Framo Mounting Instruction Main contents 1 Introduction 1401-0001-401 2 Location on board 1401-0002-401 3 Equipment handling - Storage at yard 1401-0003-401 4 Installation of submerged cargo pumps 1401-0004-401 5 Installation/Storage of portable equipment 1401-0005-401 6 Installation of submerged ballast pumps 1401-0006-401 8 Installation Installation of Installation of hydraulic Installation of hydraulic power Installation of hydraulic power unit, Installation of hydraulic power unit, closed Installation of hydraulic power unit, closed loop Installation of hydraulic power unit, closed loop system 1401-0034-4 9 Installation of electrical equipment 1401-0009-401 10 Yard equipment 1401-0010-401 12 Install ation of deck mounted car go heat exc hangers 1401-0012- 401 14 Installation of submerged tank cleaning pumps 1401-0026-4 17 Hydraulic piping 1401-0017-401 18 Cargo piping 1401-0018-401 19 Hydraulic oils - Oil filling - Flushing 1401-0019-401 20 Framo commissioning - Testing 1401-0020-401 June 2003
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Framo
Mounting Instruction
Main contents
1 Introduction 1401-0001-401
2 Location on board 1401-0002-401
3 Equipment handling - Storage at yard 1401-0003-401
4 Installation of submerged cargo pumps 1401-0004-401
5 Installation/Storage of portable equipment 1401-0005-401
6 Installation of submerged ballast pumps 1401-0006-401
8InstallationInstallation ofInstallation of hydraulicInstallation of hydraulic powerInstallation of hydraulic power unit,Installation of hydraulic power unit, closedInstallation of hydraulic power unit, closed loopInstallation of hydraulic power unit, closed loopsystem
1401-0034-4
9 Installation of electrical equipment 1401-0009-401
10 Yard equipment 1401-0010-401
12 Installation of deck mounted cargo heat exchangers 1401-0012-40114 Installation of submerged tank cleaning pumps 1401-0026-4
The Framo documentation consists of instructions and drawings for installation, operation and
service. This documentation is our property. It is not to be traced, copied or published without our
written consent, nor to be misused in any way.
Framo Mounting Instruction is the general requirements to the yards for handling and installation
of a Framo cargo pumping system, and it contains general instructions for handling, storage and
installation of Framo equipment, in addition to design and installation of the hydraulic piping
system.
It is based upon practical experience from installation of high pressure hydraulic systems in co-
operation with yards and owners all over the world. Kindly follow the instructions carefully to ensure
a successful installation and a well functioning cargo pumping system. Please make special
attention to the following:
Think safety during design:- Appropriate location of equipment.
- Sufficient service space.
- Appropriate lifting equipment for maintenance and repair of installed equipment.
- Appropriate marking of noisy areas.
Think safety during installation:- Use of correct and approved lifting equipment.
- Be aware of foreign voltage from interfaced equipment and switch off the main
switch before any work on electrical equipment.
- Hydraulic oil (on mineral oil base) has a flash point between 180-230°C,
and any leakage must not come in contact with heated surfaces.- Hydraulic pipe connections, flanges, valves etc. must not be located above
or close to heated surfaces.
Think cleanliness during installation:- Maintain a high standard of cleanliness at all times.
- Keep pipes and components clean and protected during the whole production- and
installation period.
Others:
- Do not paint mechanical parts of switches (valve shutdown switches, or equal), manometers,level gauges or similar equipment, or flexible rubber elements (flexible hoses, dampers etc.)
- Never weld on Framo equipment without special agreement.
The instructions are also based upon the authorities' requirements. These are however revised
from time to time, and it is therefore necessary to keep oneself informed about the alterations and
discrepancies between the different national authorities and classification societies.
If drawings are sent to Framo for information or comments, yard must call attention to eventual
deviation from Framo Mounting Instruction by giving remarks on the drawings.
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Framo Mounting Instruction
INTRODUCTION
No.1401-0001-4
Feb-2000
Page 3 of 4
Documentation for yard’s design and installation is supplied to the yard shortly after receiving
the order, and contains the following:
Framo Service Manual includes information for initial start-up, operation and maintenance of the
system. The manuals are supplied to the yard before commissioning.
FRAMO MOUNTINGINSTRUCTION
FRAMO DRAWINGSPUMPING SYSTEM
FRAMO DRAWINGSPIPING SYSTEM
Generalrecommendationsand requirementsfor design, handlingand installation of the Framo cargopumping system.
General ArrangementFramo specification
Equipment drawings
Technical data
System drawings
Piping specifications
Layout drawings
Component drawings
Supplied only if hydraulicpiping system is includedin Framo supply
FRAMO SERVICE MANUALPUMPING SYSTEM
FRAMO SERVICE MANUALPIPING SYSTEM
Technical data
Initial start up
Operation
Maintenance
Drawings - Part lists
Piping specification
Layout drawings
Supplied only if hydraulicpiping system is includedin Framo supply
2 ORDERING NEW PARTS - RETURN OF PARTS
When ordering new parts due to repair, guarantee claim or simply because parts are missing,
please give the following information:
- Yard / Hull no. / Name of vessel.
- Yard claim no.
- Framo sales order number (see cover for Framo Documentation).
- Item no., identification no., part name (from Framo Specification or Packing List)
and quantity required.- Required delivery date at yard/vessel, marking etc.
When parts are returned in connection with guarantee claim or repair, the following must be given:
- Yard / Hull number / Name of vessel.
- Framo sales order number (see cover for Framo Documentation).
- Reason for return.
- Name and number of part, vessel's claim no. if applicable.
The parts must be protected against rust and be properly packed.
Return of parts to: Frank Mohn Services AS. Attention: Guarantee claim co-ordinator
The Project Department is totally responsible for every order on Framo Cargo Pumping
System. To handle each individual order, a Project manager in the Project Department will be
appointed. The Project manager is the main contact during the project- and installation period.
If the order contains hydraulic- or cargo piping, this part of the order will be handled by thePiping Department which will handle the engineering, documentation and supply of piping.
A Project engineer in the Piping Department will be appointed accordingly.
Checking of the installation during commissioning and follow-up during the guaratee period is
handled by the Service Department. A Project engineer at the Service Department will be
appointed, and will be the main contact during the commissioning and guarantee period.
The Framo hydraulic system is designed as a central hydraulic ring line system. The hydraulic
power unit delivers oil to the main pressure line, and from this line it is possible to run a number
of hydraulic motors as long as the oil delivery is sufficient. In order to control the speed of themotor and to prevent over-speed, a control valve is fitted for each motor.
For most of the systems delivered today, the hydraulic power packs, system tank, oil cooler and
main filter are assembled, tested and supplied from our factory as complete compact power units.
1 FRAMO CARGO PUMPING SYSTEM
Fig. 1 Framo cargo pumping system
2 LOCATION IN GENERAL
The following factors must be considered when selecting suitable locations for the equipment:
- Most efficient suction and stripping possibility
- Cargo piping layout
- Hydraulic piping layout
- Cable layout
- Noise
- Ventilation of power pack room
- Sufficient service space
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Framo Mounting Instruction
EQUIPMENT - LOCATION ON BOARD
No.1401-0002-4
Rev.B Dec-2001
Page 3 of 8
C pipestackL
Bulkhe
ad
Cargo valve
Cargo pipeFlexible clamp
Location of bracketsfor lower support ring
Position of suction well
Clearance betweensuction bellmouth and well
Pipestack parallelto bulkhead
High pressure pipe
Service valves
Low pressure pipe
Local control valve
Exhaust trap
Stripping pipe
Valve for drop line
Drop line
Location of bracketfor intermediate support
Stripping valve
3 SUBMERGED CARGO PUMPS
Note! Submerged cargo pumps should be installed at the aft end or in the lowest part of
each tank, located either to port or starboard (to allow optimal tank emptying).
Fig. 2
Arrangement on deck
An obstruction-free zone must be prepared
above the pump, making it possible to lift the
complete pump out of the tank if necessary.
For operation the following valves and
connections must have free access:
- Local control valve
- Stripping valve
- Cargo valve (if not remotely operated)
- Cofferdam purging connection
- Cargo pipe purging connection
- Exhaust trap drain valve
- Hydraulic pressure service valve
Pumps with intermediate support
Pipe stack centerline (through the
center of cargo pipe and hydraulic
pipes) to be parallel to the bulkhead
where the bracket for the
intermediate support is welded.
Suction well
Cargo tanks should be designed with suction wells for optimal :
- Cargo pumping- Stripping
- Service access
For further information see section 4.
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Framo Mounting Instruction
EQUIPMENT - LOCATION ON BOARD
No.1401-0002-4
Rev.B Dec-2001
Page 4 of 8
4 SUBMERGED BALLAST PUMPS
Submerged ballast pumps should be installed as low as possible and in the aft part of the ship.
Suction lines to be designed with ample size to reduce pipe losses and cavitaiton.
Arrangement on deck
An obstruction-free zone must be
prepared above the pump, making it
possible to lift the pipe stack and the
pump head out of the tank if
necessary.
For easy operation the following
valves and connections must have
free access:
- Local control valve
- Evacuating control unit- Hydraulic pressure service valve
Immediately after receipt of equipment, please check that the supply corresponds to the packing
list. Any missing items must be reported to Frank Mohn Fusa AS without delay.
The equipment should be carefully inspected for transportation damage. Damages should be
recorded, photographed, witnessed and reported to carriers and to Frank Mohn Fusa AS.
2 PRESERVATION, PACKING AND MARKING
Preservation
Stainless steel components are pickled, cleaned and ready for installation.
Mild steel components are protected against corrosion by means of priming or painting outside andprotecting oil inside. The preserving oil is mixable with the hydraulic oil, and will give sufficient
protection for about 1 year provided that the blank flanges are kept on.
Un-primed mild steel seal faces are normally protected by a removable corrosion preventive
coating (Tectyl).
Packing and marking
Generally most of the Framo components are packed in plastic-covered wooden boxes.
Electrical equipment
like electrical cabinets, starters and control panels have also silica gel inside for protection againstmoisture. Ventilation openings and cable entrances on electrical motors are in addition covered by
fire resistant tarpaulin.
Power units
are normally covered by plastics and shipped in containers. If they are shipped on open flat racks,
they are covered by light tarpaulin (reinforced plastic) in addition to the plastics.
Submerged cargo- and ballast pumps
are supported by special wooden racks. If the length is more than 14 meters they are split in two
sections to simplify handling and transport.
Smaller pump units, deck trunks etc.
are fastened on pallets and covered by plastics.
The deck trunks seal faces are protected by plywood.
Prefabricated pipes
are packed on transport racks with wooden frames and covered by plastics.
Even if the components used in Framo Cargo Pumping Systems are of rigid construction, they
should always be handled with care. Never step or climb on the equipment.
Be careful not to destroy or remove the transport protection before final installation onboard.Lifting, lowering and handling in general should be done slowly and carefully to avoid damage to
motor bearings caused by vibration and shocks.
Note! Handling information given on the package must be strictly followed.
Stainless steel components must not be in direct contact with mild steel.
3.1 Handling of power units
General info
The power units are equipped with 4 lifting lugs. All of them must be used when lifting. Normally, a
lifting device with 4 slings of equal length can be used to lift the power unit. Avoid contact between
exposed parts of the power unit and the lifting slings.
If special lifting tools are required, these are supplied by Framo together with the power unit.
Note! Forklift must never be used to lift the power unit.
Transportation in container
Normally the power units are shipped in closed containers and should be taken out of the container
as shown for the cargo pumps on page 6.If the power units are shipped in containers with open top, please note that these containers have a
narrow passage at the top. Therefore, the power units must be lifted free for easy guiding and
taken out broadwise. Special care must be taken not to collide with the side walls of the container.
Fig. 1
Transportation on flat rack
If the power unit is wider than the container width, it is transported on a flat rack with a special cage
for protection. This cage must be removed before the power unit can be lifted off the flat rack.
Generally it is preferred that all Framo equipment should be stored in-door.
The equipment must be stored away from corrosive or chemically damaging fumes.Storage even for a short period in an area where work activities such as welding, grinding, sand-
blasting, painting, etc. is going on is prohibited.
For protection and easy identification, keep the equipment in the packages supplied from Framo
until installation onboard. If only some items in a box are needed for installation, keep the others in
the box until installation.
Blank flanges must not be removed before final installation.
The protection on electric motors must be kept on until start up, and will then be removed by the
Framo commissioning engineer.
Control panels must be covered after installation onboard.
As informed in chapter 2, Framo equipment is preserved for 1 year storage. This includes also
cargo- and ballast pumps due to the internal mild steel hydraulic motor and high pressure pipe.
Note! For long time storage (1 year or more), contact Framo for special instruction.
The minimum storage conditions for Framo equipment are given below.
4.1 Storage in dry and clean conditions
All electrical components must be stored in a dry, clean room where temperature is kept steadyabove dew point. Typical components are:
- Electrical control panels
- Main electric boxes
- Starters
- Electrically driven power units *
* Electrically driven power units may be stored in warehouse without steady temperature provided
that the electric motor heating elements are connected and switched “on”.
Note! Connecting power voltage to termistors will damage the termistors and eventually the
motor windings.
Warnings should be placed on the motors when the heaters are connected.
4.2 Warehouse storage
The following must be stored in a dry, clean warehouse:
- Diesel driven power units.
- Hydraulically driven components.
- All valves and fittings for the hydraulic system.
- Deck trunks in mild steel.- Portable cargo pump.
3 INSTALLATION OF DECK TRUNK AND BRACKETS FOR INTERMEDIATE
AND BOTTOM SUPPORT
Prior to pump installation the deck trunk and brackets for intermediate and bottom support have to
be welded into the tank. Use of Framo dummy gives a correct installation of deck trunk, bottomsupport brackets and bracket(s) for intermediate support.
The following installation procedure is based upon use of Framo dummy.
3.1 Framo dummy
The dummy has brackets for all flanged pipe connections on the pumps top plate for adjustment
and prefabrication.
It is neccessary to remove the flange protection for deck trunk (plywood) when using
the top plate dummy. It is important to remount the plywood after use of dummy.
The dummy equipment package and assembling of measuring pipe are shown on fig. 8a and 8b.
For length of dummy (LD), see Framo specification.
3 INSTALLATION REQUIREMENTS(independent of installation method)
To be confirmed before final installation of pump in tank.
The center line of deck trunk and the center line of pump should be identical after installation.Maximum acceptable deviation is shown in fig. 10. This is to avoid excessive stress in the pipe
stack.
The figures below also indicates how to use the laser from the “dummy equipment package” to
The pump casing has to be placed in the section before it is closed. It is of importance that the pump
casing is protective covered until the installation of pump in tank. Prior to pump installation, the deck
trunk and brackets for pump supports have to be welded into the tank. Use of Framo dummy will helpyou to get a successful installation of deck trunk and bracket of intermediate supports.
The following installation procedure is based upon use of Framo dummy.
4.1 Framo dummy
Note! It is necessary to remove the flange protection for deck trunk when using
the top plate dummy. It is important to remount the protection after use of dummy.
The “dummy equipment package” is shown on fig. 12.
Unscrew cap on evacuating control unit. Use a pulling rope as shown in fig. 23. Unwrap the cable
and connect the end to the pulling rope.
Fig. 24
Pumps shipped as one complete unit are pressure tested before leaving Framo works. Pumps
delivered in two parts or more have to be pressure tested after assembling.
Connect air supply and manometer to connections shown on fig. 25 and carefully increase pressureto max. 3 bar. Stop the air supply and observe the pressurized volume for 15 minutes (pressure
drop indicates leakage).
Flush the flange connections with soapy water to be sure of no static leakage.
Reinstall the plugs.
Fig. 25 Connections for pressure testing of cofferdam
Pull the cable through the protection pipe and bracket for evacuating control unit.
The cable end must be long enough to reach the terminals. Cut the cable in a suitable length with
Lift the pump to a vertical position. Preferably two
cranes should be used for this operation, one to keepthe pump head clear of the ground and the other for
lifting (ref. fig. 28).
The pump head shall not be allowed to slide along the
ground during lifting.
Fig. 28
Fig. 29
SB200/SB300 shipped in two sections (with total length < 20 m)
(To be assembled prior to installation)
The pumps have to be lifted by using a snatch block together with the crane on the lower part of thepump. Length of the wire through the snatch block = 2 x length of the lower part of pump.
- If necessary use a plastic hammer on top plate in order to connect to deck trunk.
- Install bushings and nuts under the trunk flange. Tighten bolts in a diagonal sequence.
- Remove the two guide pins (belonging to toolbox), and install the two remaining bushings and nuts.
Fig. 32b
- Lower the pump until the pump head approaches the pump casing.
- Remove the impeller protection. Apply grease to the o-ring in the house guide (see fig. 31a).
- Lower the remaining distance, be careful when the pump head flange reaches the guiding pins.
The pump seal ring will now enter into the pump casing sleeve, use lowest possible speed. Note! At the same time one have to watch the top plate guide pins entering into the deck trunk.
- Remove guide pins, install the two remaining stud bolts, tighten the nuts in a diagonal sequence
and lock with counter nuts (see fig. 31b).
- Install the ejector pipe and fasten the lowest pipe clamp.
- Put the level switch into the pocket, and tighten up the flange (4 bolts).
(The SB400 is delivered with the level switch installed inside the pump head.)
Fig. 31a Fig. 31b
Note! Transport bracket and guide pins should be included in toolbox when installation is completed.
Normally the HPU is located at the same deck as the auxiliary unit with the hydraulic pumps facing
forward and with the motor shafts parallel to ship centre line. The shield must be extended to the
next deck. All hydraulic piping from HPU to consumers on deck will then be in the hydraulic roomand diesel engines/electric motors will be located in the engine room.
Fig. 3 Auxiliary unit located above the hydraulic power unit
The auxiliary unit is normally a part of the
power unit. If it is delivered as a separate
item it may be oriented in any directions but
should if possible be located on the same
deck as the hydraulic power unit.
If not possible it should be located on ahigher deck level but not more than
8 meters above the hydraulic
power unit. This is limited
by the maximum allowable
drain oil pressure.
Fig. 2 Recommended HPU room arrangement
Fig. 2 and 3 shows an arrangement which gives:
- Minimum noise level in accommodation area
- Minimum noise emitted from the ship
- Easy access for maintenance
- Optimum routing of hydraulic and exhaust pipes.
- Shielding of high pressure hydraulic oil from engines/hot surfaces
and electric equipment (Shield to be extended as shown in fig. 12.)
- Machinery room ventilation can be used for the
electric motors/diesel engines.
Note! High pressure piping/flanges to be segregated
from ignition sources (exhaust, electric starters, etc.)
Auxiliary unit (if delivered separately)To prevent vibrations transmitting to the steel structure, the auxiliary unit must be mounted on rigid
foundation filled with concrete (minimum 70 mm thickness).
Auxiliary unit is resilient mounted as shown in the figure 13. Flat bars and rubber insulation aresupplied by Framo. For welding of flat bars to the foundation use the following procedure:
- Place the auxiliary unit with flat bars and rubber insulation on the concrete filled foundation.
- Spot weld the flat bars to the foundation (careful with the rubber insulation).
- Remove the auxiliary unit and the rubber insulation before the flat bars are welded to the
foundation with continuous fillet welding.
- Assemble the auxiliary unit after cleaning and painting of welding zone.
Fig. 13
If the filter/cooler unit is delivered separately, same procedure as above (fig. 13) to be used.
To achieve rated power, exhaust back pressure must be below maximum level, ref. technical data.
Exhaust pipes from several engines shall have separate outlets. The exhaust piping should not be routedat the hydraulic side of the shield. It must be routed in order to prevent entrance of water (ref. fig. 20).
Fig. 21
Note! Installation, supporting and calculation data for the exhaust piping are given in separate
instruction from the engine makers instructions.
Note! The exhaust system must be shielded .
The diesel engines are provided with a compensator at
the outlet of the turbocharger to prevent excessive
stress to engine.
The compensator for exhaust pipe allows a maximum
simultaneous lateral movement of ±10 mm and an axial
movement of ± 10 mm (ref. fig.21).
A combined silencer/spark arrestor is provided for each
engine as a separate item.
Keep the blank flange at the top of the exhaust
compensator on until initial start-up to be sure there is
no water ingress.
Fig. 20
Install the silencer as close as possible to the engine or near the outlet.
The silencer can be installed in any position from horizontal to vertical, however flow direction
indicated on the identification plate must be respected. When mounted horizontally note that the
soot collector must be at the lowest point enabling for periodically cleaning.
Refer to instruction “Installation of power unit” for recommendations regarding routing of power
cables, cable trays and supports. Yard must ensure that grounding of all motors and related
equipment is carried out.
Power pack motors are heavy consumers on board. Yard is responsible for dimensioning the power
cables with respect to thermal capacity and voltage drop during starting and full load operation.
If applicable, interface to power management system is normally implemented in power pack
starters. If starters are supplied by Framo, a power management system functional description
detailing quantity of signals, pulsed or maintained contacts etc. to be submitted. If applicable, by
pass switch shall be provided by yard.
Nuts for power cable termination points must be secured with lock nuts and tightened with torque
meter according to type of bolts/thread dimension used. This is also applicable to termination points
in starters and feeder panel.
In order to preserve original protection grade (IP), correct glands or sleeves must be used.
Refer to applicable documentation for details regarding starting methods and wiring diagrams.
Notes! Bolts, nuts, washers etc. must not be dropped into the motor as such foreign
particles will lead to short circuit of the motor.
Cables for motor-heating element and thermistors must not be interchanged,
as a voltage higher than 2.5 V will damage the thermistors.
Motor heating elements must be powered immediately after installation on board.
2.1 Power pack starter
- The thermistor amplifiers (one per power pack motor) must be installed in starters and
connected to the thermistors in the motor. Thermistor amplifiers shall trip the motor if activated.
(The amplifiers are delivered as loose items if starters are supplied by Yard).
- The running signal to control panel is also used for unloading the hydraulic pumps duringstarting. The running signal must be given as soon as start is initiated and shall be maintained
as long as the motor is running. Refer to sketches below:
In order to obtain correct direction of rotation (counter clockwise), connect phases according toapplicable diagram.
- Due to size/weight of contactors, they must be installed on a rigid/stiffened plate to avoid
vibration interference during making and breaking.
- Arrangement for space heaters to be provided.
- Ratio of current transformer to be informed to Framo if amperemeter is required on ‘Hydraulic
System Control Panel’.
2.2 Feed pump starter (closed loop system only)
The feed pumps should be fed from different power supply sources if possible. This will increase
availability as one feed pump shall always run. Arrangement for space heaters to be provided.
1. The junction box supplied by Framo to be located close to the valves. Cables prepared with el.
connector are supplied by Framo with following lengths.
- From 1 -16 valves: 2.5 m- Next 17 - 32 valves: 4.0 m
- Next 33 - 56 valves: 5.5 m
Glands for cables between junction box and valves are installed in bottom gland plate by Framo.
Glands for cables between junction box to control panel to be installed by yard unless otherwise
agreed.
2. Connect pilot pipes to suitable valves, giving orderly pipe installation.
3. Select a cable with suitable length and connect to the valve when pump no. (tank no.) and valve
correspondence is known.
4. Adjust cable length and terminate to dedicated terminals in junction box. Terminals in junctionbox are grouped and marked with pump no. Refer to interconnection diagram for details.
5. After installation, yard to recheck uniform hydraulic connection from pumps to valve and el.
connection from valve to terminals in junction box. Valves to be permanently tagged by
In general we have the same requirements for installation of yard equipment connected to the
Framo system, as for equipment supplied by Framo.
The equipment must fit in with the Framo system regarding:
- Cleanliness
- Oil type and viscosity
- Hydraulic oil consumption and pressures
- Functioning without giving pressure peaks in the hydraulic system
Hydraulic system pressure, return pressure and other information are given on the Framo hydraulic
diagrams.
Equipment and connecting pipes must be properly cleaned prior to commissioning.
Oil used for flushing, testing and preservation must be compatible with the oils meeting Framo
requirements.
Note! Never use engine oil for combustion- or engine lubrication oil in combination with hydraulic
oil or its equipment, as this will damage the hydraulic oil.
2 HYDRAULIC OIL STORAGE / CLEAN OIL DRAIN TANK
The storage/clean oil drain tank incl. necessary equipment is yard supply, and shall in addition to
storage of oil make it possible to drain off clean oil from the system during service.
To avoid water mixing with the oil and simplify drainage of water, it is recommended to slope thetank bottom down towards the bottom drain outlet. If the tank bottom is not sloped, the suction
outlet to hydraulic oil transfer pump must be minimum 100 mm above bottom drain outlet.
Hydraulic oil tanks must be vented indoor, not to open deck. Air filters should be used.
All pipes (except overflow) must have outlet openings below minimum oil level.
Fig. 1 Hydraulic oil storage tank and clean oil drain tank
The Framo cargo heater is a vertical deck mounted stainless steel heater. It consist of a channel
section and a cover. The channel section includes the heating elements, that are free to expand
vertically inside the cover. The cover can be lifted up/removed from the heater for inspection andcleaning of the elements. A lifting hook for this operation is included in toolbox.
The Framo cargo heater can be delivered in 3 different sizes, HE225/750, HE400/1000
and HE500/1000:
Thermometer
Relief valve
HeatingmediuminletFlat gasket
Cover
Heatingmediumoutlet
Thermostaticvalve
HE400/1000
Channel section
Heating
mediuminlet
Heatingmediumoutlet
HE500/1000
Channel section
HE225/750
Channel section
Heatingmediuminlet
Heatingmediumoutlet
The heater must be protective covered against
weld spatter, sandblasting during installation/
building period.
The heater is delivered with a protection cover that
must be kept on until commissioning is completed.
Pickling is required if the heater has been exposed
to iron dust during storage or corroded surfaces/
spots are detected. Framo recommend Avesta
Pickling Paste or equal types for stainless steel.
Note! Welding, sandblasting and grinding must be finished and tank must be properly cleaned
before installation of pump in tank.
For carbon steel tanks, also coating must be finished before installation.
Pickling
Pickling will be required prior to installation if the pump has been exposed to iron dust during
storage or corroded surfaces/spots are detected. Framo recommend Avesta Pickling Paste or
equal types for stainless steel.
Follow the manufacturer’s procedure for pickling before starting the work.
Blank flanges
Blank flanges and seals on top plate shall be left until connection of the pump to the vessel’s pipingsystems. By then the piping system has to be inspected for foreign bodies and cleaned.
The blank flange/protection cover on the pump’s suction opening and the protection around the
pump shaft must be kept on until pump has been installed and tank has been cleaned and
approved. The protection shall be removed only by the Framo service engineer.
Special tools required for installations are supplied by Framo in the toolbox.
See tool list for descriptions.
Bottom support /Intermediate support(s)Install the support(s) on the bracket(s) before
installation of pump.Tighten nuts as follows (fig. 24):
1) Assemble upper nut, use 190 Nm torque.
2) Tighten all bolts one more time,
use 190 Nm torque.
3) Assemble lower nut, use 190 Nm torque.
Deck trunk
Remove the flange protection and inspect the
sealing surface on the deck trunk flange.Required surface roughness is Ra 1,6 µm.
Clean the gasket groove in the top plate. Stretch the gasket
over the top plate, -take care not to damage the gasket.
The gastket has to be greased with teflon grease before
installation in the top plate. Gasket and grease are supplied byFramo. Install the gasket carefully in gasket groove while the
pump is still lying hoizontal.
Install two guide pins in top plate (180° apart).
Install lifting tool on the top plate (supplied by Framo in the toolbox)
Lift the pump to a vertical position. Two cranes should be used to raise the pump to vertical position,
one crane for lifting, the other for keeping the lower part clear of the ground.
The lower part must not be allowed to slide along the ground during lifting.
For pump above 12 metres it is recommended to use a snatch block on the lower part.Minimum length of the wire through the snatch block = 2 x length of the pump’s lower part.
Lower the pump until the top plate rests on the
deck trunk. Be careful when the guiding pins
enter the deck trunk holes.
Install rubber bushings and hexagon head boltsunder the trunk flange. Use Loctite on the bolts.
1.5 Critical length of branch lines1.6 Service spools 1.7 Optimal layout between engine room and deck1.8 Noise reduction 1.9 Pipe qualities and sizes1.10 Flanges and connections1.11 Expansion loops1.12 Venting of pipes1.13 Pilot pipes
2 Fabrication of hydraulic pipes
2.1 Degreasing of carbon steel pipes2.2 Protection of flanges2.3 Bending of pipes2.4 Welding 2.5 Fabrication tolerances 2.6 Non-destructive testing (NDT)2.7 Surface treatment / Pickling / Preservation
3 Installation onboard
3.1 General requirements 3.2 Tightening torques for bolts
• Reduced quantity of pipe components (leakage possibilities)
• Reduced installation time• Reduced pressure drop
• Increased life time
• Reduced maintenance cost
1.2 General requirementsTo obtain a long lasting and well functioning hydraulic plant, cleanliness is of great importance.Framo’s requirement is to keep the pipes and components clean and preserved during thewhole production and installation period.
Following must be considered during layout of hydraulic pipes:
• Spool length up to 12m where practical
• Stress caused by the system pressure
• Thermal expansion caused by temperature changes in the system (max. oil temp. 60°C)
• Mechanical forces caused by deflection of ship structure
Documentation:
All material used must comply with classification society rules, regarding material certificates andproduction documentation.
1.3 Detail designHydraulic pipe spools must be designed to ensure visual inspection for all inside weld seams,ref. fig. 4. Use of instruments like videoscope or similar is an acceptable inspection method.
In order to reduce stress in branch lines and main lines from thermal expansion and deflection of ship, the following tables for duplex, stainless steel and carbon steel must be used for optimum
hydraulic pipe design.
Figure 7, 8 and 9 show how the required flexibility length (L-U) changes with increasing pipe dimension witha small total piping length (one curve for all pipe dimensions) and a large total piping length (four curveswith several pipe dimensions) when assuming a maximum differential temperature ∆Tmax=50ºC (FDP).The intersection of the above mentioned curves and the upper flexibility limit will indicate the requiredflexibility length (L-U) on the axis of abscissas.For a given pipe dimension a total piping length smaller than L=15m will also require a smaller flexibilitylength (L-U) somewhere between the maximum value and the minimum required flexibility length for L=5m(linear interpolation can be performed).
D = outside diameter of pipe (mm)L = developed length of piping between anchors (m) (L1 + L2 + L3)U = anchor distance, straight line between anchors (m)K = flexibility characteristic (-)
0.5 1 1.5 2 2.5 3 3.5 4 4.5 550
100
150
200
250
300
350AISI 316L: FLEX ANALYSIS NOT REQUIRED?
0.5 1 1.5 2 2.5 3 3.5 4 4.5 550
100
150
200
250
300
35022Cr DUPLEX: FLEX ANALYSIS NOT REQUIRED?
0
0
j
j
P i p e f l e x . c h a r a c t e r i s t i c
K
P i p e f l e x . c h a r a c t e r i s t i c
KUpper flexibility limit
L-U (m) L-U (m)
OD 100, L=15 m
OD 80-90, L=15 m
OD 54-65, L=15 m
OD 38-45, L=15 m
< OD 106, L=5 m
Upper flexibility limit
OD 106, L=15 m
OD 76-90, L=15 m
OD 54-60, L=15 m
OD 35-45, L=15 m
< OD 106, L=5 m
Duplex Fig. 8 Stainless steel 316L Fi g. 9
0.5 1 1.5 2 2.5 3 3.5 4 4.5 550
100
150
200
250
300
350St 52: FLEX ANALYSIS NOT REQUIRED?
1.2 L-U (m)
Fig. 6 Carbon steel St.52 Fi g .7
P i p e f l e x . c
h a r a c t e r i s t i c
K
Upper flexibility limit
OD 100, L=15 m
OD 80-90, L=15 m
OD 54-65, L=15 m
OD 38-45, L=15 m
<OD100,L=5m
Example:Pipe OD65 withbranch lengthapprox. 5m.L-U must beminimum 1.2 m.
1.5 Critical length of HP branch linesThere is a connection between pump length and the length of HP branch lines, due to pressurewaves and pipe sizes. If HP branch line is above critical length, there will be a risk of vibration.
To avoid vibration in branch lines, table fig. 10 shows critical pipe length for branch lines topumps. This is in most cases only applicable for submerged ballast pumps and pumps in decktanks. Pipe dimensions given in Hydraulic Diagram are standard pipe sizes.
1.6 Service spools at cargo pumps and resilient pipe clampsHydraulic pipes must have an angular service spool at pump in order to make lifting of pumpspossible.
Fig. 11
KRITISKE STIKKRØRSLENGDER FOR FRAMO SD(SB) PUMPER , BASERT PÅ SIMULERING
0
5
10
15
20
25
30
35
40
0 5 10 15 20 25 30 35 40
MAX. LENGDE STIKKRØR I METER
P U M P E L E N G D E
I M E T E R
Max. length of branch lines (m)
This table is applicable for H.P. only
P u m p l e n g t h
( m )
Critical pipe length for H.P. branch lines for
Framo SD (SB) pumps.
Example:SD 100, pump length 18 m.Max. length of branch line = 13 m.
Note !
If branch line exceeds limitationsgiven in this table, pipe size to beincreased by 2 step up to servicevalve (ball valve).Please contact Framo for verification.
1.7 Optimal layout between engine room and deckIn order to get an optimum design and low noise, pipes to be routed from the engine room,through cofferdam or pipe duct, and up to main deck.
Note!
• Length “L” to be as short as poss ib le, and m aximum 8m wi thout expansion bend.
• Resi l ient c lamps and anchor points must be welded to r ig id structure.
1.8.1 Installation of resilient pipe clampsDue to fabrication tolerances on pipe supports and prefabricated pipes, pipe clamps must bepossible to adjust in order to have similar compression on rubber pads.Pipe supports must be welded to rigid structure, ref. fig. 19.
Recommended procedure :
1. In order to make adjustment more easy, resilient pipe clamp to be welded to an angle bar or similar, prior to spot welding to pipe support.
2. Check acceptable load for resilient pipe clamps.
3. Angle bar with resilient pipe clamp must be spot welded to pipe support.
4. After all pipes are in position and aligned, angular bar must be adjusted, if necessary tosimilar compression on rubber pads. Clamps must not be overloaded.
5. Welding of bracket to be completed.
Note! Carbon steel pipes mu st be painted with comp lete paint ing system before instal lat ion, to avoid corros ion in clamping zone.
Following pipe lines must be resiliently installed:
Pipe lines: Requirement:
All hydraulic lines, except pilot lines on deckCargo lineDrop lineStripping lineCooling water (HPU)
Fuel connection (HPU)Exhaust connection (HPU)
Distance between clamps, see table page 9Minimum 2 pcs close to pumpIf clamp is requiredIf clamp is requiredFlexible bellow
1.8.2 Resilient bulkhead penetrationFramo resilient bulkhead penetrations are type approved for A0 bulkheads.By additional insulation, the penetrations are approved for A60 bulkheads.
Materials: Stainless steel / rubber / fire protection.
1.8.3 Installation procedure for Framo resilient bulkhead penetration
In order to obtain a correct installation of the resilient bulkhead penetration, the followingprocedure must be followed:
1. Reinforcement of bulkhead/deck by use of additional stiffeners is required due to cut out inbulkhead plate. See fig. 23.
2. Hole in bulkhead/deck to be cut out according to actual size. See table, measure A.3. To obtain correct distance from bulkhead to
penetration flange, temporary adjustmentpieces can be cut to reduce distance. For increase of distance shims to be used
(Ref. measure B and C).4. Install bulkhead penetration temporary by tack
welding.5. Support rings to be dismantled.6. Pipe inside to be fitted to bulkhead flange.7. Remove the adjustment pieces.8. Check alignment: radial = ±5mm
axial = ±6mm9. Trunk to be sequence welded to bulkhead.
Use welding consumables for carbon steel/stainless steel (309 Mo).
10. Reinstall the support ring, and check alignment (item8
).11. Outside pipe to be fitted after adjustment and welding.12. After sandblasting and painting of bulkhead/deck plate, remove protection tape.
Prior to start of surface treatment bulkhead penetration must be protected by use of canvasor simular.
Trunk dim. OD øA B C D øE
ø168,3 170 58 76 144 198
ø200 202 69 87 156 230
ø219,1 221 69 87 156 249
ø290 293 103 121 190 322
ø290 HP, DN100/110 293 123 141 210 322
ø355,6 359 83 101 170 386
ø406,4 410 84 102 172 438
Fig. 22
Fig. 23
A = Hole for trunkB = Min. distance from
bulkhead to cover (mark in trunk)
C = Max. distance frombulkhead to cover (mark in trunk)
All hydraulic pipes must be cold worked to give a smooth internal surface in order to
reduce the pressure drop and to ensure sufficient cleaning during oil flushing.
Recommended material qualities below are based upon pipe material available in the market,and life time of pipe system:
LOCATION PIPE LINE MATERIAL QUALITY
Pipes on open deck High pressure pipes Carbon steel St. 52.4Option: Duplex Stainless steel
Pilot pipes Duplex Stainless steelReturn pipes Stainless steel 316L
Pipes indoor All pipes Carbon steelOption: Stainless steel 316L
Note! Longi tudinal welded return pipes must be fabr icated by approved mi l l for fabr icat ion
of w elded p ipes.
Pipe dimensions
Pipe dimensions given in Framo hydraulic diagrams show the minimum internal pipe diameter.This is based upon max. permitted pressure drop calculation for each vessel.
The wall thickness is depending upon class requirement, material quality, material treatment andbending of the pipes actually installed.It is yards responsibility to ensure that the wall thickness complies with the classification society
rules. The thickness given on the hydraulic diagram is for guidance only.
When the hydraulic piping system is part of Framo’s delivery, Framo will do the necessarycalculations according to classification society rules.
For further information regarding pipes, see Framo piping catalogue.
FRAMO PIPE STANDARD
Table 1 - Pressure pipes
Carbon steel / Stainless steel
Table 2 - Return pipes
Stainless steel (316L)
DN OD x thickness CS / SS DN OD x thickness
DN 15 18 x 2,5 / 1,5 DN 15 18,0 x 2,0
DN 20 25 x 3,0 / 2,5 DN 20 28,0 x 2,0
DN 25 30 x 4,0 / 2,5 DN 30 35,0 x 2,0
DN 30 38 x 5,0 / 3,5 DN 40 44,5 x 2,0
DN 35 45 x 5,0 / 4,0 DN 50 54,0 x 2,0
DN 40 54 x 6,0 / 5,0 DN 70 76,1 x 2,0
DN 50 65 x 7,0 / 6,0 DN 80 84,0 x 2,0
DN 60 80 x 10,0 / 7,0 DN100 106,0 x 3,0
DN 70 90 x 10,0 / 8,0 DN125 131,0 x 3,0
DN 80 100 x 10,0 / 9,0 DN150 156,0 x 3,0DN100 120 x 12,0 / 10,0
In order to get a leakage free hydraulic system it is of great importance to use flanges with cleanand damage free “flange face”. Any damage on sealing surface may cause leakage.
Note! “Flange face” must be protected dur ing product ion period in worksho p.
Data is based on designpressure limited to 320 bar.
Expansion of pipe line
Expansion of pipe line can be made by expansion loops or by off-set in pipe layout,as shown in fig. 42.
Note! Flexibi l i ty and stress analysis mu st be carr ied out, in order to make suff ic ient
f lex ib i l i ty of pipes and correct pos i t ion o f res i l ient anchor point and clamps.
MD = For distance between clamps, see table on page 9.
1.12 Venting of pipes
Heating and venting valve arr. to be fitted on highest part of hydraulic pipe lines (HP/LP), inopposite end of HPU. Air venting plugs to be fitted at all high points of pipes (HP/LP).
1. The junction box to be located close to valve blocks. Distance ‘L’ is limited by cablelengths. Cables with el. connectors are supplied with following lengths:
• From 1 – 16 valves : 2,5m• Next 17 – 32 valves : 4,0m
• Next 33 – 56 valves : 5,5m2. Connect pilot pipes to a suitable valve, to get an optimum pipe routing.3. Select a cable with suitable length and connect to dedicated terminal in Junction box.
Note! Water bal last pumps m ust be connected to dif ferent valve block s. This to ensur e
operat ion of bal last system if on e valve block is ou t of service.
Resilient pipe clamps indoor
Pilot pipes OD 12 or 18mm
Fixed bulkhead
penetration
400
400
Use flanges for
pipe to pipe joint
JunctionBox
Resilient mounted
Indoor DeckEl. cable
Framo supplyFramo supply
" L "
Remote controlValve blockFramo supply
Note!
• •• • Marking of valves / pum ps to be don e by Yard after instal lat ion of p i lot pipes and
cables.
• •• • Pilot pipes on op en deck mus t be of stainless steel material.
Pilot lines must be routed in order to give sufficient flexibility and a professional lay out.Expansion loops are required, maximum distance between loops is 25m. If installed in
catwalk, expansion loops for pilot lines must correspond with expansion joint in catwalk.For dimension of expansion loops, see fig. 46.
Pilot pipes must be installed in max. 2 layers, in order to have access to tighten bolts in flanges.Flanges to be turned as shown in fig. 47, in order to avoid contact between flanges and pipes.
2 FABRICATION OF HYDRAULIC PIPESIn order to reduce installation time, prefabrication of hydraulic pipes can be carried out inworkshop up to possible extent (~80 - 85%). Adjustment pipe to be used at bulkhead
penetrations and between service valves and pumps only.
2.1 Degreasing of carbon steel pipes and accessories before
production
Note! Preservat ion oi l may cause toxic gasses durin g welding.
2.2 Protection of flangesThe seal surface must be protected during the entire production period. Flanges must be
protected by use of blank flanges, rubber gaskets and min. 4 bolts.
2.3 Bending of pipesBending of pipes where ever possible is preferable. Use cold bending method only.
For low pressure pipes use of «mandril» inside the pipe is required. «Mandril» material must beplastic/teflon or similar to avoid damage of pipe surface.«Mandril» must be cleaned prior to use.
Bent section of pipe must be free of wrinkles on inner side, and ovality max. 7%.
A = Minimum distance between two bends acc. to bending machine used.
B = Minimum length after bending (tool clamping).Dmin. = Minimum diameter after bending.Dmax. = Maximum diameter after bending.R = Bending radius, ref. class requirements.Tmin. = Minimum required wall thickness after bending.
Table 1 - Pressure pipes – Bending data
(Carbon steel / Stainless steel)
Table 2 - Return pipes – Bending data
Stainless steel (316L)
DN OD x thickness A B R DN OD x thickness A B R
DN 20 25 x 3,0 / 2,5 470 200 100 DN 20 30,0 x 2,0 505 220 120
DN 25 30 x 4,0 / 2,5 505 225 120 DN 30 35,0 x 2,0 570 225 140
DN 30 38 x 5,0 / 3,5 590 300 152 DN 40 44,5 x 2,0 465 300 178
DN 35 45 x 5,0 / 4,0 475 300 180 DN 50 54,0 x 2,0 565 300 216
DN 40 54 x 6,0 / 5,0 540 300 216 DN 70 76,1 x 2,0 790 475 305
DN 50 65 x 7,0 / 6,0 110 360 260 DN 80 84,0 x 2,0 865 490 335
DN 60 80 x 10,0 / 7,0 250 400 240 DN100 106,0 x 3,0 340 600 318
DN 70 90 x 10,0 / 8,0 285 500 270 DN125 131,0 x 3,0 300 650 393
DN 80 100 x 10,0 / 9,0 300 600 300 DN150 156,0 x 3,0 470 850 468
DN100 120 x 12,0 / 10,0 360 650 360
DN110 130 x 13,0 / 11,0 390 650 390
Option: Heat induction bending
Bending by heat induction can be used for carbon steel pipes only, provided that actualprocedure is approved by classification society.
Note! Pipes must be degreased before bending , and pickled after bending.
2.4 WeldingWelding procedures and quality control to be carried out according to classification societyrules. TIG welding with purging gas (Argon) is recommended.
To be grinded if tolerances are
exceeded
t
Max 1 + 0.1t
Welding of “weldoflanges” and “threadolets” – High and low pressure
Following procedure must be followed carefully in order to obtain a high quality branchconnection.
1. Hole “A” must be drilled in run pipe, corresponding to inner diameter of weldoflange.Ref. fig. 51. Note! Flame cutt ing is not acceptable .
2. Weldoflange is machined for medium range run pipe. In order to meet requirements of Welding Procedure Specification (WPS), machining must be carried out to fit actual runpipe. Ref. fig. 52 and 53.
3. Welding according to approved welding procedure, for each material grade. TIG welding(GTAW/141) is recommended. Pipe must be filled with purging gas (Argon) in order toprevent oxidation of welding root.
2.5 Fabrication tolerancesIn order to avoid leakage, it is of greatest importance that the condition and alignment of flanges are checked prior to installation. The flange face must be clean and free from any
damage on the sealing surface. Before tightening of flange bolts radial off-set and axial gapshould be checked.
Fig. 54
2.6 Non destructive testing (NDT)NDT to be executed according to Classification Society rules.
WORK SHOP PRESSURE TESTING
High pressure : 1,5 x design pressure.
Medium :Fresh water with corrosion inhibitor.Proposal: DYNO PK 6050 or equal.
SandblastingBefore priming carbon steel pipes must be sandblasted on the external surface.Roughness to be: SA 2.5 or according to requirement in actual painting system.
Note! Internal surface mu st not be sandblasted.
PrimingExternal surface must be primed immediately after sandblasting/pickling. Use primer according to actual painting system.Proposal: Zink Rich Epoxy.
Note! Final coat ing of pipes must be done before instal lat ion
onboard.
Cleaning
After sandblasting and priming pipes must be cleaned inside.Remove all blank flanges before cleaning.If required, pipe to be honed inside by grinding stone.
Cleaning medium: Fresh water with corrosion inhibitor. Proposal: Dyno PK6050 or equal.
Recommended temperature: 80°C to obtain cleaning and fast drying.
OPTION: Pickling (carbon steel)
Note! Pickl ing medium c an be dangerous for people and environm ent. Use necessary
protect ion out f i t .
If carbon steel pipes are corroded on internal surface, pickling is necessary before priming.Use following procedure:
• Adjusting spool pieces must be minimum 2 - 3 m long in order to give sufficient alignment.
• During installation of adjusting spools, pipe ends must be moved (forced) 3 - 5 mm inlongitudinal direction in order to avoid damage of o-rings.
Fig. 59
3.2 Tightening torques for boltsIn order to obtain correct pretension, the threads, plus screw heads and contact surface of nutsagainst foundation, must be clean and lubricated before tightening.
The lubricating agent should be Molybdenum sulphide on screw connections of stainless steel
type (A4-80 or similar).
If pneumatic or electric hammer is used during assembling this should be used for light tightening, followed by tightening with a torque wrench.
If no torque is specified in service instruction or on drawing, use tightening torqueaccording to table:
This document is intended as a guide with some examples for possible cargo piping on
Chemical carriers, Oil product- and Crude oil tankers. Other design criteria may apply for FSOP’s and OBO’s.
The cargo piping arrangement will depend on type of vessel, cargoes to be carried and number of segregations, but should always be arranged for optimal efficiency regarding loading,discharging, draining and cleaning.
In addition to the different authorities and owner’s requirements, the following main items mustbe considered during design:
- Cargo piping material.- Segregation and a minimum risk of cargo contamination.
- Self-drainage or easy draining of piping and components.- Optimal arrangement and number of valves.- Valves. Type-Material-Operation (remote and/or local operation).- Number of flanges reduced to a minimum.- Easy access for operation and maintenance of equipment.- Service spools for dismantling and maintenance of equipment.- Maximum cargo pressure and equipment design pressure.- Mechanical forces from ship structure.- Anchor points and expansion loops.- Resilient pipe clamps close to the Framo cargo pumps.- Flexibility between Framo cargo pumps and cargo drop line.
From a stripping point of view, an arrangement with the manifolds (crossovers) below cargodeck lines, and with the deck lines sloping against the manifolds is preferred. From a loadingpoint of view, an arrangement with the manifolds above cargo deck lines is preferred.Plus- and minus for the different arrangements are given in page 6, and regardless of manifoldlocation, arrangements should be made to reduce or avoid the drawback of the selecteddesign.
Cargo can be loaded through the Framo submerged cargo pump, but the loadingcapacity/pressure is limited by an anti-rotation brake in the pump, (preventing the impeller fromrotating during loading).Separate cargo drop lines should always be installed to obtain a satisfactory loading rate, and
also to make it possible to by-pass the cargo pump during loading.
For cargo circulation (cargo heating with deck heaters or circulation of cargoes with highcontent of sediments), the drop line outlet in tank should be as far away from the cargo pumpinlet as possible.If limited space on deck, drop lines may be routed inside the cargo tank.
Pressure transducers for remote reading of cargo pressure should preferably be installedbetween the cargo pump and the cargo valve, making it possible to read the cargo pressurewhen the cargo pump is running, even with closed cargo valve.
A typical chemical carrier has normally fully segregated cargo tanks, i.e. one pump, one cargoline and one manifold for each tank.
Cargo piping material is normally stainless steel.
Efficient stripping and cleaning of cargo pipes after discharge are normally given the highestpriority, and we therefore recommend that the cargo deck line is sloping toward the manifold asshown in fig.1. For different arrangements, see page 6.
Oil product and crude oil tankers usually have 2 - 6 segregations with two or more submergedcargo pumps connected to each cargo line and manifold.
Fig. 2 shows a typical arrangement with two pumps connected to one common cargo deck lineand manifold (crossover).
Cargo pipe material may be stainless steel or coated carbon steel.Maximum flow velocity should not exceed 6 m/s in stainless steel pipes, and 3,5 m/s in coatedpipes (or flow limits given by the coating supplier).
- Coated carbon steel pipe dimensions have to be increased compared with stainless steel toobtain the same loading and discharge rate due to the lower flow velocity limit. Limited spoollengths are recommended to ensure proper coating and satisfactory inspection.
- Stainless steel piping gives reduced dimensions, reduced number of flange connections,reduced weight, and reduced volume of cargo and washing water to be drained from the
piping system. Flushing with fresh water after eventual tank cleaning with seawater isrequired.
Due to the ship size and large cargo pipe- and manifold dimensions,it is most practical to install the cargo deck lines parallel to deck.
It is recommended to install a common drain line to improve the stripping and cleaningpossibilities for the cargo lines after discharge.
During the last years, efficient stripping of cargo tanks, pumps and its associated piping system
has been a very important part of the cargo handling operation.
General key words:- Minimum cargo left onboard after stripping.- Shortest possible stripping time.- Lowest possible Air/Inert gas consumption.- Easy cleaning.
When designing the cargo piping system, the key word is Self-Draining, both for piping andcomponents. Even small details may improve the drainage possibility.The piping should be self-drained without pockets and “dead pipe ends”.Typical examples are shown in fig.4.
Drain
Fig. 4
Separate drain lines may be used to compensate for non self-drained pipes, but this inducemore lines to be cleaned, and discharge time (time for emptying the cargo lines) will normally
Typical stripping arrangements for Framo cargo pumps are shown in fig. 9-10.
1. Cargo pipe purging connection. Suppliedseparately by Framo for installation by Yard.
2. Cargo valve (Yard supply).Butterfly or ball valve type, remotely and/or manually operated. If the valve is manuallyoperated, it should have gear to control theclosing time. See section 3, chapter 4.
3. Stripping valve (Yard supply).Ball valve type, manually operated. This valvemust be easy to operate and located close tothe purging connection item 1.
For the most common used dimensions of stainlesssteel cargo pipes, recommended distance betweeneach flexible clamp is given in the table fig. 14.
For more details regarding installation and max.loads, see section 17.
Fig. 14
Resilientpipe clamp
Cargo line
Drop line
Resilient mounted
M i n. 2 0
x O D
Nominal
diameter
(mm)
Recommended
distance
(m)
100 - 125 2,5 - 3,0
150 - 200 3,0 - 4,0
250 - 350 4,0 - 5,0
The Framo cargo pumps are resilientmounted to the deck trunk, and minimum 2of the pipe clamps close to the pump mustbe of resilient type to maintain the flexibilityand to avoid vibrations being transmitted tothe deck structure. (Fig. 12).
If the cargo drop line is connected close to thepump as shown in fig. 13 also the drop linemust be resilient clamped. The drop line mustbe routed to have sufficient flexibility to avoid
expansion forces being transmitted to thepump.
The drop line outlet in tank should be as far away from the pump’s suction inlet aspossible, especially for installations with cargodeck heaters where the pumps are used for circulation.
High pressure hydraulic pumps, motors and control valves have close tolerances and require clean
hydraulic oil to obtain reliability, good performance and long lifetime.
Contaminated oil will not provide satisfying lubrication and is a leading contributor to reduced
efficiency, excessive down time and increased maintenance costs.
There are three types of possible contamination in hydraulic systems:
- Solid particles Increased wear, reduced oil- and component life time, sticking valves,
unexpected system shut downs.
- Water Reduced lubrication, generating of metal particles to the
system, corrosion, reduced life time for oil and components.
- Air Pressure shocks and serious damage to hydraulic pumps, motors,
piping and other components, loss of oil and oil pollution.
The contamination may enter the system:
- During production and assembling of the system.
- During hydraulic oil filling. (New oil from supplier, refined and blended under “clean” conditions
is not clean).
- Together with the atmospheric air through air venting on the hydraulic tanks.
- By wear and tear generated within the system.
- During service.
To prevent contamination, it is important to maintain a high standard of cleanliness at all
times.
- Keep pipes and components clean and protected during the whole production- and assembling
period.
- The hydraulic oil must always be filtered by using the Framo hydraulic oil transfer unit when oil
is filled into the system from the storage tank.
- Oil filling must be done without mixing air into the oil during oil filling. It is very time-consuming
to get rid of air when it is mixed into the hydraulic oil.
- Hydraulic tanks must be vented indoor and if possible through air filters.- Wear and tear to be prevented by checking the hydraulic oil quality and cleanliness regularly,
and by replacing filter elements when necessary.
- Keep all parts clean during service and assembling. Refill with clean oil, vent and flush carefully
after assembling.
Cleanliness level:
The required cleanliness level is based upon ISO Solid Contaminant Code ISO 4406. The code
was revised during 1999 and are now referring to 3 sizes of particles, 4 - 6 - and 14 micron(c).
(Previous code referred to 5 - and 15 micron).
A typical result according to the revised code will be 18/16/12.Framo will only use the two last digits referring to 6- and 14 micron(c).
For pressure testing of the return lines, the hydraulic oil transfer unit can be used.
Oil must not be filled into the system before the Framo commissioning engineer has inspected and
accepted the cleanliness of the piping system and the associated system- and storage tanks.
If the hydraulic oil cooler and/or main filter box have been supplied separated from the HPU, (for closed systems only) the return line in-between must be checked very carefully before oil filling.
Initial oil filling must be carried out according to chapter 4 and in co-operation with the
Framo commissioning engineer.
It is recommended only to fill oil into the hydraulic pressure lines and start with pressure testing of
these lines. If leakages occur during the test, the oil may simply be transferred to the return side
before repair, by using the hydraulic transfer unit.
Before oil filling, check that:
- All HP service valves (ball valves) are in open position and blanked off in the open end.
- All ball valves on the snap-on coupling stations are in open position, ref. fig.1.
- The system back-up valve is closed in order to reduce the leakage over the valve to a minimum.
For pressures above 315 bar, a small leakage is normal.
- The heating and venting valve is closed. For pilot operated heating and venting valve, HP
service valve to be closed. For test pressures higher than 350 bar, HP service valve to be open
and blanked off in the open end.
After oil filling according to chapter 4, item 4.1, and proper air venting:
- Start the pressure testing pump and adjust the pressure in small steps up to approximately 70
bar. After the pressure is stabilised, hold this pressure while the complete piping system is
checked for leakage.
- Leakage control must be made by visual inspection and by monitoring irregular pressure drops.
Note that normal internal leakage in some hydraulic components might cause a certain pressure
drop during the inspection period.
- The visual inspection of the piping system should be carried out in two steps. First a quick
overview of the system to ensure that there is no major leakage, then every connection has to
be checked for leakage.
- Continue to raise the test pressure in steps up to approximately 150 bar, and check for leakage
as described above.
- Finally, the test pressure is to be adjusted in steps up to max. pressure according to theclassification society requirement or at least system pressure + 70 bar for the pressure line
(ref. page 4). Hold this pressure until the complete piping system is examined for leakage
(minimum 10 minutes or according to the classification society requirement).
When pressure testing of pressure lines is finished, continue to fill the return lines according to
item 4.1. Pressure test the return lines (ref. page 4).
When all preparations have been made according to item 4.2 and initial start-up of hydraulic power
packs are finished, follow the procedure given below. System pressure to be max. 70 bar.
Main lines
- Start one power pack and run at system pressure of max. 70 bar.
- Open the heating valve (Pilot operated valve can be opened by plugging the pilot connection).
- Run for approximately 5 minutes and take oil sample.
- Stop power pack.
- If cleanliness level is above 16/12, start circulation with jockey pump (for open systems) or
feed pump (for closed systems).
- When cleanliness level is 15/11 or better, start necessary number of power packs for flushing of
main return line. System pressure max. 70 bar. Manually operated heating valve can be kept
open, but pilot operated heating to be turned off and HP service valve to be closed. Open
service valves to necessary number of branch lines to obtain sufficient oil flow.
- Check cleanliness level regularly. If level increases above 16/12, stop flushing and start
circulation to reduce number of particles.- Fill in the Flushing report included in the Framo Commissioning Protocol.
- Flush until cleanliness level 15/11 or better.
- Check flow and temperature according to flushing diagram.
5 FLUSHING
Flushing is the last and final cleaning procedure in order to remove particles that has entered the
system during installation, and to bring the cleanliness of the system oil up to an acceptable level.
All Framo components are flushed prior to shipment and need no flushing if the blanking equipmentis in good condition and kept on until final installation. Use of the Framo hydraulic power unit for
flushing has proven to be the most efficient, time saving and practical procedure to avoid
unnecessary dismantling, oil spillage and possible entrance of contamination during assembling.
It is absolutely necessary that our procedure is followed very carefully if the Framo power
unit is used for flushing. Hydraulic pumps must not run with pressure below 50 bar.
Before starting the main hydraulic pumps for flushing, the hydraulic oil in the system tank must have
cleanliness level 15/11 or better.
An oil sampling procedure is included in the Framo Service Manual.
Note! Initial oil filling and start-up of the system has to be done by the Framo service engineer.
The oil flow must be turbulent in order to remove particles from the inner surface of the pipes and
transport them to the filter. Necessary flushing capacities based upon inside pipe diameters and oil
temperatures are given in the flushing diagram.
Oil flow for each power pack is given in Technical Data for the installation.
Recommended average oil temperature during flushing is 50°C.
The flushing time depends on system size, cleanliness and piping material. Stainless steel pipes
require normally less time for flushing than mild steel pipes.
The following figures may be used as a rough estimate:
6 OIL FILLING OF COMPONENTS, CIRCULATION AND VENTING
All by-passed components, cargo pumps etc. must be filled with oil and vented properly after
flushing to avoid air mixed into the system.
It is very important to get the air out of all components and hydraulic lines instead of having the
oil/air mixture back to hydraulic tank, hydraulic pumps etc.
Note! Oil filling has to be done slowly to let the air escape through the venting connections.
Air in the system is indicated by:
- Back flow to the hydraulic tank during stand still
- Great difference between tank level at low and high system pressure
- Foaming
- Discolorated oil
Please note that Framo is not responsible for damages caused by air in the hydraulic oil, or if the
system has been started without Framo commissioning engineer’s approval.
Branch lines
- Close the heating valve.
- Start necessary number of power packs for the arranged number of branch lines to be flushed
simultaneously.
- Open ball valve to the branch lines and follow the same procedure as for the main lines.- Continue until all branch lines are flushed to cleanliness level 15/11 or better.
Main lines, 2 nd sequence
- Start necessary numbers of power packs for flushing of main return line.
- Open the heating valve and ball valve to necessary number of branch lines to obtain sufficient oil
flow.
- Flush until cleanliness level 15/11 or better.
Pilot pipes and pipes with inside diameter less than 25 mmFor these pipes turbulent flow is not obtainable due to the high pressure drop. It is therefore required
that the pipes are purged with clean nitrogen.
Other methods like “Pigging” (special plugs blown through the pipe by using a special tool) may be
used, but the results depends very much upon pipe material, quality, welding and pipe lengths.
Please contact Frank Mohn Services AS if such methods are considered to be used.
Branch pipes for dry mounted pumps and thruster motors