Aoxing Ship Management

12 Operation and Maintenance of Framo Submersible Pumps

Below notes are general guidelines and may differ from the actual onboard system,
please refer to Pump Maker’s ‘Technical Data Manual’ for detailed information.

12.1 Principal Components

12.1.1 Power Pack Room:

Hydraulic Pumps driven by individual motors, Hydraulic oil tank, Thermostatic control
valves and cooler, Filter.

12.2 Pump Description

12.2.1 Pump Body

12.2.2 The pump head is welded or flanged to the Pipe stack. The hydraulic motor, which is
of very compact design, is located inside. The pump head and is surrounded by Return
hydraulic oil. A short, independent Shaft, supported by bearings lubricated by Hydraulic oil, is
connected to a single-stage Impeller.

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12.3 PUMP HEAD

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12.4 Seal Arrangement

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12.5 Portable Pump
12.5.1 Storage on Board

Forecastle / Bosun store

The portable pump and flexible hoses must be cleaned and ready for new pumping
job before the equipment is placed in storage room onboard.

The storage room must be clean and dry, and the pumping equipment must have easy
accessibility.

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The flexible hoses are filled with hydraulic oil. Drain off approx. one cup of oil from the
hoses before storage (when disconnecting from the main system). Control bend radius
for the flexible hoses during storage (min 800 ml)

Control that the units are safely supported, and check that the Snap-On coupling and
starting head/flow control valves are greased and protected.

12.6 Operation Of Framo Cargo Pumping System

12.6.1 Loading Through The Cargo Pump

Take Cargo sample upstream of manifold valve.

Open manifold valve party, to fill cargo line on deck.

Take sample upstream of cargo pump discharge valve.

Open cargo pump discharge valve. Keep manifold valve in throttle position until the
1-foot sample is taken.

Open manifold valve slowly until required pressure/capacity is reached.

Note: Maximum acceptable loading pressure is 8 bar at the pump top cover plate.

If a separate drop line is installed, start loading through the pump only until the 1-foot
sample is taken, and the cargo tank level is above the drop line outlet.

Open valve to drop line and continue loading through both the pump and the drop
line.

Note: * For sampling procedures, ref. Charterer’s requirements.

For technical data, ref. FRAMO service manual.

12.6.2 Discharge Of Parcel Cargoes

Start the hydraulic power plant and increase the hydraulic system pressure to
approximately 150 bar. If the hydraulic oil temperature is below 20°C, circulate the oil
for heating at maximum 100 bar prior to raising the hydraulic system pressure to 150
bar.

Start the cargo pump slowly and let it run with hydraulic pressure 40-50 bar for
approximately 1-2 minutes with closed cargo pump valve.

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Raise the pump’s discharge pressure above manifold pressure to avoid “back flow”
(over pumping). Then open the cargo pump discharge vale.

Increase the hydraulic motor pressure until required discharge pressure or capacity is
achieved. If required, increase the hydraulic system pressure.

Follow the same procedure for the other parcel. Ensure that enough hydraulic power
is available. If not, the hydraulic pressure will drop, and the capacity/ head will be
reduced.

The hydraulic system pressure should be maximum 15 bar above the highest
consumer pressure in order to minimize energy consumption, noise level, and wear
and tear.

Note: Remember to purge the cofferdam before and after using the cargo pump!

12.6.3 Discharge Of Homogeneous Cargoes (Parallel Pumping)

Start the hydraulic power plant and increase the hydraulic system pressure to
approximately 150 bar. If the hydraulic oil temperature is below 20°C, circulate the oil
for heating at maximum 100 bar prior to raising the hydraulic system pressure to 150
bar.

Connect as many shore lines of ample size as possible. A low back pressure on shore
side will have a positive influence on capacity and power consumption. The pipe losses
(discharge pressures) are increasing when the capacities are increasing.

Start the cargo pump slowly let it run with hydraulic pressure 40-50bar for
approximately 1-2 minutes with closed pump discharge valve.

Raise the pump’s discharge pressure above manifold pressure to avoid “back flow’’
(over pumping). Then open the cargo pump discharge valve.

Follow the same procedure for the next pump (s). Ensure that enough hydraulic power
is available. If not, the hydraulic pressure will drop, and capacity/ head will be reduced.

Increase the hydraulic pressure (pump speed) until required discharge pressure or
capacity is achieved. If required, increase the hydraulic system pressure.

The hydraulic system pressure should be maximum 15 bar above the highest
consumer pressure (Cargo pumps) in order to minimize energy consumption, noise
level, and wear and tear.

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Pump capacity should be controlled by the pump hydraulic pressure, not by throttling
the cargo discharge valve or any other valve in cargo piping system. This can be
achieved easily by keeping all cargo pump controllers in max. Position and regulate
the main hydraulic system pressure until required discharge rate is achieved. If
necessary each cargo pump must be balanced individually by decreasing/ increasing
cargo pump hydraulic pressure.

Generally we recommend to run as many pumps in parallel as practical, at a reduced

hydraulic pressure, rather than just a few pumps at maximum hydraulic pressure.

At the end of the discharge, the cargo pump may run dry or suck air through vortex,
which will be indicated by vibration in pump and hunting in the hydraulic pressure.
This can easily be avoided by reducing the cargo pump hydraulic pressure through this
sequence.

12.6.4 Stripping

Reduce the cargo pump hydraulic pressure to approx. 100*bar, at the end of
discharging, or when the pump starts to lose suction, indicated by vibrations and
hydraulic pressure pulsations.

Empty the cargo tank at reduced hydraulic pressure (100 bar). Throttling of cargo valve
may improve the stripping result.

When the cargo tank is empty, close the cargo pump discharge valve and keep the
cargo pump running. Purge cargo deck line to minimize back pressure during stripping
of cargo pump. Then open the stripping valve and purge the raiser pipe with
compressed air or inert gas. Always strip against lowest possible back pressure. The
stripping medium pressure has to be at least 3 bar higher than the cargo back pressure
to obtain minimum stripping time. Purge until air breaks through the impeller,
indicated by a booming noise in the cargo tank, and a hydraulic pressure drop.

Close stripping valve.

Stop Purging, and stop the cargo pump.

Purge the pump’s cofferdam.

Note: * Pump speed (hydraulic pressure) depends on discharge head, specific gravity
and viscosity of the cargo and differs from ship to ship. Ideal speed must therefore be
based upon experience on board.

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STEP 1

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STEP 2

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STEP 3

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STEP 4

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STEP 5

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STEP 6

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STEP 7

How to obtain the best stripping result on existing “FRAMO” ship

Trim/ List of Vessel

Back pressure

Wearing-ring condition

Type of Ship – Single bottom, double bottom

Cargo pump speed

Suction well design

No leakage on cargo discharge valve

Type of production year of cargo pump

12.6.5 Tank Cleaning

To keep dry tank top and still avoid dry running tank washing the tank cleaning
machines capacity (flow into tank) and the cargo pump’s capacity (flow out of tank)
must be equal. Reduce the cargo pump hydraulic pressure until the capacities are
balanced.

Before the tank cleaning is finished, close pump’s cargo discharge valve and open
stripping valve to allow an increase in water level. Run the pump at approximately 110
bar against closed cargo pump discharge valve for 1 - 2 minutes to clean the cargo
pump.

Remember to flush the pump and tank with fresh water if sea water has been used
for tank cleaning.

This procedure is to be followed for purging of submerged cargo pumps with (dry)
cofferdam.

12.7 Procedure To Be Followed For Purging Of Submerged Cargo Pump With Dry
Cofferdam
12.7.1 Why Purging The Cofferdam?

Leakage detection

Condition monitoring of the shaft seal system

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Avoid that leakages are blocking the cofferdam

12.7.2 How To Purge The Cofferdam

12.7.2.1 Preparation

Place a suitable container underneath the exhaust trap to collect the leakage.

Check that valve and bottom of exhaust trap is not clogged by residue after last
purging operation. Stick up with a pin if necessary.

Check that the drain hole from the relief valve on the purging valve block is open.
Location design of purging valve is different for the various pump types. For technical
details, refer to the pumps service manual.

Connect air or inert gas supply to the Snap-On coupling on the purging valve.

Drain the supply line for condensed water.

12.7.2.2 Purging Precautions

NOTE: To prevent damage from dangerous cargoes, take necessary precautions, wear
safety gear, and avoid contact with drain from exhaust trap.

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Open valve on air/inert gas supply line

Check that air/inert gas is coming out of the exhaust trap vent line. (Cofferdam is open)

The relief valve on the purging valve block is set to an opening pressure of 3 –3.5 bar,
so a small leakage here is normal.

Purge cofferdam in several sequences if required.

Drain exhaust trap between each sequence.

Disconnect air/inert gas supply

Close exhaust trap drain valve

Measure the amount of leakage, -evaluate and log the purging result.

12.7.3 Evalution Of The Purging Result

12.7.3.1 Cargo Leakage

Cargo in the cofferdam can come from shaft seals, flange face seals in pipe stack/pump
head or damage (cracks) on the pipe stack/pump head

A small leakage rate over the shaft seals up to about 0.5 L/day during pump operation
is normal, and replacement of seals should not be necessary with this leakage rate.
For short periods of time, higher leakage peaks can occur.

The leakage rate is also depending on the type of cargo. Some cargoes like naphtha,
condensate etc. penetrate the shaft seals more easily than lube. Oils, vegetable oils
and other viscous cargoes. If the leakage rate is up to about 2 liters/day, the pump
must be purged a couple of times daily, and inspected as soon as possible to find the
reason for the leakage.

Intensify the purging if the leakage rate is increasing above acceptable level. If this is
not keeping the leakage under control, close the hydraulic service valve. Do not
operate the pump, use the portable pump to discharge the cargo. The development
of a cargo leakage can be followed if purging is done according to specified intervals.
Thereby maintenance work can be planned, and unexpected shut down due to
leakage can be avoided.

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12.7.4 Hydraulic Oil Leakage

Hydraulic oil in the cofferdam can come from shaft seals, flange face seals in pipe
stack/pump head or damage (cracks) on the pipe stack/pump head.

A small leakage rate into the cofferdam up to about 10ml/h (0.25 L/day) from the
mechanical oil seal or lip seal during pump operation is normal. For short periods of
time, higher leakage peaks can occur.

12.7.5 Precautions to Be Taken When Handling Special Types Of Cargo

The main rule is to have the cofferdam clean, dry and vented to atmosphere through
the exhaust trap vent line, in order to avoid any leakages.

However when handling certain groups of cargoes it may be an advantage to fill the
cofferdam with liquid to improve the seal life time and to avoid cargo blocking the
cofferdam.

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12.7.5.1 Recommended Type of Liquid In Cofferdam

The list below gives recommended type of liquid in the cofferdam for some groups of
cargoes. This is a general advice as the ship crew have to learn by experience which
type of liquid gives the best results for the great number of different types of cargoes.

12.7.5.1.1 Acid Cargoes

After discharging and purging is finished. It can be an advantage to circulate fresh

water through the cofferdam to remove all residue after a leakage.

12.7.5.1.2 Polymersing Cargoes

Fill cofferdam with 5-10 liters of specified solvent to avoid blocking of cofferdam.

12.7.5.1.3 Crystallizing Cargoes

Fill cofferdam with 5-10 liters of fresh water. The cofferdam may also be filled
completely and arranged with a small water circulation.

12.7.5.1.4 Fenol, Stearine Etc.

A circulation of hot water through the cofferdam can avoid clogging. (But remember
some of these types of cargoes are very dangerous, poisonous).

12.7.5.1.5 Heated Oil Products (Fuel Oil, Crude Oil)

Fill cofferdam with approx. 5 – 10 liter of diesel oil/white spirit to keep any leakage
into cofferdam in liquid form. This is especially important after stripping and during
tank cleaning.

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12.8 Air Venting In Hydraulic System

12.8.1 How to detect Air In The System

1) Cargo Pump will not start from remote - Possible

2) Level Variations in the hydraulic oil tank at different system pressure.- Yes
3) Back flow to hydraulic oil tank during stand still. - Yes
4) Foaming in the hydraulic oil tank. - Yes
5) Oil sample “milky”/white, or air bubble mixed into the oil - Yes
6) Abnormal noise from hydraulic pumps or motors. - Possible
7) Uncontrolled pressure variations (hunting) during operation. - Possible
8) Pressure peaks/shock in the system during start/stop of consumers. - Possible

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12.9 The Ten Commandments

1) Purge regularly
2) Dismantle a pump only after identifying the problem.
3) Pressure test the pump, cofferdam and pipe stack using the kit
4) Use genuine spares
5) Use pump performance curves to establish condition of the pump
6) Do not increase system pressure more than 15 bar above the highest consumer
requirement.
7) Avoid air (like plague!!)
8) Keep oil clean
9) Send oil samples for analysis regularly and never mix oil grades
10) Implement a planned maintenance system for the entire cargo handling
system

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