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No. 1000-0134-4Rev. A: 01Jul04Framo

Submerged Ballast Pumps

Operation manual

SB200SB300

SB400

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Framo Submerged Ballast Pumps

OPERATION MANUAL

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

1000-0134-4Sept-20002 of 1301Jul04/AGAa

CONTENTS

1 GENERAL DESCRIPTION................................ ................................ ............................. 22 OPERATING INFORMATION................................ ......................................................... 5

2.1 Ballasting / deballasting................................................................................ 52.2 Cofferdam control......................................................................................... 8

3 MAINTENANCE INFORMATION................................ ................................ .................. 104

TROUBLE SHOOTING ................................ ................................................................ 11

1 GENERAL DESCRIPTION

The Framo hydraulically driven submerged ballast pump consists of five main parts:- Pump casing/ air separator- Pump head

- Pipe stack- Top plate/Control valves- Evacuating system

Figures in this procedure are made general for all types of submerged ballast pumps. For furtherinformation, see drawings for the actual ballast pump.

Pump casing / Air Separator

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OPERATION MANUAL

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

1000-0134-4Sept-20003 of 1301Jul04/AGAa

Cofferdam connection

Header tank

HP

HP service valve

Non return valve

Compr. air

Evacuating controlsystem cable

Pilot line

LP Thermal expansion

Evacuating control unit

Filter/water trap(Yard supply)

Local control valve

Manometer

Bellow

Radial support

Resilienttop plate connection

Top plate

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Framo Submerged Ballast Pumps

OPERATION MANUAL

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

1000-0134-4Sept-20004 of 1301Jul04/AGAa

Ejector

Filter/water trap

Compr. air

PLC

Evacuatingcontrol unit300

225

150

75

0BAR ON

PRIMING

WBP

Illuminated lamp

Evacuating system

The air separator is integrated in thepump casing. The pump casing isequipped with a level switch forautomatic start and stop of theevacuating system.When there is air in the pump casingthe level switch will be in the low levelposition. The ejector will start

evacuating the pump casing and suctionpiping (priming on).When the water level again reach thehigh level position, the ejector will stop.

Illuminated lamp on the pump controlpanel indicates that the evacuatingsystem is in operation.

Note!

The evacuating system is only activatedwhen pump control is switched on.

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OPERATION MANUAL

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

1000-0134-4Sept-20005 of 1301Jul04/AGAa

Suction Discharge

Bypass

WBP

Hydr. motorValve, open =

Valve, closed =

Fig. 4 Water gravitating through the ballast piping system.

2 OPERATING INFORMATION

To get maximum lifetime of the pumps, operatethe pumps within the operation range (ref. fig. 8).

When starting ballasting, the ballast water willnormally gravitate through the ballast pipingsystem.Keep suction valve and discharge valve closedand open by-pass valve, to avoid gravitation

through the ballast pump (ref. fig.4).

Note!

The ballast water must not gravitate throughthe pump, as this may damage the hydraulicmotor.

2.1 Ballasting / deballasting

As the flow caused by gravitation decreases, the pump has to be started to increase the capacity.

- Check that the hydraulic system is started and enough hydraulic power is available.

- Check that pressurized air for evacuating system is available.

Note!HP service valve should always be open except when carrying out service work on the pump.

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OPERATION MANUAL

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

1000-0134-4Sept-20006 of 1301Jul04/AGAa

Fig. 7

Pumping

The ballast pump is designedto operate with dischargehead between 20 and 30 mlc(design head).

When running pump at lowdischarge head and high

motor pressure, the capacitywill be higher than normal.This may lead to heavyvibrations and damage tothe pump.There are two ways to bringthe pump back to theoperation range:

a) Reduce speed / hydraulicmotor pressure.

b) Throttle the dischargevalve.

Limit of operation

Pressure loss

discharge system

Pressure loss,throttle discharge valve

ea

75%

50%

100%motorpressure

a

b

Capacity Q

OPERATION

RANGE

Fig. 8

Note!Performance diagram for the actual pump gives the operation range

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OPERATION MANUAL

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

1000-0134-4Sept-20007 of 1301Jul04/AGAa

Stopping the pump

When the ballast tank is empty, the pumpwill lose suction. The evacuating system

will be operating continuously, indicated

by the priming lamp on the control panel.

Close the discharge valve, and stop thepump. Close the suction valve.

Note!

Do not run the pump unnecessary whenthe pump lose suction.

Air

300

225

150

75

0BAR ON

PRIMING

WBP

Reduced hydr.motor pressure

Stop

Fig. 10

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OPERATION MANUAL

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

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2.2 Cofferdam control

The pump cofferdam is essential for segregation of the pump hydraulic section from the ballast andfor seal monitoring. Cofferdam control to be carried out at regular intervals for the purpose of:

- Cofferdam liquid between the seal faces due to static overpressure in the cofferdam.- Condition monitoring of the shaft seal system by surveillance of the liquid level in the header tank.

Cofferdam liquid

Ethylene glycol or propylene glycol* : 50-60 %

Use pure glycol without additives.Commercially available automotive anti-freeze shouldnever be used. Some of the additives in anti-freezetend to form deposits on seal parts and therebycausing failure on the seals.

Corrosion inhibitor: 0.9%(Rocor NB Liquid or equal) (initial dosing)

Other types of corrosion inhibitors for cooling watersystems can also be used. The corrosion inhibitormust be compatible with glycol. The mix ratio andthe use of the corrosion inhibitor must be accordingto the suppliers data sheets, as this can vary for thedifferent types available.

D i li d t 40 50%

Open

Max level

Fill

glycol water

Not Framo supply

Hose

Headertank

Service hole

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The cofferdam volume depends on pump type and pump length. The following formulas give approx.

volume (in litres) required to fill cofferdam to high level mark in header tank:

Pump type Pump head Pipe stack Header tank Total

SB200 2,5 L x 0,5 2,5 5 + (L x 0,5)

SB300 80 L x 3,5 12 92 + (L x 3,5)

SB400 95 L x 3,5 12 107 + (L x 3,5)

SB600 125 L x 3,5 12 137 + (L x 3,5)

L = Pump length in metres. (See Framo specification)

Monitoring of cofferdam level

We recommend regularly control of the cofferdamlevel.

The liquid level in the header tank varies withthe temperature of the ballast water,

hydraulic oil and ambient temperature.Fig.13 indicates normal level variations with atemperature change of 10C on thecofferdam liquid.

Because of level changes due to temperaturevariations, the level should always bemonitored at the same temperature, i.e. at

l ti t t

Max.

Min.

Drain off andlog volume

Normal level at normaloperating temperature

Refill andlog volume

Normallevel variations

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Draining of cofferdam

Draining of cofferdam shall be done byusing special draining tools from Framotoolbox:

Draining of pipe stack:

- Connect the drain tool to the cofferdamconnection on pump head.

- Unscrew drain plug.

Draining of pump head:- Install the drain tool for pump head.

- Connect air to the drain tool, see fig. 15.

Drain tool -pipe stack

Drain plug

Pipe stack

Pump headConnect a hosefrom drain tool toa recovery tank.

Fig. 14

AirDrain tool -pump head

Connect a hosefrom drain tool toa recovery tank.

Connect pressurizedair to pump head.

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OPERATION MANUAL

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4 TROUBLE SHOOTING

Symptom: Possible reason: Remedy: *)

Ballast pump operational

problem

(First it is necessary to

verify if the problem is in

the pump control system or

in the pump head itself).

General Ref. system service manual - Trouble shooting

section

The pump will not start a) Ballast pump remote

control system failure

b) Pump control valve

failure

c) Pump impeller stuck.

c1)Foreign objects stuck inpump or other

mechanical problem

a) Ref. instruction for Remote control system

b) Ref. Instruction for Pump control valve STC

c1)Pump head to be inspected.

Pump is vibrating heavily a) Control system problem

b) Rotating parts out of

balance.

a) Ref. instr. for Pump control system.

b) Impurities stuck in impeller or othermechanical problem.

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OPERATION MANUAL

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Symptom: Possible reason: Remedy: *)

Dropping level in headertank. (See also chapt. 2.2)

General

Note!Always pressure test pumpprior to and afterdismantling. This is requiredto locate possible leakage

and to confirm no leakageupon completion of repair.

a) Worn mechanical seawater seal

b) Leaking seal element inflange connection

c) Crack in piping

Pressure test pump cofferdam system at approx.3 bar.Check for leakage if required spray with soapywater to locate the leakage.

Note!

For inspection of pump head / shaft seal it is

required to lift pump out of pump casing prior topressure test.

a) Replace mechanical sea water seal.Also, carefully check sleeve for possibledamage-wear.

b) Check for loose bolts and for pitting corrosionin seal faces in case of corrosion repair is

required.Assemble using new seal element.

c) Contact a Framo Service Station

Raising level in header tank.(See also chapt. 2.2)

General Pressurize pump return side at approx 4 bar andcheck for and locate the leakage.

Note!

F i ti f h ft l it i i d

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No. 1000-0134-4

Page 13 of 13

LOG FORM FOR LIQUID FILLED COFFERDAM ON FRAMO SUBMERGED BALLAST PUMPS

VESSEL NAME: ____________________________________ TYPE OF LIQUID USED IN COFFERDAM: __________________________________

Header tank level to be measured in mm above low level mark on sight glass. 10 mm on sight glass is equivalent to:

For SB200: 0,12 litres volume. For SB300/400/600: 0,36 litres volume.

Pumplocation

Date andyear

Header

tank level(mm)

Ballast water

temperature(C)

Hydraulic oil

temperature(C)

Ambient

temperature(C)

Hours of operationsince last control

Comments (Action taken) Signature / Date