Min Hang District Shanghai 201108 China

Telephone: Telefax: E-mail:

+8621 61155000 +8621 61155001 [email protected]

Frank Mohn do Brasil Ltda Av. Presidente Vargas, 463-19 0 Andar 20071-003 - Rio de Janeiro - RJ Brazil

Telephone: Telefax: E-mail:

+5521 25077898 +55 21 2507 7888 [email protected]

2

FRAMO

No.: Date: Page: Rev.:

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

2.0

GENERAL DESCRIPTION

2.1

System description (designl hydraulic)

0242-2576-4 13Jan10 1

The cargo pumping system is designed for a flexible and safe operation of all equipment installed. It consists of one hydraulic motor driven cargo pump installed in each cargo tank, ballast pumps, tank cleaning pumps, portable pumps and other consumers, all connected via a hydraulic ring line system to a hydraulic power unit. The submerged cargo pump is a single stage centrifugal pump with the impeller close to the tank top, giving a good pumping performance of all kinds of liquids and with excellent stripping performance. The hydraulic section is surrounded by a cofferdam that completely segregates the hydraulic oil from the cargo. Hydraulic system control panel

i!5B9°1 Remote control assembly Heating and venting valve

Hydraulic power unit

Tank cleaning pump

Submerged ballast pump

Portable pump

Submerged cargo pump

Thruster motor

The hydraulic power unit consists of electric motor- and/or diesel engine driven hydraulic power packs, where the hydraulic pumps are of axial piston type and swash plate design with variable displacement. The pump displacement is hydraulically controlled via the pressure regulator on each pump and by this system, the oil delivery from the hydraulic pumps will always be the same as the oil consumption for the hydraulic motors. To control and limit the speed of the motor, a control valve is fitted for each motor. To keep the hydraulic oil clean and hydraulic oil temperature within desired range, a full flow filter and cooler are installed in the main return line. To regulate the oil temperature, a cooling water inlet valve is controlled from the Framo control system. To prevent impurities from entering the hydraulic system, the system is also pressurized (2-6 bar) when not in operation. Depending on the installation, this is done by a jockey- or feed pump.

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.:

0242-2576-4

Date: Page: Rev.:

2

13Jan10

The discharge from all cargo-, ballast- and other pumps connected to the system may be remotely controlled from Framo control panel, vessel's integrated control system (ICS) or locally at each pump via the control valve. The portable pump is controlled locally at the pump via the control valve. The equipment is manufactured in Norway and the most important benefits of the system are: - Segregation of cargoes for vessel's safety and the environment. - Maximum transport volume. - Efficient stripping and tank cleaning. - Hydraulic system without any electrical power equipment in cargo area. - Automatic regulation of power needed and impossible to overload.

2.2

System description (electric) The Framo cargo pumping system is controlled by a Programmable Logic Control (PLC) installed inside the control panel. The PLC is programmed by Framo and provides the logic for safe operation of the system. This section should be read in conjunction with dedicated system drawings.

2.2.1

ALARM SYSTEM

All alarm inputs, except "Wear indication" are normally closed, meaning that the system is built up on normally closed contacts. Hence if a contact opens or there is a loose wire, an alarm condition occurs, i.e. FAIL TO SAFE. The alarms are divided into two groups: a) b)

Shut down Alarm for indication (pre-warning) only

Each alarm is indicated with a flickering light and an acoustic signal. The "Horn silence" button must be operated before it is possible to confirm the alarm by the "Acknowledge" button. Group a) alarms: The "Reset" button must be operated to clear the alarm. Group b) alarms: Automatic reset Please refer to instrument list for applicable alarms and time delay.

FRAMO

2.2.2

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.: Date: Page: Rev.:

0242-2576-4 13Jan10 3

POWER SUPPLY Most hydraulic system control panels are supplied via two separate power feeders, main- and back-up. In case of failure to main feeder, automatic change-over to back-up will take place. For increased availability and simplified trouble shooting, the control system is electrically divided into separate sub-systems. Each sub-system has its own 24VDC power supply. Failure in one system is not likely to interfere with other systems. The feeders and DC power supplies are monitored by relays provided with status lamps. The lamps illuminate when corresponding feeder! supply is in good condition. A failure on any of the feeders! supplies or short circuit will generate a potential free (dry contact) power failure alarm to the engine control room in addition to alarm at the control panel. Refer to wiring diagrams for detailed arrangement.

2.2.3

FEED PUMPS The feed pumps are started!stopped manually from control panel or from the electric starter cabinet. However, when initiating start of the first main power pack, two of the feed pumps will automatically be started (high capacity mode) before the power pack is started. When the power packs are stopped, the feed pump will switch from high capacity mode to low capacity mode (only one feed pump running) automatically after 10 minutes if this is not done by operator. Only two feed pumps can run simultaneously. Interlocks are made to prevent running of all three. A running signal is provided for indication on the control panel. The high capacity mode is used to keep feed pressure on the suction side of the main hydraulic pumps. Two feed pumps must therefore be running before the main power packs can be started. If one of the feed pumps stops when running in high capacity mode and the power packs are running, the third feed pump will start automatically. If the running signal for the third feed pump is not obtained within 3 seconds, the feed pressure low alarm will be initiated and the system will be shut down. One of the feed pumps must always be running when the system is not in operation and if it stops, the protection pressure low alarm is initiated. At system shut down, the feed pumps will stop together with the first power pack.

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

rDDJ FRAMO

2.2.4

No.: Date: Page: Rev.:

0242-2576-4 13Jan10

4

POWER PACKS The power packs are started/stopped manually from control panel or from the electric starter cabinet. The power packs can be started in any sequence. Maximum 4 starts should be made during an hour. Maximum 2 following starts can be made, then 15 minutes between each. The starts are controlled by the PLC, including starts from the electric starter cabinet. "Closed" signal from limit switches on suction line for each power pack will stop or prevent start of the corresponding power pack only. An alarm light is provided for each power pack to indicate closed valve. If more than one power pack is loaded and the hydraulic oil temperature increases to 65°C or above, the control system will automatically unload all power packs in sequence except for one. The running light will start flashing for the unloaded power packs, and the high oil temperature alarm is re-initiated each time a new power pack is unloaded. The power packs will automatically be reloaded in sequence when the hydraulic oil temperature has decreased below 60°C.

2.2.5

SYSTEM PRESSURE CONTROL System pressure is set by the potentiometer on the control panel, as a voltage input to the PLC. The PLC output is amplified by a proportional valve driver card controlling the proportional pressure control valve for the system pressure. The set pressure is automatically set to zero until one of the power packs has been loaded.

Manual set ressure : .

'\'---'~

•

Proportional pressure control valve

PLC

.f---+---"---" - -

:c........4---i

r --~alve

System pressure transmitter

The manual set pressure is automatically compared to the actual pressure. If a pressure drop occurred, for example by starting too many consumers in proportion to number of power packs running, the PLC is limiting its output set pressure to maximum 60 bar above actual pressure. This is to avoid pressure peaks when starting another power pack or stopping a consumer. This function can be manually overruled in manual override mode1 and is automatically overruled in mode 2.

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

E[j] FRAMO

2.2.6

No.: Date: Page: Rev.:

0242-2576-4 13Jan10

5

REMOTE CONTROL OF HYDRAULICALLY DRIVEN PUMPS The command signals from potentiometers at the front of the control panel are fed directly into the proportional valves for speed control. The built in pressure transmitters give a 4-20 rnA (0-300 bar) feedback signal to the instruments on the control panel.

2.2.7

EMERGENCY STOP ARRANGEMENT Following emergency stop arrangement is provided by Framo according to class requirements:

2.2.8

-

Emergency stop push buttons located on deck are stopping the cargo pumps only, other consumers are not affected.

-

Emergency stop push button located on hydraulic system control panel and central location outside engine room are stopping the hydraulic system.

-

If bow thruster motor and control system is installed, the emergency stop push buttons located on thruster panels are stopping the bow thruster only, other consumers are not affected.

SYSTEM SHUT DOWN Please refer to instrument list for applicable shut down functions. If a shut down function is initiated, the PLC will give shut down command to the power packs in sequence. The first power pack stops immediately and delay between shut down command of each following power pack is 0.75 seconds.

2.2.9

COOLING WATER INLET VALVE The valve is automatically controlled and will open at hydraulic oil temperature above 50°C. It will stay open until the temperature decreases to below 30°C, then it will close. If no power packs are running and the hydraulic oil temperature is below 49°C, the valve will be closed. If there is a mismatch between command- and feedback signal, an alarm will be released. If failure in the temperature monitoring loop, the valve will be opened.

2.2.10

ELECTRIC CONTROLLED BALLAST PUMP EJECTOR The ejector for the priming system is automatically controlled by the PLC. The PLC receives input from a level switch installed in the pump casing and controls the solenoid valve for the ejector pilot air, starting and stopping the ejector. Time delay for start and stop is 2 seconds and the logic incorporates an interlock to prevent starting the ejector unless at least one power pack is running and operator's hydraulic pressure command is more than 30 bar.

ffi FRAMO

2.2.11

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.: Date: Page: Rev.:

0242-2576-4 13Jan10

6

DIESEL ENGINE CONTROL SYSTEM Refer to separate instruction.

2.2.12

INERT GAS PRESSURE LOW Input from external system for shut down of cargo pumps: - visual and audible alarm provided, group a).

2.2.13

CARGO PRESSURE HIGH Input from external system for shut down of cargo pumps: - visual and audible alarm provided, group a).

2.2.14

INTERFACE TO VESSEL'S INTEGRATED CONTROL SYSTEM (ICS) The Framo cargo pumping system can be operated! monitored from Framo control panel or from ICS. The mode is selected in front of the Framo control panel. For control and monitoring signals, refer to dedicated system drawings.

2.2.15

INTERFACE TO POWER MANAGEMENT SYSTEM (PMS) A "start request" signal is sent from the Framo electric starter to PMS. Start is prohibited until a "power available" signal is received from PMS. For detailed arrangement, refer to dedicated system drawings.

3

SERVICEMANUAL FOR CARGO PUMPING SYSTEM

ffi FRAMO

No:

614974

Date/Sign: 10.05.2010/PET Sect: 3 Rev.:

3 Technical data TECHNICAL SYSTEM DATA

0076-0873-4

PUMP SPECIFICATIONS

40

PUMP TYPE TK150-2

0115-1110-405

112

PUMP TYPE SD150-6

0115-1110-402

132

PUMP TYPE SD200-6

0115-1110-401

192

PUMP TYPE SB300-4

0115-1110-404

230

PUMP TYPE MA150/200-2

0115-1110-403

PERFORMANCE DIAGRAMS

40

PUMP TYPE TK150-2

0169-1675-4

112

PUMP TYPE SD150-6

0169-3350-4

132

PUMP TYPE SD200-6

0169-3349-4

192

PUMP TYPE SB300-4

0169-3351-4

192

PUMP TYPE SB300-4

0169-2039-4

230

PUMP TYPE MA150/200-2

0169-3352-4

No.

FRAMO

0076-0873-4

Date/sign.: 28.01.2007/BL Page: 1 Rev.:B 25.08.09/PET

TECHNICAL SYSTEM DATA

1 System data Hydraulic oil consumers

Consumers 12 of Cargo pumps SD200 2 of Cargo pumps SD150 1 of Portable pump TK150 2 of Ballast pumps SB300 1 of TC pumps MA 150

3

m /h 600 300 150 750 120

Design capacity mlc kg/dm 3 125 0,75 125 0,75 50 0,75 25 1,025 110 1,025

Hydraulic data I/min bar 250 534 310 215 130 172 242 194 183 226

cSt 1,0 1,0 1,0 1,0 1,0

Hydraulic oil supply 2 of Electric hydraulic power packs 2 of Diesel hydraulic power packs Total hydraulic oil supply:

2 x 8071/min 2 x 810 I/min

= 1614 I/min 1275 bar = 1620 I/min 1 275 bar = 3234 I/min 1 275 bar

Simultaneous operation (design) 6 of Cargo pumps SD200 (3600

m3 /h - 125 mlc - 0,75 kg/dm 3 - 1,0 cSt)= 3204 I/min 1275 bar

Simultaneous operation (examples) Number and type of consumers 1 x SD200 2 x SD200 4 x SD200 6 x SD200 4 x SD200+2xSB300

Max. oil consumption I/min 534 1068 2136 3204 2524

Number and type of power packs 1 x Electric 2 x Electric 2 x Electric + 1 x Diesel 2 x Electric + 2 x Diesel 2 x Electric + 2 x Diesel

Max. oil supply I/min 807 1614 2424 3234 3234

Heat dissipation - Ventilation Hydraulic power unit heat dissipation:

102 kW

Recommended ventilation capacity for hydraulic power pack room: 10,28 m3 /s (Based upon inlet temperature 35°C, 10°C temperature rise, specific heat capacity 1.005kJ/kgK and gas constant 0.287kJ/kgK. Combustion air for diesel engines is also included).

FRAMO

No. Date/sign.: Page: Rev.:B

TECHNICAL SYSTEM DATA

0076-0873-4 28.01.2007/BL 2 25.08.09/PET

2 Com ponent data Electric motors

Characteristics Number of motors Protection (IP) Power supply (V I Hz I Ph) (kW) Power installed (rpm) Speed (A) Current (A) Starting current (direct) (%) Efficiency Power factor (Cos cp) (V) Heating power at 220 V Insulation-I Temp. rise class Remarks

Main power packs 2 55 440/60/3 420 1780 660 4422 96 0,87 200W F/F

Feed pump 3 55 440/60/3 11 3436 18,2 150 86,6 0,91 1x25W F/F

Hydraulic oil transfer unit 1 55 440/60/3 1,3 3460 2,6 16

NA FIB

Diesel engines Data based upon ambient temperature 25°C at 760 mmHg and relative humidity of 30%

Characteristics Number of engines Power installed: Type of cooling water Heat transfer rate Cooling water requirement (min.! max.) Cooling water inlet temperature Maximum cooling water inlet pressure Cooling water pressure drop (min.! max.)

(kW)

(kW)

(m 3/h)

(0G) (bar) (bar)

2 425 Fresh Water 313 15-21,6 36 3,45 1,7/3,4

Specific fuel oil consumption

(litres/h)

105

Intake air flow Exhaust gas flow Exhaust gas temperature Maximum exhaust gas back pressure

(Iitres/s) (Iitres/s) eC) (mmHg)

506 1345 409 76

Air start: Air consumption for air starter at: 6,2 bar 8,3 bar 10,3 bar Maximum air inlet pressure

(m3/s) 0,16 (m3/s) 0,21 (m3/s) 0,25 (bar)

10,3

TECHNICAL SYSTEM DATA

FRAMO

No.

0076-0873-4

Date/sign.: Page: Rev.:B

28.01.2007/BL

3 25.08.09/PET

Hydraulic oil coolers Number of coolers Type of cooling water: Heat transfer rate: Cooling water inlet temperature: Minimum required cooling water flow: Pressure drop at minimum required flow: Maximum cooling water flow: Maximum cooling water inlet pressure:

1 Fresh Water 480 kW 36°C 100 m3 /h 25,9 mwc (~p design) 15,9 mwc (~p measuring, Pl - P2) 100 m3 /h 40 mwc

For cooling water pressure drop curve (~p measuring, Pl - P2), refer to the dimensional drawing for the cooling water accessories. The cooling water accessories include a spectacle orifice in the cooling water outlet line, refer to the schematic diagram below.

Spectacle orifice

Cooling water inlet

"/"S

Hydraulic oil cooler

v A

.

~p

measuring, Pl - P2

~p

design

T~S

Cooling water outlet

v A

~

The "free" bore of the spectacle orifice marked "adjustable" (the smallest of the two) to be modified at site during commissioning and used instead of the one assembled, if required for one of the following reasons: - measured pressure drop (~p measuring, Pl - P2) is outside the min.! max. range given above. - measured pressure drop (~p measuring, Pl - P2) is within the min.! max. range given above, but higher cooling water flow than minimum required makes disturbance of the cooling water balance onboard.

Cargo pumps Inert gas/air consumption for one stripping sequence of each pump SD200: Inert gas/air consumption for one stripping sequence of each pump SD150: Required inert gas/air pressure: Number of stripping sequences for each pump:

3

4.0 Nm 3 2.4 Nm 6 - 7 bar 2 (max. 3)

Portable winch Air consumption: Required air pressure:

78 Nm 3/h 6-7 bar

E1IJ FRAMO

No. Date/sign.: Page: Rev.:B

TECHNICAL SYSTEM DATA

0076-0873-4 28.01.2007/BL

4 25.08.09/PET

Cargo heaters Design data for heating of Heavy fuel no.6 - 380 cSt! 44°C - 950 kg/m3 - 1720 kJ/kgoC

Characteristics Number of cargo heaters Capacity Heating medium data: Type Pressure Inlet temperature (on heater) Outlet temperature: Consumption: Cargo data: Type Inlet temperature (on heater) Viscosity at inlet temperature Flow Pressure drop

(kW)

(barg) (0C) (0C) (kg/h)

10 700

Saturated steam 4,0 151 90 1093

(see above) 44 eC) (cSt) 380 (m3/h) 128 (bar) 0,46

2 550

4,0 151 90 859

44 380 166 0,66

ffi FRAMO

No.

TECHNICAL SYSTEM DATA

Date/sign.: Page: Rev.:B

3 Hydraulic oil, Lubricants and Fuel Hydraulic oil For type of oil, see separate instruction. Total oil volume in the system except for storage/ drain tank, is approximately 9 m3.

Lubricants Bearing grease for electric motors: Good quality lithium base or lithium complex grease. Base oil viscosity 100 - 140 cSt at 40°C. Consistency grade 2 or 3. Temperature range -30°C - +120°C continuously.

Lubricating oil for diesel engines: For type of oil, see separate instruction. Lubricating oil type on engines at delivery:

Shell Rimula Super SAE15-40 Total volume: 50 litres (Cummins)

Fuel DMA marine distillate fuel according to ISO 8217 to be used for diesel engines.

Others Coolant for diesel engines: For type of coolant, see separate instruction. Coolant type on engines at delivery: Glyco Shell (40 %) added Fleetguard DCA4 coolant additive Total volume: 66 litres (Cummins)

0076-0873-4 28.01.2007/BL 5 25.08.09/PET

Elij

0115-1110-405 No.: Date/Sign.: 8.12.04/SG

PUMP SPECIFICATION

Page:

FRAMO

1 of 1

Rev.: TYPE: TK150-2 DUHH56-A225-S

PUMP DATA SERVICE: Portable CASING: NS 14460 MATERIALS IMPELLER:

SHAFT: NS14460

DRAWINGS, INSTALLATION AND CONSTRUCTION

PERFORMANCE DATA

34CrAIMo5

DRAWING/INFORMATION

DRAWING NO:

Calculation procedure

0115-1110-415

CHARACTERISTIC:

DUTY:

Capacity Head Specific gravity Viscosity Power required Speed Hydraulic oil flow Hydraulic oil pressure

(m3/h) (mlc) (kg/dm3) (cSt) (kW) (rpm) (I/min) (bar)

Control valve setting: ADDITIONAL INFORMATION

Control valve codification: Total weight, empty:

REMARKS:

TEST FM: 150 50 0,75 1,0 34,0 2983 172 130 172 I/min

SC25fTK150 183 kg

REMARKS:

150 50 1,0 1,0 45,3 2983 172 173 275 bar

IDOl

0115-1110-402 No.: Date/Sign.: 8.12.04/SG

PUMP SPECIFICATION

Page:

FRAMO

Rev.:

1 of 1 E

25.08.09/PET

TYPE:

S0150-60THH107-B325-S PUMP DATA SERVICE: Cargo CASING: EN1.4432 MATERIALS IMPELLER:

SHAFT: CF3M+Mo

DRAWINGS, INSTALLATION AND CONSTRUCTION

PERFORMANCE DATA

DRAWING/INFORMATION

DRAWING NO:

Calculation procedure

0115-1110-412

Pipestack specification

0181-3370-4

CHARACTERISTIC:

DUTY:

Capacity Head Specific gravity Viscosity Power required Speed Hydraulic oil flow Hydraulic oil pressure

(m3/h) (mlc) (kg/dm3) (cSt) (kW) (rpm) (I/min) (bar)

Control valve setting: ADDITIONAL INFORMATION

EN1.6582

Control valve codification: Total weight, empty: Oil volume:

Option:

Internal use only: A71326

REMARKS:

Internal use only. TEST FM:

300 125 0,75 1,0 101,1 2810 310 215 310 I/min STC-30-T 3F-*-P'R 819 kg 75 litre

Temp sensor

REMARKS:

260 94 1,0 1,0 87,5 2434 268 215 275 bar

[]j

No.: 0115-1110-401 Date/Sign.: 8.12.04/SG

PUMP SPECIFICATION

FRAMO

Page:

1 of 1

Rev.: E

25.08.09/PET

TYPE:

S0200-6 OTHH200-C370-S PUMP DATA SERVICE: Cargo CASING: EN1.4432 MATERIALS IMPELLER:

SHAFT: CF3M+Mo

DRAWINGS, INSTALLATION AND CONSTRUCTION

PERFORMANCE DATA

DRAWINGIINFORMATION

DRAWING NO:

Calculation procedure

0115-1110-411

Pipestack specification

0181-3369-4

CHARACTERISTIC:

DUTY:

Capacity Head Specific gravity Viscosity Power required Speed Hydraulic oil flow Hydraulic oil pressure

(m3/h) (mlc) (kg/dm3) (cSt) (kW) (rpm) (I/min) Jbar)

Control valve setting: ADDITIONAL INFORMATION

EN1.6582

Control valve codification: Total weight, empty: Oil volume:

Option:

Internal use only: A41812

REMARKS:

Internal use only. TESTFM:

600 125 0,75 1,0 198,0 2576 534 250 53411min STC40-TF-*-P-R 1358 kg 148 litre

Temp sensor

REMARKS:

520 94 1,0 1,0 171,5 2231 462 250 275 bar

I

Elij

No.: 0115-1110-404 Date/Sign.: 8.12.04/SG

PUMP SPECIFICATION

FRAMO

Page:

1 of 1

Rev.: E

25.08.09/PET

TYPE:

58300-4 MUHH200-A405-5 PUMP DATA SERVICE: Ballast CASING: NS14450 MATERIALS SHAFT:

IMPELLER: NS16570

DRAWINGS, INSTALLATION AND CONSTRUCTION

PERFORMANCE DATA

EN1.6582

DRAWINGIINFORMATION

DRAWING NO:

Calculation procedure

0115-1110-414

Pipestack specification

0181-3371-4

CHARACTERISTIC:

DUTY:

Capacity Head Specific gravity Viscosity Power required Speed Hydraulic oil flow Hydraulic oil pressure

(m3/h) (mlc) (kg/dm3) (cSt) (kW) (rpm) (llmin) (bar)

Control valve setting: ADDITIONAL INFORMATION

Control valve codcification:

Intemal use only. TEST FM:

750 25 1,025 1,0 69,8 1170 242 194 24211min STC30-T OF-*-P-R

Total weight, empty:

955 kg

Oil volume:

129 litre

Intemal use only: A7360

REMARKS:

REMARKS:

750 25 1,0 1,0 68,1 1170 242 189 275 bar

I

ffi

0115-1110-403

No.:

PUMP SPECIFICATION

FRAMO

Date/Sign.:

8.12.04/SG

Page:

1 of 1

Rev.:

B

BU10.01.07

TYPE: MA150/200-2 MUHH63-A300-F

PUMP DATA SERVICE: Tank Clean. CASING: NS16520 MATERIALS IMPELLER:

SHAFT: NS16520

DRAWINGS, INSTALLATION AND CONSTRUCTION

PERFORMANCE DATA

NS14310

DRAWING/INFORMATION

DRAWING NO:

Calculation procedure

0115-1110-413

CHARACTERISTIC:

DUTY:

Capacity Head Specific gravity Viscosity Power required Speed Hydraulic oil flow Hydraulic oil pressure

(m3/h) (mlc) (kg/dm3) (cSt) (kW) (rpm) (I/min) --.lbaQ

Control valve setting: ADDITIONAL INFORMATION

Control valve codification:

Test pressure:

Internal use only: A7359

REMARKS:

TESTFM: 120 110 1,025 1,0 62,6 2811 183 226 1831/min

STC30-T O-*P-R

24 bar

REMARKS:

120 110 1,0 1,0 61,1 2811 183 220 275 bar

Pump1ype Imp. (mm) Driver Remarks

No.

Order no. : Construct: Released:

: TK 150 225. : A2F 56

/1

j.;~~.~

r-...

-;::-

8.fiS

..

0"-

I

0

Elf.) IN

(cSt) 1.00

(kg/dm3) 1.00

I

!

-

I

0

2983.

.:'14f

I

~

(rpm)

1

I

If.)

0169-1675-4

Drowingno.

Performance Diagram for FRAMO Pump

I

Ii

1

i

55

--

! !

0.0

N ,.....

0

I

i

!

8 ..-

r-...

.-

I

I

a.~

If.)

8 ....

i

I

i

0.0

r-...

I

I

fiS

0.0

"

I

f5

I

1

If.)

N

!

I

a 0

sO

, I

I I

l())

I

I

I

150

200

r-...

f9 ~l

'0 0

£55

250

300

350

1

I !

!

l

!

I!

I~

"

I

I

I

!

1

I

i

~

I

0

~

I

~

~

I

~I

a

I I

I I

0

I

~

150

........

0

"7. :~· · · ·- · · · -· -· · -..·-·-· - ..·.. ..

.././.................

-+--------+300

.

250 - ..- ...-...........- ..- - - -....._ -

250

~

iil

~

200

I,~···~

200

2

,

150

3

100~------------~-----------.----.--~----------.----~-------------,--1100

50~-----------------4------····

-·----------~·------··-·----------~!--------·-----------t50 !

O+---~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~---o 250 500 750

__~O 1 000

Capacity (m3/h) 175.-------------------,-------------------~------------------~-------------------.175

150

150

125

100

~-------

~--r----~,--------~----·------·--··---~---------------------t100

I" '" '"

.

I

75

50

~----------------+_-----

....... ----.-.

·-----f50 3

25 -------------------~-------------------.-.--.----------------~---------------f25

o~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~--~o 250 500 750 1 000

o

Capacity (m3/h)

ffi

PERFORMANCE DIAGRAM FRAMO PUMP 88300-4

FRAMO

Capacity:

Speed: Driver:

0169-3351-4

Date/Sign.:

20.08.09/PET

Rev.: Page:

750 (m3/h) 25 (mlc)

Head:

No.:

1170 (rpm)

Specific gravity:

1,025 (kg/dm3)

Viscosity:

No.

1 of 1

(bar)

188

1 (cSt)

405 (mm)

Impeller

A2FM 200

250~-------------------------.--------------------------,-------------,-----------~250

200 - - - - - -

-

------ ---- I I

----

t--_ _ _+ - - - ~1~4------------+------------~--------------4_------------~----------~------------1150

e

~

iil

'""-~

OJ ~ ~

5 1004-------------;Q)

-!------------------+-------------~ 100

50 - -...~-----~-r__------------+-----

.

-----------~-----

. -..----. --+-..--------+·-------------t 50

,\'0'"

Ca""city (m3Ih) 40~------------------~---------~-----------~------------_;------------140

------------i----.-------- ....-.----

" E

~2oi-------------~---------

"'"

. -+----------~---

30

-----~,-----------_+-------------~20

I

-----+-"----- - - - - 10

10

,\'0'"

Capacity (m3Ih)

Performance Diagram for FRAMO Pump

Drawing no:

Order no.: SB300 01.06.2004 RHa 405 Construct: A2F200 Released: Speed limitation curve and operation point is given in pump performance diagram for the order.

Pump type: Imp. (mm): Driver: Remarks:

No. 1 2 3 4 5

(bar) 50 100 150 200 250

0169-2039-4 (kg/dm3) 1,025 1,025 1,025 1,025 1,025

(cSt) 1 1 1 1 1

50

~----~----~------~----~----~------~----~----~

45

+---~~----~------+-----~-----+------~----4-----~

30

+-----~----_4----~~----~----~----~~----+_----~

20

+-----~----~------~~--~-----+-~----~--~+-~--~

0-

E

15+-----~-----~~----+-----~~~-+------~~--+---~~

5

10

+-----~----_4------+_~~~----_+~~~~----+_----~

5

+------+------~~~~----_4----~~----_+------~----~

1

o

+------+------~----~----_4------+_----_+------~----~

o

200

400

600

800

1000

Capacity Q (rn3/h)

1200

1400

1600

ffi

PERFORMANCE DIAGRAM FRAMO PUMP MA150/200-2

FRAMO

120 (m3/h)

Specific gravity:

Head:

110 (mlc)

Viscosity:

Speed:

2811 (rpm)

Impeller

Capacity:

Driver:

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

1,025 (kg/dm3)

No.

1 (cSt)

0169-3352-4 20.08.09/PET 1 of 1

(bar) 226

300 (mm)

A2FM 63 400

400

...-.-.. 350

300~---------------+---------------~---~···~---------+---------------4----------------f300

-.-----.-.........-.-. 250

250

....... - 200

100t----------------4-------------·----r---------------+-------------·--~----------------1100

50t-------------·--+-·--------------·-·---+---·------·-------+---------------.~-----------------

50

O~~--~--~~--+_~--__--~~--~--~~--~--~_+--~~--~--~~--~--~~--~~O

o

100

200

300

400

500

Capacity (m3/h)

1 5 0 r - - - - - - - - - - - - - - - . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , - - - - - - - - - - - - - -___- - - - - - - - - - - - - - - , 1 5 0

125

125f------

································,c:........, ..........., ......, __

100 ---------.. -- .............. --...- .. .

i

75

---- .. -_.....

-.-~

100

t"- - - - --- -"--- --- -

'··l··'i·,·······.......

Q

'"

+. ____._.

I

:r:

15

I j

50f---------------+i-----

25

I ~-~-t--i

i

. -·

--.....;..---.----..- - - - - '..... - - ' - - . - . - - - - - - - i - - - -

- .. -·-----·----------r-----------·----~-----------------125

~~~_l____r____.__~~__.___4

o .J.--...----..--.------.-----l

o

100

-------,50

200

300

Capacity (m3/h)

400

0

500

4

ffi FRAMO

4.0

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.: Date/sign.: Page: Rev. A:

0242-0004-4 30SepOO 1 08Nov06

INITIAL START-UP Depending on the installation, one jockey pump or three feed pumps are installed. When reading this chapter, please be aware of the type installed in your system. The initial start-up shall be carried out/supervised by Framo commissioning personnel due to guarantee conditions etc. After a major overhaul/ service, Framo should be consulted before new start-up. After maintenance/repair, follow the same routines as described below and in separate instructions for the component or part of system involved in chapter 8, section 1. Hydraulic system adjustment and pressure settings are made during factory testing prior to delivery and controlled during initial start-up. Readjustment is therefore normally not required unless this has been interrupted during major overhaul.

4.1

Preparationl checking prior to start-up

4.1.1

Visually inspect components and lines for possible damage.

4.1.2

Oil filling, pressure testing and flushing to be done in accordance with relevant chapter of the Framo Mounting Instruction.

4.1.3

Alarm and shut down functions to be checked out in accordance with instrument list.

4.1.4

If diesel-hydraulic power packs are installed, alarm and shut down functions for the diesel engines to be checked out in accordance with separate instruction for diesel engine control system in chapter 8, section 1.

4.2

Starting jockey- or feed pumps

4.2.1

Assuming oil filling and venting is completed according to separate instruction. Start the jockey- or one feed pump and check direction of rotation. Inspect for leakage, watch for abnormal noise. For installations with feed pumps, stop the first feed pump and repeat the procedure for the next pumps and check that the pressure on the suction inlet to the main hydraulic pumps is 6 bar.

4.2.2

Vent hydraulic pressure- and return lines. Check oil level in hydraulic tank, refill if necessary.

lDDJ FRAMO

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

4.3

Starting power packs

4.3.1

Start the jockey- or two of the feed pumps.

4.3.2

Start one power pack and check direction of rotation. Inspect for leakage, watch for noise.

No.: Date/sign.: Page: Rev. A:

0242-0004-4 30SepOO

2 08Nov06

Stop the first power pack and repeat the procedure for the next power packs. Check that the drain line temperature from the hydraulic pumps is below 80°C, with suction inlet temperature of 55°C. 4.3.3

When item 4.3.2 is completed, stop all power packs and leave the jockey- or one feed pump running for circulation.

4.4

Starting cargo pumps and other consumers

4.4.1

For oil filling, venting and initial start-up of cargo pumps and other consumers, see separate instructions in chapter 8, section 1.

4.4.2

During running, all connections must be checked for leakage. Main pressure- and return lines to be vented on the highest points. When all consumers have been run and the whole system is rid of air, reduce the system pressure to minimum and stop all power packs.

Note!

Always leave the jockey- or one feed pump running to keep the hydraulic system pressurized. All valves in main return line and ball valves in front of the cargo pumps and other consumers must be open, unless required closed for service.

5

ElD1 FRAMO

5.0

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

No.: Date: Page: Rev.:

0242-2577 -4 13Jan10 1

NORMAL OPERATION To prevent impurities from entering the hydraulic system, the system is also pressurized (2-6 bar) when not in operation. Depending on the installation, this is done by the jockey- or one feed pump. When reading this chapter, please be aware of the type installed in your system. Circulation of hydraulic oil by the jockey- or feed pump to keep the hydraulic system pressurized, also gives a continuous air venting and filtration of the oil.

5.1

Start! stop of power packs

5.1.1

Before starting the power packs, check the following: Hydraulic system tank oil level. That the cooling water pump for hydraulic oil cooler is running. That the ventilation fan for power packs is running. That necessary numbers of generators are running. That the potentiometer for system pressure is in minimum position. That the speed control valves for all consumers are in minimum position.

5.1.2

Start required number of power packs. Number of power packs running (oil delivery) should correspond to number of consumers to be operated (oil consumption). This to avoid too many power packs running at reduced capacity, causing increased running hours, wear and tear.

Note!

If diesel hydraulic power packs are installed, running at low load condition should be limited.

5.1.3

Set the system pressure to 15-25 bar above the highest consumer (hydraulic motor) if hydraulic oil temperature is above 20°C. If hydraulic oil temperature is below 20°C, see 5.1.5.

Note!

If the system pressure is set excessively higher than consumer (hydraulic motor) pressure, the surplus energy will change into heat and this loss of energy means waste of fuel.

5.1.4

For operation of cargo pumps and other consumers, see separate instructions in chapter 8, section 1.

Note!

Never operate the system in a way that system pressure drops below 50 bar (only possible by starting too many consumers compared to the number of power packs running, if the hydraulic system adjustment is correct).

FRAMO

5.1.5

No.: Date: Page: Rev.:

SERVICE MANUAL FOR CARGO PUMPING SYSTEM

0242-2577 -4

13Jan10

2

If the oil temperature is below 20°C, open the heating and venting valve for heating with only one power pack running at reduced hydraulic system pressure, refer to fig. 1. Depending on the installation, operation of the heating and venting valve is locally at the valve only or it is remotely controlled from the control panel.

Operation temperature for Framo systems Hydraulic oil temp. CC)

co '-

0Q) ... ... 00

tIl_ 0 .... (/) til tIl>.c. C.(/) ... .... 0> Q) .Qe:;= e:~c. til Q) Q)

244

-

> c. e:

~oo

~e:c.

e ---~

\

~

r?

~ ~ r-...r-.. ;::::

PP1

_Q)O o.cz;=oo

242 -

1

2 3 4 20

-

248

-'-

:::J

en en

~ a. 246

~

,

I I I

240

250 (ij

wE =Q)~ _:';:::::;0

E (J)

e: .e: e: :::J ....

E 2en

>-

(J)

-

_:=00

I---

c~c.

244

tIlQ)Q) > C. e:

-

~cc.

242

_Q)O o.cz;=oo

-

I I I 1

2 3 4 20

Pump angle (0) Capacity (%)

Diagrams showing load sharing between two pumps.

---- - I,\r--- ..... r-.... ~-

~oo

240 5 6 7 8 9 10 11 12 1314 15 40 60 80 100

-;:>,

0>:;::;

e: 0Q) -e: e: .... .... :::JO .... 0 ]l E _ -Q)">.

Figure 4: Electrical control system.

ffi

Pump Remote Control

FRAMO

No.

1375-0091-4

Date/sign.: Page: Rev.:

10.01.2005ITS 6 of 12

;

REMOTE CONTROL VALVE (MOOG) ,'--- -.- - --_._ .. _ .. _ .. _._ .. ,

::~1rB '" .vlSlEilLJf ::. P R -:;--,--~-----,::~,-.-------:

- --- - --: Supply pressure Supply pressure isolating valve I ::1 test p o i n t : " ,-- - - --"""-~

c,,-\,

Alt. position

'i}i~ of venting plug ,,,,,

Compensator (adjustable)

Fig. 3A: STC, main parts with fixed compensator.

Fig. 38: STC, main parts with adjustable compensator

Pilot oil is supplied either internally through an orifice A (ref. fig. 5), but usually externally through pilot connection X (orifice A plugged). From the type identification one can see whether the valve should have a pilot orifice or a plug. For most FRAMO Speed Torque Controllers integrated on top plate, equipment for purging of the cofferdam are built into the valve. For further description and operating information refer to service manual for the cargo pump. For all valves delivered afier January 2002, a last chance filter (strainer) is included in pilot connection, to reduce possibility of valve failure due to particles.

ffi

Service Manual Pump Control Valve, STC

FRAMO

No.

1375-0027-4

Date/sign.: Page: Distr.:

07JuI95/RSP 5 of 13

Rev.G:

12Jun07fTS

External

2. OPERATING INFORMATION FRAMO Speed Torque Controller, STC, is designed to control the discharge from centrifugal pumps powered by a common ring main hydraulic system. The valve has three main functions, ref. fig. 4: 1.

Torque Control (TC). The valve is used to control the torque of the hydraulic motor independent of inlet pressure (P1). The local control valve with hand wheel regulates the pilot pressure and thereby the inlet pressure to the) motor (P2). This can also be done by means of a remote control valve.

2.

Maximum Speed Control (max. SC). The valve limits the oil flow to the hydraulic motor. This function overrides the TCfunction. This can be observed during certain discharge situations: Any attempt to increase motor inlet pressure P2 by turning the local, or remote, control valve against maximum position, or by increasing inlet pressure P1, will be ignored by the STC valve. Some valves are delivered with an adjustable compensator. By using this valve, maximum speed can be reduced to approx. 65 % of specified maximum speed. Maximum speed setting can only be regulated locally. Turn CCW to reduce maximum speed. Turn CW until hand-wheel stops, to adjust back to specified maximum speed. The adjustable compensator is used to reduce maximum speed during stripping, tank cleaning, and other pump operations where maximum speed/maximum discharge head is not required. For operation of compensator, refer to pump operation manual.

3.

Closing. The valve will close off the oil flow when pilot pressure is reduced to minimum, either locally or by remote control valve.

0-

I

"C

h---

co Q)

J:

Maximum speed reduced by adjustable compensator

•

Capacity Q(m3/h)

Fig. 4: Pump curve (principle) The valve may be equipped for both local and remote control, but it is required that when using the local control, tile remote control valve must be set in maximum position and vice versa.

ffi

Service Manual Pump Control Valve, STC

FRAMO

No. Date/sign.: Page: Distr.: Rev. G:

1375-0027-4 07 JuI95/RSP 6 of 13 External

12Jun07ITS

3. MAINTENANCE II"FORMATION No routine service is required for the Speed Torque Controllers. Service on the valve is only necessary in case of malfunction (refer to "Trouble shooting", chapter 6).

3.1 Safety instructions Never unscrew or try to service the valve when pressurized.

BEFORE SERVICE ON STC, ALWAYS CLOSE THE HYDRAULIC PRESSURE INLET VALVE AND VALVE ON PILOT LINE. OPEN THE LOCAL CONTROL VALVE. MAKE SURE THAT ALL PRESSURE CHAMBERS IN THE VALVE ARE RELEAVED BY USING THE BLEED PLUGS.

The valve is made of stainless steel. Therefore it is very important that all threads are cleaned and lubricated properly. A clean "Molybdenum disulphide" (Molycote G-n plus or similar) is to be uSBd on all threads. Never use force on plugs, bolts, pilot valves etc. that tend to seize. O-rings, O-ring grooves and seal faces must be kept clean, undamaged and oiled. Do not use chlorinated solvent as cleaning fluid. They will damage the O-ring seals and contaminate the hydraulic oil. In addition they are not recommended due to health hazard. Before initial start-up and after service, the valve must always be vented. Filling and venting of cargo pump is described in separate filling- and venting procedure. The compensator valve is fitted with an adjustment screw. This is preset at FRAMO's test stand and must under no circumstances be adjusted. Wrong adjustment of the valve may cause the hydraulic motor to overs peed and break down. Warranty claims will be refused if the compensator seal is broken. Never try to run the pump without plug/ orifice A installed. Too high pilot oil supply may cause the hydraulic motor to overspeed and break down and cause permanently damage to the valve. Always use correcl: torque when assembling the valve and valve parts. Too high torque for pilot cartridges may cause malfunction. Note: Torque wrench for correct setting is included in Framo Tool box for this purpose.

Service Manual Pump Control Valve, STC

FRAMO

No.

1375-0027-4

Date/sign.: Page: Distr.: Rev. G:

07JuI95/RSP 7 of 13 External 12Jun07fTS

3.2 Dismantling I assembling Standard tools Name Allen key

8mm

Spanner

19mm

Spanner

27mm

Screw driver no.50/R-11 0 Screw driver no.90/R-17!i

The most common reason for maintenance is to clean the Last Chance Filter (LCF). Another reason is that orifices are clogged. All the orifices can be reached without loosening the valve from the top plate or the cover from the valve block, ref. fig. 5. The pilot orifice A (internal or external) is the most likely one to get clogged.

r----------l

,:OrificesA:,

-Bl·L~=~·L. -

-17--.d"'''-''-''\,'i'~~,

LCF

r--~-~---------·i I

._,-

I I

'

I

_._.-

-1-I I

I

"----------------

Fig. 5: Exploded view of orifice(s) A and orifice B The pilot valves are of cartridge type and may simply be unscrewed. All the pilot valves have to be assembled with a special torque, and a torque wrench should be used. Too high torgue setting may cause malfunction.

ffi

Service Manual Pump Control Valve, STC

FRAMO

1375-0027-4 No. Date/sign.: 07 JuI9S/RSP 8 of 13 Page: Distr.: External Rev.G: 12Jun07ITS

To inspect the pressure reducing cartridge and the venturi meter, it is necessary to dismantle the cover from the valve block.

ALL PARTS MUST BE CLEANED THOROUGHLY, INSPECTED AND DEFECTIVE COMPONENTS MUST BE CHANGED. USE ONLY GENUINE SPARE PARTS.

For valves integrated 011 top plate (STC**-T): For mounting and dismantling of the valve from the top plate and hydraulic connections: See service manual for the pump. ALL BOLTS AND NUTS HAVE TO BE ASSEMBLED WITH A SPECIAL TORQUE. IF NO TORQUE IS SPECIFIED, USE TORQUE ACCORDING TO FOLLOWING TABLE: M6 9.2 Nm

STAINLESS STEEL BOLTS AND NUTS, QUALITY A4-80 Nl8 M10 M12 M16 44 Nm 76 Nm 190 Nm 22 Nm

M20 370Nm

All bolts and nuts are to be fastened using a torque wrench. Remember to coat the threads and underneath bolt hE!ads/ nuts with "Molybdenum disulphide" prior to assembling. PILOT VALVES Assembly torque: 40Nm. Torque wrench in Framo Tool box. To get access with torque wrench on local control valve on some valves, it is necessary to unscrew directional valve, tighten local control valve, and then screw in and tighten directional valve.

3.3 Compensator check The complete compensator may be unscrewed by crew, to verify that the piston is moving freely. Note: The valve is tested and adjusted very carefully at FRAMO's test stand, and touching the adjustment (sealed) is prohibited. If referred to in troubleshooting: Unscrew complete compensator valve from STC. Check that piston rests against circlip. If not, carefully push against end of piston, to make the piston move freely. Clean and lubricate if necessary, but do not dismantle the valve. Reinstall valve.

ffi FRAMO

No. Date/sign.: Page: Distr.: Rev.G:

Service Manual Pump Control Valve, STC

1375-0027-4 07JuI95/RSP 9 of 13 External 12Jun07ITS

3.4 Venting of the valve Standard tools Name

Spanner

10 mm

Any air pockets remaining inside the valve may cause malfunction. Vent by slightly unscrewing the two venting plugs (see fig. 6), at minimum system pressure. A flexible hose with inner diameter 7 mm to be connected as shown, to prevent oil spill. The local control ValVE! {pressure relief} also needs to be vented. There is a separate venting plug for this purpose. Return side of hydraulic system should be pressurized during venting (Feed pumps running). Venting of the local control valve is only to be carried out when the valve is completely relieved. Flexible hose

l.ocal control valve Venting plug (P2)

Manometer lnilr,tlmntnr

inlet

Pilot conn. (x) _ _...- .

Venting plug (P2)

Fig. 6: STC with venting plugs Note: From September ~~006 all STC valves are delivered with a new type local control valve, without air venting plug.

ffi FRAMO

4.

Service Manual Pump Control Valve, STC

No. 1375-0027-4 Date/sign.: 07JuI9S/RSP Page: 10 of 13 External Distr.: Rev. G: 12Jun07fTS

SPARE PARTS

Refer to separate spare part drawings.

5. SERVICE INTERVALS No routine service is required. The Last Chance Filter (LCF) in pilot connection should be cleaned if clogged, and need no periodically checking. When trouble shooting, refer to chapter 3: Maintenance information.

ffi FRAMO

No.

Service Manual Pump Control Valve, STC

Date/sign.: Page: Distr.:

Rev. G:

1375-0027-4 07JuI95/RSP 11 of 13 External

12Jun07fTS

6. TROUBLE SHOOTING For maintenance information refer to chapter 3. The manometer on top of the valve shows the pilot pressure to the main pressure reducing cartridge. Under normal circumstances pilot pressure approximately equals the inlet pressure to the hydraulic motor (P2). Inlet pressure to the hydraulic motor (P2) can if necessary, be measured by replacing the venting plug (P2) on the side of the STC block (ref. fig. 6) by minimess coupling and a manometer. Symptom:

Possible reason:

Remedy:

The valve seems to be closed even though the manometer indicates a sufficient pilot pressure.

The valve is functioning, but the pump impeller is stuck.

Measure the inlet pressure to the hydraulic motor (P2). If there is a high P2-pressure, the valve is OK. Check the pump.

Remote control valve malfunctioning.

Ref. service manual for remote control valve for troubleshooting.

Local control valve leaking.

Check the torque setting. Check the o-rings. Cross-change with another local control valve. Replace defect valve.

Compensator stuck in open position.

Ref. chapter 3.3

Orifice B is clogged.

Check I clean.

Spool in directional valve is stuck.

Check the torque setting. Unscrew valve and check if spool can easily be moved. Check the o-rings. Replace defect valve.

Last Chance Filter is clogged.

Disconnect pilot flange, unscrew LCF, and check/clean.

Orifice A is clogged Of internal pilot oil supply).

Check I clean orifice(s).

The valve is closed, but an pressure P2 can be read because of the breakaway torque of the motor.

No action needed.

The STC fails to open and the pilot pressure is insufficient, even though the local and remote control valves are in max position.

The valve seems to be open even though the pilot pressure is relieved.

ffi FRAMO

Service Manual Pump Control Valve, STC

No.

1375-0027-4

Date/sign.: Page: Distr.: Rev. G:

07 JuI95/RSP 12 of 13 External 12Jun07fTS

Symptom:

Possible reason:

Remedy:

The valve will not closle, and the remote control valve is checked and found to be OK.

The local control valve is not able to relieve the pilot pressure

Set the local control valve in minimum position. Check that the torque setting is correct. Vent the valve by using the venting plug on the hand wheel. Replace defect valve.

Too high pilot oil supply.

Check orifice A or external pilot oil supply.

Orifice B is clogged.

Check I clean orifice.

Directional valve is not functioning.

Check the torque setting. Check the o-rings. Unscrew valve and make sure that the spool can easily be moved. Cross-change with another valve. Replace defect valve.

The STC is in normal max Speed Control mode. This will cause a correct limitation of P2.

Before assuming the STC to be faulty, check the operating conditions. Make sure that the system pressure is not set too low. NOTE: If the service valve on the STC inlet (P1) is closed, it should always be possible to build up max. pilot pressure.

For valves with adjustable compensator: Maximum speed limitation reduced by compensator.

Turn hand-wheel on compensator CW until it stops.

Directional valve is leaking from pilot circuit to return.

Check the torque setting. Check the o-rings. Replace defect valve.

Insufficient capacity I too low inlet pressure to tile motor (P2). The external pilot system is checked and found to be OK.

ffi FRAMO

1375-0027-4 No. Date/sign.: 07JuI95/RSP 13 of 13 Page: External Distr.: 12Jun07fTS Rev. G:

Service Manual Pump Control Valve, STC

Symptom:

Possible reason:

Remedy:

Insufficient capacity because of too low pilot pressure.

Leakage from pilot line to return through the local control valve because of: a) Too high torque setting. b) Sticking valve parts. c) Permanently leakage (damaged cone/ sleeve, spring etc)

a) Unscrew and retighten the local control valve correctly. Regulate to max. after air venting. b) Reduce pilot pressure to min. by remote control valve and increase immediately to max. again. A careful knock on the hand wheel when regulating from min. to max. may also help closing the valve. c) Check the o-rings. Cross-change with another local control valve. Replace defect valve.

Compensator leaking.

Check compensator according chap. 3.3

Last Chance Filter is clogged.

Disconnect pilot flange, unscrew LCF, and check/clean.

Orifice B is clogged.

Check I clean orifice.

Too high pilot oil supply.

Check pilot orifice A or external pilot oil supply.

Compensator stuck in closed position.

Check compensator according . chap. 3.3

Air pockets in pilot line or air pockets inside valve.

Ref. filling and venting procedure. Vent the valve. Old type local control valve (with bleed plug on top) is especially sensitive to air.

Orifice B is clogged or missing.

Check I clean orifice.

Damaged a-rings or back-up rings. Insufficient tightening.

Check I replace. Use correct torque setting.

Damaged seal face.

Contact FM Services.

The valve is not compensating I the motor is overspeeding.

Hunting and vibration.

Oil leakage.

7. SPECIAL TOOLS Torque wrench for pilot valves; local control valve, directional valve and compensator. Included in Framo Tool box.

TROUBLE SHOOTING

\EliSJ I FRAMO I

1000-109-4 06Sep95 I RHa

PROCEDURE

Page 1

I

t

I I,

ii

INTERCHANGE OF HYDRAULIC CONTROL VALVE

I I

I:I!

When trouble shooting running problems for a hydraulic driven pump, an interchange of the hydraulic control ValVE! will give important answers about where the problems are situated. To make such an interchange, there must be available two control valves with equal max. flow setting. The second valve must be situated on a well functioning pump.

! 1)

Close service valves for the two pumps.

2)

Dismantle necessary piping from the two hydraulic control valves.

3)

Loosen the control valves from top cover plate, and lift the control valve upwards.

4)

Check that connection sleeve is in correct position in upper part of pipestack/ top cover plate. Short Emd inside pipestack, long end towards control valve. (Ref. fig. 2)

5)

Check that o-ring and back up ring are in correct position on the sleeves.(fig. 1)

6)

Interchange the hydraulic control valves and be sure that o-rings and o-ring grooves between valve and top cover plate are in good condition.

7)

Assemble piping, fill oil and ventilate for air.

Fig. 1

NB! Use correct torque seiting when fastening bolts and nuts (ref. Service Manual for the pump)" 8)

9)

Test run pump and check if the problem is still there. Yes:

The problem is located to the pump. If the other pump is still running good, both control valves are in good order.

No:

The problem is located to the control valve, and the problem should be moved to the other pump.

After this test, necessalY maintenance should be done and a/l equipment to be reassembled into original position.

tlutvayd!instruksll0.QQ-cUl09rL...._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-----'

I !

ffi FRAMO

I

I

I

TI~OUBLE

SHOOTING

1000-109-4 06Sep95 I RHa

PROCEDURE

Page 2

.

Use correct torque setting

O-ring with Back rin

Long End

Short End

Fig. 2

tlutvavdilnstrul(s71 000-1 09

-

H~fdraulic

Oils meeting Framo General Specification ,

Trade

name~;

-

~.,-.

No. Date/sign.: Page: Rev. D:

1400-0068-4 03Ju189/BL 1 of 1 20Aug09

1) and general specification

for hydraulic oils for use on Framo hydraulic system designed after 6-83 Company

Trade name

ANTAR

VISGA 46 * f------------i-----------f

BP

ENERGOL SHF HV 46* HYSPIN AWH-M 46*

General specification Hydraulic oil to be used on Framo hydraulic system must meet the following specification unless a different specification is received in writing from Frank Mohn AS. 1.

DIN 51524 part 2 for antiwear hydraulic oils type HLP.

2.

Sperry Vickers 35VQ25 A 11 XX20 test as described in Sperry Vickers form M-2952-S.

3.

FZG Al8,3/90 test, load stage 10 according to DIN 51354 part 2.

4.

Viscosity ISO VG 46. According to ISO 3448.

5.

Viscosity index. Min. 95. According to ISO 3448. If a high VI oil is to be used, we recommend an oil viscosity for initial filling of 50-55 cSt at 40C. If necessary by mixing with an ISO VG 68 oil.

6.

Pour point, Max. -26C. According to DIN 51597.

CASTROL

EXXONMOBI

DTE 25 DTE 15 M * DTE 10 EXCEL 46*

FAMM

RANDO OIL HD 46 RANDO OIL HD Z 46 *

SHELL

TELLUS 46 TELLUS T 46 *

TOTAL

VISGA46 *

GULF OIL MARINE

GULFSEA HYDRAULIC HVI PLUS 46 *

If another hydraulic oil is intended used, Frank Mohn AS must be contacted for comments.

Mixing of the different hydrclulic oils should be avoided. If different hydraulic oils have to be mixed, the oil companies in question must run a compatibility test and guarantee the compatibilily prior to mixing. Formulation of different oils is a continuously changing process. The oils listed here are according to information available to Frank Mohn As meeting general specification stated in this paper. It is, however, the responsibility of each oil company to specify hydraulic oils meeting this specification. Re-branded oil is not accept.able.

* High viscosity index oils (VI> 140).

Note: High V.I. oils are only required for low temperature applications.

Reference:

1)

1400-0086-4

OPERATION TEMPERATURE/VISCOSITY FOR FRRMO HYDRAULIC SYSTEMS

. Rev. A: 12Jan05/HL

tv

-20' I

1000

rf' J

I

,

,

200

, " ,, ,,, , " ,"

100

~

110

"-

60

Hln ec::c. to ISO 3448.

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. ..

"'« "'~:~ I~ I ,

=

~

..

,~

"' ".'-:''' ,,,

'"

~

.,>0

',~

/"

40

>

u ~

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./"

.,

ecc. to ISO 3448.

Hex

,,

;

1

I

,

,

400

~

eo'

50'

, " , ,, , ,

600

(/)

4(/

20' I

"'--

~

20

= -

~~-,

,,

,

15

----- -----------,,

,

,

, 10

I -30'

I

-10'

HEATING

I

I

10'

LIMITATION

OF SYSTEM ON OPERATION

20'

30'

.0'

SO'

eo'

70'

, ,,

,,

80'

a.

::I::

At rE'ducE'd Max 100 bar hydro systE'm pressure pressure

I)

a.

For high E'fflclency and long bearing lifetime

::I::

UJ 0-

:I:

a:

a: oJ ex:

UJ

t-

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=-

0

Cl

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HydraulIC oil temp. - pump suctIon sIdE'. HydrauliC 011 VISCOSity: [SO VG46 acc. to ISO 3448. LimItations on system operation are referring to viSCOSity. and temperatures Indicated are for guIdance only. (SomE' hydrauliC 011 blends may exceed lImits for

VG46 oil. esp. at lower temp) See F.m. Instruction 1400-068-4. for approved hydraulIC 01 I. POInts I,') Indicated on dIagram are for a standard.

VG46 hydr-"ulle all WIth vIse. Indt'x of 105.

,, ,

,, til ", 9ll'

TempE'rature t

NORMAL OPERATING RANGE OPTIMUM RANGE

,

I

EliJ]

No. 1400-0063-4 Date/sign.: 07Mar89/BL 1 of 3 Page: Rev. C: 070ct09/HHo

OIL SAMPLING PROCEDURE

FRAMO

NOTES BEFORE SAMF'LING Sampling containers

-- _----

==".. o:.poI!

.....

Special FRAMO sampling containers. These containers are certified clean and dry.

I

Precleaning

I

((

))

.

Aerosol

-

I

Other sampling containers to be precleaned.

-- - - - - -

)}

Strong soap solution

..

------

((

NB! Do not use other bottles.

\I

),

Hot tap water

------

----

SAMPLING PROCEDURE All sampling shall be taken from sampling valve. The sampling procedure must be followed precisely in order to avoid external contamination that will invalidate the result. Never obtain a sample by breaking a line, e.g. by cracking a joint or by draining a hose. Always take the sample under the cleanest conditions possible.

Proceed as follows: 1. Operate the system for at least 30 minutes prior to taken the sample.

ffi

OIL SAMPLING PROCEDURE

FRAMO

2. Remove plug. Open the sample valve and let the oil flush out for about 10 seconds.

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

1400-0063-4 07Mar89/BL 2of3 070ct09/HHo

3. Open the sample container. Don't touch the sample valve.

Only ifuse of alternative sampling container:

Fill up 113 of

Rinse container

Discard fluid

container

'L

~, ,. ", i:

. '.

PIIJ~

~

III 4. Fill up the sampling container. NB!. Keep the cap in your hand to avoid soil/dirt.

5. Cap the sampling container immediately.

7. Fill in a oil sample label. Apply the label to the sampling container.

6. Close the sample valve NB! Assemble the plug.

ffiJ

OIL SAMPLING PROCEDURE

FRAMO

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

1400-0063-4 07Mar89/BL 30f3 070ct09/HHo

Hydraulic oil testing Test method

Limit/ref.

Cause and effect

Action required if level is exceeded

Particles

ISO 4406

Code 16/12 (max. level)

High particle level will cause excessive wear of hydraulic components and malfunction of hydraulic system.

Replace filter cartridges. Contact Frank Mohn Services for assistance.

Viscosity

ASTMD445

(Lower limits): VG46: 38 cSt at 40°C 6 cSt at 100°C

Reduced viscosity indicates: High shear load / insufficient shear stability. - Mixing with another liquid.

Replenish with same oil type VG 100 oil (ISO VG 68 alternatively) Oil sample to be sent to oil supplier to check for other liquids. Action to be taken in cooperation with FMS and oil supplier.

Water

ASTMD95

-

VG32: 28 cSt at 40°C 5 cSt at 100°C

Increased viscosity indicates: Excessive oxidation. Mixing with another liquid.

300 ppm

High water content will: - Increase wear Increase corrosion - Damage the additive package/clog filters for some types of hydraulic oils.

-

25 % reduction (ref. new oil)

This is for most hydraulic oils the normal antiwear additive and should be monitored carefully. A decreased level will cause increased wear in the system.

Replenish with normal fresh oil and contact Frank Mohn Services for assistance.

(Ref. new oil)

A significant change indicates mixing with another liquid.

Action to be taken in cooperation wlFrank Mohn Services and oil supplier.

(Ref. new oil)

A significant change indicates mixing with another liquid.

Action to be taken in cooperation wlFrank Mohn Services and oil supplier.

Critical values depend on the oil used and must be informed by the oil supplier. (50% increase from new oil values indicates oxidation of the oil.

Rapid change requires additional analysis in cooperation with Frank Mohn Services and the oil supplier.

High chloride content will: - Increase wear - Increase corrosion

Stop intrusion of seawater and contact Frank Mohn Services for assistance.

Calcium is a part of the additive package in some hydraulic oils. An increased calcium level indicates mixing with another type of oil (for inst. engine oil). Calcium added to the oil this way will damage the additive package, causing a total breakdown of the system.

At increasing level further analysis must be carried out in cooperation with Frank Mohn Services and the oil supplier.

-

Zinc and Phosphor

Specific gravity

ASTMD 1298

Flash point ASTMD92

Tan (total ASTM D 664 Ref new oil. acid no.) mgKOHIg

Chlorides

2~;

Calcium

(Ref. new oil)

ppm

C Check for leaking oil cooler and water content in storage tank. - Use oil purifier to reduce water content. Contact Frank Mohn Services for help.

ffi FRAMO

FILT~R ELEMENT_ .... :... REPLACEMENT INSTRUCTION FOR CLOSED LOOP SYSTEM

Vent plug

]

Main return line valve

]

Filterbox

]

No. 1400-0393-4 Date/sign.: 19Sep05 / SF Page: 1 of 1 Rev.: A 30Jun06 / RT

Main suction ] valve

Drain valve

]

I O-ring I

1 2 3 4 5 6 8 9

Stop all power packs. Keep one feed pump running. Close main return line valve and main suction line valve. (The oil by-passes filter unit). Open drain valve and venting plug. The oil in the filter chamber drains to tank. Dismantle end cover and remove the filter elements. Note: Filter element is not cleanable. Install the new filter elements and end cover.(Ensure that o-rings are in place and not damaged). Close the drain valve. Open main return line valve. When filter house and return pipes are completely filled with oil, close the vent plug. Open main suction valvE!.