No.

1000-0134-4
Framo Rev. A: 01Jul04

Submerged Ballast Pumps

Operation manual

SB200
SB300
SB400
SB600
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 2 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

CONTENTS
1 GENERAL DESCRIPTION ................................ ................................ ............................. 2
2 OPERATING INFORMATION................................ ................................ ......................... 5
2.1 Ballasting / deballasting................................................................................ 5
2.2 Cofferdam control......................................................................................... 8
3 MAINTENANCE INFORMATION................................ ................................ .................. 10
4 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 further
information, see drawings for the actual ballast pump.

Pump casing / Air Separator

The pump casing is bolted to a foundation. Air entering the pump through the suction line will be
separated in the air separator and removed by the evacuating system.

Pump head
The pump head includes the hydraulic motor, impeller and sealing arrangement. A cofferdam
completely segregates the hydraulic oil from the ballast water. The cofferdam is filled with
water/glycol.

Pipe stack
The pipe stack consists of a hydraulic section and an arrangement with pipe and cable for the
evacuating system.
Supports on the pipe stack prevent horizontal movement and allow for vertical expansion.

Top plate/ Control valves

The pipe stack penetrates the top plate. A sealing arrangement between top plate and pipe stack
allows the pipe stack to expand. The pump control valve STC(Speed Torque Controller) and
evacuating control unit is located at the top plate.
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 3 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

Header tank
Evacuating control
system cable
Cofferdam connection
Pilot line

HP Thermal expansion
LP
Compr. air

Evacuating control unit

Non return valve

HP service valve
Manometer
Filter/water trap Top plate
(Yard supply) Resilient
top plate connection
Local control valve
Bellow

Radial support
Anodes Pump control valve
(STC)

Hydraulic pressure pipe

Intermediate
support Hydraulic return pipe
Cable

Ejector pipe
Pipe stack
Cofferdam pipe
Anodes
Suction line

Pump head
Anode
Level switch

Discharge
line
Pump casing/
Anode air separator

Fig. 1
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 4 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

Evacuating system
The air separator is integrated in the Illuminated lamp
pump casing. The pump casing is PLC
equipped with a level switch – for PRIMING
automatic start and stop of the WBP
Evacuating
evacuating system. 300 control unit
When there is air in the pump casing 225
Filter/
the level switch will be in the low level 150
water trap
position. The ejector will start 75 Compr. air
evacuating the pump casing and suction 0
piping (priming “on”). BAR ON

When the water level again reach the

high level position, the ejector will stop. Ejector

Illuminated lamp on the pump control

panel indicates that the evacuating
system is in operation.

Note!
The evacuating system is only activated
when pump control is switched “on”.

Suction line Level switch

Discharge
line

Fig. 2

Priming with 7 bar air supply pressure to ejector

The evacuating capacity for the air driven ejector is
-8
given in fig. 3.
0
60
-6 0 0/ 30 0
B4 2 00/
Vacuum (mwc)

SB
S

Volume 1 m3
-4
With a air supply pressure of 7 bar to the ejector,
the air consumption will be;
-2
For SB200 and SB300 pumps: 1.1 Nm3/min (18 Nl/sec)
For SB400 and SB600 pumps: 2.9 Nm3/min (49 Nl/sec)
3 3 20 40 60 80 100 120 140
(Nm = normal m ) Time (seconds)

Fig. 3 Curve indicating vacuum in a 1 m 3 volume

(suction line) versus priming time.
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 5 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

2 OPERATING INFORMATION
To get maximum lifetime of the pumps, operate Valve, open =
Hydr. motor
the pumps within the operation range (ref. fig. 8).
Valve, closed =

When starting ballasting, the ballast water will

normally gravitate through the ballast piping Suction Discharge
system. WBP

Keep suction valve and discharge valve closed

and open by-pass valve, to avoid gravitation
through the ballast pump (ref. fig.4).
Bypass
Note!
The ballast water must not gravitate through Fig. 4 Water gravitating through the ballast piping system.
the pump, as this may damage the hydraulic
motor.

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.

Starting of pump Hydr. motor

PRIMING
Open ballast pump suction valve. WBP
Start the pump slowly, and let it run 300

with hydraulic motor pressure 50 bar Suction Discharge 225

WBP
for approx. 1 minute. 150

75

0
BAR ON

Bypass Start

Fig. 5
Close bypass valve, open discharge
Hydr. motor
valve and increase hydraulic motor
PRIMING
pressure until required capacity is
WBP
achieved. 300
Suction Discharge
WBP 225

Note! 150

Avoid running pumps against closed 75

discharge valve for a longer period. 0
BAR ON

Bypass

Fig. 6
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 6 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

Pumping
The ballast pump is designed
to operate with discharge
head between 20 and 30 mlc
(design head).

When running pump at low

discharge head and high
motor pressure, the capacity
will be higher than normal. Fig. 7
This may lead to heavy
vibrations and damage to Limit of operation
100% m
Head H

the pump. otor p

ress
There are two ways to bring ure Pressure loss,
the pump back to the 75% throttle discharge valve
operation range: Pressure loss
50% OPERATION b discharge system
RANGE
a) Reduce speed / hydraulic
motor pressure. a
b) Throttle the discharge
valve. Capacity Q

Fig. 8
Note! Performance diagram for the actual pump gives the operation range

End of deballasting
With low water level in the ballast tank the pump capacity must be reduced to avoid loss of suction.
An gradually increasing amount of air will enter the pump suction line via the vortex forming at the
suction bell mouth. Air will accumulate in the pump casing (air separator) and the evacuating system
will eventually be activated – priming light in control panel switched on.
The pump capacity must be reduced to match the water inflow to the suction bell mouth area (the
inflow is depending of the tank layout, opening in stiffeners etc.). This is most critical when emptying
a ballast tank furthest away from the pump, especially when pumping from ballast tanks located aft of
the pump when the ship is in aft trim condition.
Reduce hydr. motor pressure
For some systems the hydraulic motor when the priming light turns on.
pressure will automatically be reduced to PRIMING
balance the capacity of pump against WBP

supply to the suction line. 300

225

150

75

0
BAR ON

Vortex

Suction bell mouth Stiffeners

Fig. 9 End of deballasting (ship in aft trim condition)

 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 7 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

Stopping the pump

When the ballast tank is empty, the pump
Reduced hydr.
will lose suction. The evacuating system motor pressure
will be operating continuously, indicated
PRIMING
by the priming lamp on the control panel. WBP
300

Close the discharge valve, and stop the 225

150
pump. Close the suction valve.
75

0
Note! BAR ON

Do not run the pump unnecessary when Stop

the pump lose suction.

Air

Fig. 10

Operation of pump from local control valve

The ballast pump can be operated from the local
PRIMING Handle in Local control
control valve at the STC valve.
WBP maximum valve, OPEN
300
position
Open local control valve by turning counter-clockwise. 225

150

Set the remote control handle in the maximum position. 75

0
BAR ON

Start the pump by closing the local control valve by

turning clockwise. Run the pump as described for Fig. 11
remote controlled operation.
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 8 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

2.2 Cofferdam control

The pump cofferdam is essential for segregation of the pump hydraulic section from the ballast – and
for 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.
Not Framo supply
Cofferdam liquid Open

Ethylene glycol or propylene glycol* : 50-60 % Fill

Max level glycol water
Use pure glycol without additives. Header
Commercially available automotive anti-freeze should tank
never be used. Some of the additives in anti-freeze
tend to form deposits on seal parts and thereby
causing failure on the seals.
Service hole

Corrosion inhibitor: 0.9%

(Rocor NB Liquid or equal) (initial dosing)

Other types of corrosion inhibitors for cooling water

systems can also be used. The corrosion inhibitor
must be compatible with glycol. The mix ratio and
the use of the corrosion inhibitor must be according
to the suppliers data sheets, as this can vary for the
different types available.
Hose
Demineralised water: 40-50%

Freezing point ~ - 35°C v. 50% glycol

Freezing point < - 40°C v. 60% glycol Drain tool

Volumetric
expansion : 0 - 60°C ~ 63.5 x 10-5 litre/litre°C

Drain
Filling after service: plug

- Install the drain tool and unscrew the drain plug.

Connect a hose to the drain tool. It is then Connection
possible to fill the cofferdam through the hose to cofferdam
while venting at the header tank.
Fill the cofferdam until liquid level stabilises at
max. level mark on the sight glass.

- Water/glycol to be filled after filling of hydraulic oil.

Fig. 12
Topping up cofferdam:
If required, top up the header tank until liquid level is at “normal” level (see fig. 13).

* Other names for ethyleneglycol: monoethyleneglycol, 1.2 ethanediol, ethanediol.

Other names for propyleneglycol: monopropyleneglycol, 1.2 propanediol, propanediol
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 9 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

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 cofferdam
level.
Drain off and
log volume
The liquid level in the header tank varies with Max.
the temperature of the ballast water,
hydraulic oil and ambient temperature. Normal level at normal Normal
Fig.13 indicates normal level variations with a operating temperature level variations
temperature change of ±10°C on the
cofferdam liquid. Refill and
Min.
log volume
Because of level changes due to temperature
variations, the level should always be
monitored at the same temperature, i.e. at
normal operating temperature.

Consumption of cofferdam liquid can be up to

about 2 litres/100 running hours. Fig. 13

When pump is running the normal leakage rate for mechanical seals can be up to 2-5 ml per hour,
but leakage up to 20 ml per hour is acceptable.

Enclosed (page 13) is a log form that can be used as a help to monitor the condition of the seal
system.

Evaluation of the changes in liquid level in header tank

A sudden decreasing level in header tank can indicate that it is air in the cofferdam system,
which most likely occurs in the first period after initial water/glycol filling or complete refill after
service.

Abnormal decreasing level over a period of time indicate a worn out mechanical sea water seal,
and overhaul might be necessary.

A sudden increasing level in header tank indicate a worn out mechanical oil seal, and
overhauling may be necessary (ref. chapter 4, Trouble shooting).

IN CASE OF ANY DOUBT, please contact a Framo Service Station for assistance.

Note! Always pressure test the cofferdam with 3 bar to verify the leakage prior to any
dismantling of the ballast pump.
 No. 1000-0134-4
Framo Submerged Ballast Pumps Date/sign.: Sept-2000
Page: 10 of 13
OPERATION MANUAL Rev. A: 01Jul04/AGAa

Draining of cofferdam
Draining of cofferdam shall be done by Drain tool -
using special draining tools from Framo pipe stack
toolbox: Drain plug

Draining of pipe stack: Pipe stack

- Connect the drain tool to the cofferdam
connection on pump head.
- Unscrew drain plug.
Connect a hose
Pump head from drain tool to
a recovery tank.

Fig. 14

Draining of pump head:

- Install the drain tool for pump head. Connect a hose
from drain tool to Connect pressurized
- Connect air to the drain tool, see fig. 15. a recovery tank. air to pump head.

Drain tool - Air

pump head

Fig. 15

3 MAINTENANCE INFORMATION
Prior to entering a ballast tank for doing service it is essential to become familiar with the ship's
safety rules and requirements regarding cargo-handling equipment. Do not enter a ballast tank
before the tank is confirmed gas free.

Before doing service on pump, always close and lock the HP service valve.

Close the ballast valves (suction line and discharge line). Ensure that the valves are in closed
position until the work/service is finished (info sign to be placed on the control panel/computer).

Before starting to dismantle impeller, wear rings etc.,make sure that pipe stack/ pump head is
secured properly in order not to drop down when work is in progress.

Note! To prevent contamination and hazardous situations it is important to avoid oil spill during
maintenance and repair work. Drain in accordance with procedures ( “Instruction for
maintenance and repair” for actual pump).

The operator should be confident that all flange connections are in satisfactory condition so as to
prevent hydraulic oil and cargo spills.

After any work has been carried out in the ballast tank, always check that the tank is free for foreign
objects.

Framo Submerged Ballast Pumps
OPERATION MANUAL
4 TROUBLE SHOOTING
Symptom:
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).
The pump will not start
Pump is vibrating heavily
Too low pumping capacity
*) Ref. instruction for maintenance and repair for actual pump.
Possible reason:
General
a) Ballast pump remote
control system failure
b) Pump control valve
failure
c) Pump impeller stuck.
c1)Foreign objects stuck in
pump or other
mechanical problem
a) Control system problem
b) Rotating parts out of
balance.
a) Control system problem
b) Worn wear rings.
Impurities stuck in
impeller, or other
mechanical problem
No. 1000-0134-4
Date/sign.: Sept-2000
Page: 11 of 13
Rev. A: 01Jul04/AGAa
Remedy: *)
Ref. system service manual - Trouble shooting
section
a) Ref. instruction for Remote control system
b) Ref. Instruction for Pump control valve – STC
c1)Pump head to be inspected.
a) Ref. instr. for Pump control system.
b) Impurities stuck in impeller or other
mechanical problem.
a) Ref. instr. for Pump control system and instr.
for Pump control valve.
(If required interchange pump control valve
as described in instr. 1000-0109-4)
b) Pump head to be inspected

Framo Submerged Ballast Pumps
OPERATION MANUAL
Symptom: Possible reason:
Dropping level in header General
tank. (See also chapt. 2.2)
Note!
Always pressure test pump
prior to and after
dismantling. This is required
to locate possible leakage
and to confirm no leakage
upon completion of repair.
a) Worn mechanical sea
water seal
b) Leaking seal element in
flange connection
c) Crack in piping
Raising level in header tank. General
(See also chapt. 2.2)
a) Leaking mechanical oil
seal
b) Leaking seal element in
flange connection(s).
c) Crack in piping
The ejector do not start Low level signal from ballast
tank level switch not
detected.
The ejector do not stop Low level signal from ballast
tank level switch not
detected.
*) Ref. instruction for maintenance and repair for actual pump.
Note!
Evaluate if changed parts as sleeves, mechanical seals etc. are possible to recondition.
Send these parts to Framo Service Station and ask for an evaluation.
Reference to associated instructions
1000-0109-4: Interchange of pump control valve
1375-0027-4: Service manual for Speed Torque Controller (STC)
No. 1000-0134-4
Date/sign.: Sept-2000
Page: 12 of 13
Rev. A: 01Jul04/AGAa
Remedy: *)
Pressure test pump cofferdam system at approx.
3 bar.
Check for leakage – if required spray with soapy
water to locate the leakage.
Note!
For inspection of pump head / shaft seal it is
required to lift pump out of pump casing prior to
pressure test.
a) Replace mechanical sea water seal.
Also, carefully check sleeve for possible
damage-wear.
b) Check for loose bolts and for pitting corrosion
in seal faces – in case of corrosion repair is
required.
Assemble using new seal element.
c) Contact a Framo Service Station
Pressurize pump return side at approx 4 bar and
check for and locate the leakage.
Note!
For inspection of shaft seal area it is required
to lift pump out of pump casing, see instruction
for maintenance and repair.
a) Replace mechanical oil seal (replaced seal to
be reconditioned if feasible)
b) Check sealing surface for possible damage –
repair if damaged.
Assemble using new seal element.
c) Contact Framo Service Station
Stop the pump and check level switch and
related wiring to control panel.
Stop the pump and check level switch and
related wiring to control panel.
 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.

Header Ballast water Hydraulic oil Ambient

Pump Date and Hours of operation
tank level temperature temperature temperature Comments (Action taken) Signature / Date
location year since last control
(mm) (°C) (°C) (°C)