Ajit Vadakayil - Deepwell Pumps On Chemical Tankers - Capt Ajit Vadakayil

8/15/2016
AjitVadakayil:DEEPWELLPUMPSONCHEMICALTANKERSCAPTAJITVADAKAYIL
1
Lainnya BlogBerikut
Ajit Vadakayil
Su n d a y, De c e m b e r 1 2 , 2 0 1 0
DEEPWELL PUMPS ON CHEMICAL TANKERS CAPT AJIT VADAKAYIL
FRAMOPUMPANDPUMPINGOPERATIONS
Follow ers
Pengikut(3695)Berikutnya
Ikuti
About Me
Blog Arc hive
2016(108)
2015(76)
2014(73)
Deepwell pumps have done away with the suction pipeline where 90% of pumping problems
lie.
It has almost eliminated cavitation for free flowing liquids. Fluids are broadly classified as
Newtonian and non Newtonian depending on their obedience to the laws of classical
mechanics. Newtonian fluid/ rate of flow is proportional to the force applied.. Some will not
flowtilltheforceexertedisgreaterthantheyieldpoint.
DeepwellpumpsonourchemicaltankersaremainlyNorwegianFramoandJapaneseDeepwell
typesonafew.
JD ( lets call Japanese deepwell pumps JD for convenience ) pumps have huge
disadvantagesoverFramopumps.
1) The JD SS impeller is locked by a SS washer and nut which can work loose. In Framo a
nylonboltandwasher(disposable)isusedwhichprovidesbetterfrictioncoefficient.Aloose
impellercancauseexplosion.
http://ajitvadakayil.blogspot.co.id/2010/12/deepwellpumpsonchemicaltankerscapt.html
Capt.AjitVadakayil
2013(120)
beenincommandof
chemicaltankers(mainly)
formorethan6640days
spreadover30years(a
worldrecord!).My
Chemicalpostsarefreefor
ALLsailorsonthisplanet.
Anyprofitmakingpersonor
institutionpublishing
extracts,mustclearlywrite"
reproducedfrom
ajitvadakayil.blogspot.com"
,itpaystoremember,that
thechemicalcontentsare
patented.Thisblogsitewill
transformyourmind.You
yourself,aretheteacher,the
pupil,themessiah,the
seeker,thetravellerandthe
destination.Itisno
measureofhealthtobewell
adjustedtothisprofoundly
sicksociety.Iamfrom
INDIA,themotherofall
civilizations.Iwillbere
writingworldhistory,and
thiswillsurelynotgratifythe
evilhijackersofhuman
history.Awakenyourinner
voice.Experiencethejoy
ofyourownbeing.Your
ownconscienceisthebest
interpreter.Inatimeof
universaldeceit,tellingthe
truthisarevolutionaryact.
Thenakedtruthcannever
behatespeechor
defamation.Thisblogsite
doesnotsacrificetruthon
thealtarofpolitical
2012(173)
2011(316)
2010(165)
December(76)
WINSTON
CHURCHILL,
THE
UNKNOWN
SIDECAPT
AJIT...
SUDDEN,BY
OLIVER
STRANGE
CAPTAJIT
VADAKAY...
CHARLES
DARWINAND
HISAPPLE
CAPTAJIT
VADAKAY...
STATIC
ELECTRICITY
ONCHEMICAL
TANKERS
CAPTAJ...
EPOXYZINC
TANKS
PRACTICAL
ASPECTSON
CHEMICAL
TAN...
CLAYSLURRIES
ONCHEMICAL
TANKERS
CAPTAJITVA...
ANDTHE
WINNERIS
CAPTAJIT
VADAKAYIL
1/24
8/15/2016
2) The JD cargo seal is mechanical while for Framo it is a double lip seal teflon ring.
Mechanical seal cannot run dry as it will over heat and get damaged. This overheat is not
conducivetosafety.
3) JD pumps do not have a jockey pump which in a Framo system runs round the clock 365
daysayeartopreventcargoingressintohydraulicsystem.Herethecofferdamispressurised
byair/nitrogenfromafixedpipelineconnectiontopreventcargoingressintocofferdam.This
serves to cool the mechanical seal too. While on a Framo air blow to purge the cofferdam is
from an air flexible. Fixed air connections can cause high density free flowing cargoes like
Sulphuric acid to ingress the compressed air lines. Jockey pump provides continious air
venting, filtration of hyd oil and prevents moisture ingress. If the JD system does not have a
feed/ jockey pump, it is important to purge air from the highest point it could be on top of
thecrane.
4)Framousesrotatingimpellerasanonreturnvalvewhilestrippingstack,whileonJapanese
modelstherecouldbeanonreturnflapjustontopoftheimpellerwhichisahugedisadvantage
whenyouwanttoclearthesuctionpitoffsedimentsbyblowingairorsteam.
5)InJDthehydraulicinletvalveisopenedonlywhenthecargotankpumpisrun.OnFramo
theballvalveforhighpressureinletisclosedonlywhileservicingthepump.
6) Latest Framo pumps have stripping cones to feed impeller which reduced the rob to less
thanalitre.
HereweshalltalkaboutatypicalFramosystemwhichisfittedonmajorityofEMSships:
Rememberacargopumpwithablockedcofferdammustneverbeused.Cofferdamseparates
thehydraulicsystemfomthecargosystem.Thecargosealsconsistsofuppersinglecofferdam
lipseal and lower double cargo lip seal mounted on ceramic sleeve. Both must be changed
togetherasperFramorecommendation.Thewearringsneednotbechangedunlessthereisa
significantreductioninpumpcapacityorsweepingpartygetsaffectedbycargospray.
For2powerpacksyouwillhavehavetostartthesecondgenerator.
Mainhydsystempressuremustbe15barsabovethehighestconsumer.
The number of pumps you can use at full speed is governed by the hyd oil consumption of
eachasperlistpostedinCCR.
Removeairfromhydsystemalwaysatthehighestpoint.
Powerpackhasventinterlock.
AlwaysstarttheFramopumpwiththedischgvalveshut.Whenstartingdischgopenthecargo
dischg valve only when the dischg pressure is above manifold common pressure ot you will
haveabackflow.
Whenthereishighbackpressureitisbettertodointernalstripping.Ifthereisnopossibilityto
dothisensurethatthedischgfromtankisgoingashoreandnottoanothertank.Forthisboth
thetanksdischgpressuremustbehigherthanthemanifoldpressure.
Itisbettertorunasmanypumpsinparallelaspracticableatareducedhydpressurethanjusta
few pumps at max hyd pressure. 2 pumps at 100 % capacity is same as 4 pumps at 50 %
capacity. The advantage is reduced hyd system pressure on old ships where the hyd lines are
corroded.
When starting screw booster pump ( molasses/ clay slurry ) without bypass ensure that the
deliverysidevalvesinclshoretankisopen,oryouwillspringaleak.
Emptytankatreducedpressure.Ifrequiredthrottledeliveryvalveondeck.Thisisnotreqdif
youhaveasuctionwell.
correctness.Youshall
knowthetruthandthetruth
shallsetyoufree.Dont
everunderestimatethevalue
ofthisblogsite.
Viewmycompleteprofile
LEADERSHIPAT
SEACAPT
AJIT
VADAKAYIL
COLOURON
CHEMICAL
TANKERS
CAPTAJIT
VADAKAYIL...
SPIRITANDCHE
GUEVARA
CAPTAJIT
VADAKAYIL
MANAGINGTIME
CAPTAJIT
VADAKAYIL
CHANGE
MANAGEMENT
CAPTAJIT
VADAKAYIL
HEXENE1ON
CHEMICAL
TANKERS
CAPTAJIT
VADAKAY...
SUPERTYPHOON
BART,THE
PERFECT
STORM
AJI...
BRITISH
MUSEUM,
HOUSEOF
STOLEN
TREASURES
ANDVAN...
PUMPING
SYSTEMSON
CHEMICAL
TANKERS
CAPTAJITV...
NOTICEOF
READINESSON
CHEMICAL
TANKERS
CAPTAJ...
DELTABRAIN
WAVES
AJIT
VADAKAYIL
SAILORSDOCRY
!CAPTAJIT
VADAKAYIL
THECAPTAIN
SLEEPS
TONIGHT
CAPTAJIT
VADAKAYIL...
THESCOURGE
OF
COMMUNALIS
MCAPTAJIT
VADAKAYIL...
BILLOFLADING
ONCHEMICAL
TANKERS
CAPTAJITV...
2/24
8/15/2016
Whenyouhavesuctionwellandlessbackpressurelikewhenstrippingsaltwater,assoonas
thetankisemptyclosecargovalvefastandstoppump.
Pumpspeeddependsuponbackpressure,viscosityanddensityofcargo.
WhenusingtheCCRjoysticktodischargemakesurethelocalcontrolSTCisfullyopen(fully
clockwise)
StrippingcannotbedonefromCCRespeciallyifthereisnosuctionwell.asitisimportantto
heartheboomingsoundwhenthetankgetsempty.
Strippingprocedure:
KeepsomebodyinCCR.Reducepumphydpressureto100barswhenpumplosessuctionas
indicatedbypressurefluctuation.
Go on deck and shut STC / FCV ( turn anticlockwise to shut) till hyd pressure drop by 10
bars. You must see the movement of needle. The idea is to avoid surge while transfer of
control.
Nowthecontrolisondeck.
TellCCRtofullyopentheremoteflowcontroljoystickleverbypushingitmaxupward.
Shutcargodeliveryvalveonceyouheartheairrushinginsidestack.
Connectcompressedairtostackandstripstack.
(At7kgpressure.Thereisnoneedtoopenandshutairastheliquidalwaysremainsatbottom
andairontopinstackasperthelawsofPhysics.Ensureairisopenedslowlytoavoidliquid
hammer especially with dense liquids like Sulphuric acid. This can cause the ptfe gasket to
creepandsprayacidonthestripper.Attimeofstrippingstack50barshydpressureisenough.
NeverrunFramopumplessthan50bars.Itisnotpossibleonthelatermodels.)
Oncestackisemptyyoucanhearthepumpracing.ShuttheSTC/FCV(turnanticlockwise)
toreducepressure.
Closecargodischgvalvefirst.
ThenputoffpumpfromCCRbypullingdowntheremoteflowcontrolleverfully.
Ifthetankisaftofmanifoldandthereisgoodsterntrimthensuperstripthetopline.Youmust
have have Polypropelene super strip hoses. Basically you are transferring liquid from inboard
endofshutmanifoldvalvetooutboardend.
Purge the cofferdam. Neglecting purging with high mp heated cargoes will result in a blocked
cofferdam. Before purging cofferdam check that the relief valve ( lifts at 3 bars ). First drain
the compressed air line from the lowest point. Or you get wrong measurement in container.
Purgeseveraltimes,notonce.
Purgingthecofferdammustbedoneasaritual
1)Immediatelyafterloading
2)12hrsafterloading
3)Ifleakingpurgeeveryday,otherwiseevery7days
4)Ifdoingrecirclikeclay,thenbeforeafterstart/stop.
5)Before/afterdischg.
FilluptheFramopurginglog,chiefofficermustensure.
Noaircomingoutmeansablockedcofferdam.Usesteam/solventtocleartheblock.
DIRTYSECRETS
OFBOSTON
TEAPARTY
CAPTAJITVA...
TALLOILON
CHEMICAL
TANKERS
CAPTAJIT
VADAKAYI...
LAWSOF
ENERGY
WAVESCAPT
AJIT
VADAKAYIL
ENERGY
CONSERVATIO
NON
CHEMICAL
TANKERS
CAPTA...
RESPIRATORY
FILTERSON
CHEMICAL
TANKERS
CAPTA...
TOXICCARGO
SPILL,
CHEMICAL
TANKERS
CAPTAJIT...
PROPYLENE
OXIDEON
CHEMICAL
TANKERS
CAPTAJITV...
INTHETHETA
STATE
AJIT
VADAKAYIL
CARGOCLAIMS
ANDLOSSES
ONCHEMICAL
TANKERS
CA...
AYURVEDIC
MASSAGEAND
QUANTUM
MEDICINE
TURMERIC...
LASTCRUSADER
OFTHELAST
INQUISITION
CAPTAJI...
FATIGUEON
CHEMICAL
TANKERS
CAPTAJIT
VADAKAYIL...
THUMBRULES
FOR
STRATEGIES
CAPTAJIT
VADAKAYIL...
VAPORRETURN
SYSTEM
CHEMICAL
TANKERS
CAPTAJIT...
3/24
8/15/2016
Tofillupcofferdamwithwater(whiledischgMolassesetc)usethesamesystemofpurging
cofferdaminreverse.Thismeansthattheairpurgingconnectionmustbeopenedouttovent
airoutwhichisdisplacedbywater.Forcargoeslikeclayslurrythewatermustberecirculated
orthecargosealswillgetdamaged.
Fillingupcofferdam with ( to avoid cargo ingress and improve seal life , always ensure hyd
returnpressureconvertedtoheadishigher)
Phenol/causticrecirchotwater.
TDI/MDIandpolymerisingcargofillupwithDOP(VDis13.5)
CrystallisingcargolikeMolassesfillupwithFW
Phosphoricacid/recircwithFWtoremoveresidue
Clayslurry/Kaolinflushcofferdam3timesdaily.Dontusedeepwellpumptostriptank.
Flushing of cofferdam during dischg of viscous cargoes has cooling effect on friction heat
betweencargosleeveandceramicsleeve.
Hydoilleakageintocofferdamupto200mladayisnothingtoworryabout.
Forthisyouhavetostandthesampleforoiltoseparateoutfrommixture.
ForHydoilincofferdam,pressurisethehydreturnside.Changemechoilsealorshaftseal.
If cargo leaks into the cofferdam dont just change the seal. First find out where the leak is
from.Topressuretestcofferdamblankbyrubbergasketthereliefvalveandtestforpressure
dropat3kgandsoapwater.400mlofcargoincofferdamwhenpumpisrunningthefulldayis
ok.
It is better to superstrip the topline before stripping the pumpstack when you are dealing with
viscousLuboils,Molassesetc.Thiswayyouareabletostripagainstthelowestbackpressure.
For your info Molasses is NEVER loaded through framo pump if there is no filter at ships
manifoldthere might be the odd old shoe or cane piece coming along. High brix Molasses (
Columbianis93)isusuallypumpedoutbyFramoportablescrewpumpMP125,ofhead100
m.ThepumpcanbereversedtodisposeofffibresofMolassesinthescrews.
Duringtankwashensurethebottomisalwaysdry.Waterinmustbeequaltowaterout.Inthe
endallow10cmofwashwaterbuildupbystoppingthepump.Thenrunpumpfullspeedfor3
minutestoflushinternalparts.Atthistimeopenandshutstrippingvalvetoflushthestripping
line.
Neverallowsaltwatertoremaininpumpstack.AlwaysflushwithFW.
Every 6 months Framo pump wear test should be carried out. This can be done by running
FramowithdischgvalveshutasgoodspeedandFWasmedium.Wearringsgetwornoutby
runningapumpdry.Dryrunninghappensduringstrippingandtankcleaning.TheFramopumps
canberunagainstaclosedcargovalvewithoutanriskofeventualoverheatingasthewearring
losscomesbackintothetank.
The bearings in the Framo cargo pump is lubricated and cooled by hyd return oil and so the
pumpcanrundrywithoutanydamage.Thismeansthatthehydreturnoiltemperatureisalso
abearingmonitoringsystem.Analarmwillbeactivatedifthetempisgreaterthan60degC.If
temp exceeds 65 deg C all powerpacks are automatically unloaded except one. When temp
drops <60 deg C they will be automatically reloaded. System reset button must be activated
before any pump can be restarted. The temp is automatically maintained between 30 and 50
degCbycoolingwater.
When picking up anchor and for stations keep system pressure sufficiently high. Max main
Hydpressureallowedisaround240bars.Thereturntotankis4kg.Jointleaksonoldships
always happen while starting, due to air bubbles smashing in pressure line, and expansion in
returnline.
Cargoincofferdammeanscargoseal,ceramicsleeve,pumpheadsealleaks.
Ceramicsleevescanbepolished.WornsealscanbereconditionedbyFramoshoreservice.
UNIVERSAL
LAWS
AJIT
VADAKAYIL
CHEMICAL
TANKERS,
TANK
CLEANING
OPERATIONS
CAP...
PERSONAL
BRANDING,ME
INC.CAPT
AJIT
VADAKAYI...
FORTHENOT
TOOBRIGHT
CAPTAJIT
VADAKAYIL
DEEPWELL
PUMPSON
CHEMICAL
TANKERS
CAPTAJITV...
SECRETSOF
EGYPTIAN
PYRAMIDS
REVEALED
CAPTAJI...
JETTISONOF
CARGO,
CHEMICAL
TANKERS
CAPTAJITV...
CHEMICAL
TANKERS,
DISCHARGE
OPERATIONS
CAPT...
CALIBRATION
ONCHEMICAL
TANKERS
CAPTAJIT
VADA...
BURNEDOUT
VERSUS
STRESSEDOUT
CAPTAJIT
VADAK...
STAINLESS
STEELCARGO
TANKS
SUS316L,
CHEMICAL
TAN...
POTASSIUM
PERMANGANA
TEON
CHEMICAL
TANKERS
CAP...
CULTURAL
WISDOM
CAPTAJIT
VADAKAYIL
RASPUTINAND
HISWART
Oilincofferdammeansmechorlipshaftseal,pumpheadsealsleaks.
4/24
8/15/2016
Ifhydoil/cargoleakageistoomuchclosehydvalvesanduseportableFramo.
Cofferdamseperatescargosectionfromhydsection.
Cargosealisexposedonlytostaticheadfromcargo.
AvoiddryrunningofFramopumpsorsteamingstackformorethan10min.
Toreplaceawornshaftbearingthecompletepumpneedstobewithdawnbytheshorecrane.
Thefollowingpassageisforbettertechnicalunderstandingofswivelangle/swashplateandis
availableinthetechnicalmanuals
Framopowerpackloadsharingisbyammeterorswashplateangle.
FCV has been replaced by STC on new Framo systems. STC or speed torque control valve
prevent overspeed of pumps. STC regulated hyd pressure and limits the flow of hyd oil to
pump motors . The max outflow is adjusted by Framo manufacturer and the adj screw is
sealed. If the seal is broken the warrantly claims will not be honoured. The construction of a
hydmotorisexactlythesameasthehydpump.
Pilotpressurecontroller:
To keep a balance between oil delivery and consumption a PCV is needed. This valve is a
steplessremotecontrolfromCCR.WhensystempressurereachedthesetvalueofthePCV,
the valve will open for oil to the pump angle control cylinder. The swivel angle will now
balanceout.Iftheoilconsumptionfromthecargopumpisincreased,systempressurewilldrop
slightlyandoilflowthroughthePCVwilldrop.Theswivelanglewillnowincreaseuntilanew
balance is achieved between oil delivery and consumption. By means of this system , oil
deliverywillalwaysremainsameasoilconsumption.
Thecoarsefilteronthesuctionsideofthepowerpackpumpis100micronswhilethefinefilter
onthedeliverysideofpumpis10microns.
TheflowintothecargopumphydraulicmotorisregulatedbyFCV.Thecontrolsignalintothis
valvecanbeadjustedlocally(deck)orremotely(CCR)withthemotorrpmdependingupon
hyd delivery pressure. Varying hyd pressure varies motor rpm. In closed system the level of
hydpressureisfedbacktothecontrolsideofpump.Thissignaladjuststheswashplateofthe
pumpadjustingthedeliveredhydoilquantity.Thepilotpumpsuppliesthedesiredhydpressure
signaltotheswashplatecontrolandthussignalisadjustable.Thefeedpumpmaintainsaslight
positivepressureonthesuctionsideofthepumpandshouldonlydeliverfluidwhenthemain
systemhassomeleakageorthehydoilcontractsduetoloweringtemp.
KeepthespecialFramotoolslike
Antirotatingtoolforimpellerhub
Extractorsforimpeller/hub/sleeve/hydmotor
Assemblingcylinder
Mechsealassembler
Draintool
Drainpump
Jack
Liftingbolts
Mirror
Plasticstrips
Etcinasafeplaceandnotmixedupwithothertools
WhenloadingthroughtheFramopumpmustthemanufacturersratesbeNEVERbeexceeded.
When planning the loading rate the density of the cargo must be considered to avoid possible
irreparabledamagetothesubmergedpump.
Incaseacofferdamisblockednoairreturnedwhilepurginginformthechemicaloperator.
CAPTAJIT
VADAKAYIL
ANNEX1OIL
PRODUCTSON
STAINLESS
STEEL
CHEMICAL
TA...
KERALA,A
BRIEFHISTORY
OFPARADISE
ONEARTH
C...
ANOBELPRIZE
AND
KNIGHTHOOD
FORTAGORE
CAPTAJI...
PIGGINGON
CHEMICAL
TANKERS
CAPTAJIT
VADAKAYIL...
PERFECTSIX
PACKCAPT
AJIT
VADAKAYIL
MEDITATION
WITHOUT
TEARSCAPT
AJIT
VADAKAYIL
TOMBSTONE
EPITAPHS
CAPTAJIT
VADAKAYIL
PREDICTIVE
MAINTENANC
EON
CHEMICAL
TANKERS
CAP...
PORTUGUESE
INQUISITION
INGOA
ORDEREDBY
FRANCISX...
STYRENE
MONOMER,
CHEMICAL
TANKERS
CAPTAJITV...
HAPPINESS
FROMWITHIN
CAPTAJIT
VADAKAYIL
TEAMWORK,
TEAM
DYNAMICS
CAPTAJIT
VADAKAYIL
COREVALUES,
EXEMPLARY
CAPTAJIT
VADAKAYIL
POLYMERISATIO
NAND
INHIBITIONON
5/24
8/15/2016
NEVER use abrupt and sudden movements of the Framo joystick in the CCR. When starting
discharge, keep pump at slow speed until all checks have been completed, before increasing
pumpspeed.Whendischargingagainsthighbackpressuredointernalstripping.
Whentankcleaning,thecargopumpstrippingcapacityshouldbebalancedagainstthevolume
of washing water being introduced to the tank. NEVER OPERATE THE CARGO PUMP
DRY
SimplerulesforthecorrectoperationoftheFramoPumps
1Purgecofferdam,beforeduringandafteruse.
2Checkbackpressureinreturnfiltersandinoilcooler.
3Refilltheoiltankthroughthefilterbox.
4Drainoffanywaterorsedimentintheoiltank.
5Slowdownpumpwhentankcleaning.
PORTABLEFRAMOPUMP
CHEMICAL
TANKERS...
CERTIFICATEOF
FITNESSON
CHEMICAL
TANKERS
CAP...
ONTHETRAIL
OFTRUTH
CAPTAJIT
VADAKAYIL
ABBAREVIVAL
CAPTAJIT
VADAKAYIL
SULPHURICACID
ONCHEMICAL
TANKERS
CAPTAJITVA...
MOLASSESON
CHEMICAL
TANKERS
CAPTAJIT
VADAKAYI...
NARUTO
ECLIPSES
HARRY
POTTER
CAPTAJIT
VADAKAYI...
MENTORINGAT
SEACAPT
AJIT
VADAKAYIL
DNA,NASA,
ARSENICAND
PHOSPHORUS
CAPTAJIT
VA...
INTHEZONE
CAPTAJIT
VADAKAYIL
GUTFEELING
AND
INTUITION
CAPTAJIT
VADAKAYIL
If a vessel is fitted with individual deepwell pumps, then she will also be required to carry at
leastoneportablepump.
Thepumpsshouldbetestedatleast4timesayearandhydrauliccouplingsondeckshouldbe
identified,keptoperationalandcoveredwithdensotape.
The use of the portable pump occurs when a main tank pump fails and the tank can only be
dischargedusingtheemergencyprocedures.
The use of the portable pump is a labour intensive and high risk operation, which can be
furthercompoundedbythenatureofthechemicaltobedischarged.
Iftheemergencypumpistobeused,thentheterminalandownersshouldbeadvised.
The terminal should also be aware of any problems anticipated and cooperation and
communicationisvitalforthesafeandefficientdischargeofthecargo.
BLUEAVATAR
ANDVIAGRA
CAPTAJIT
VADAKAYIL
GEORGEC
SCOTTTHE
GABBAR
SINGHOF
HOLLYWOOD
...
November(36)
June(15)
May(25)
April(9)
March(3)
February(1)
2009(10)
6/24
8/15/2016
The pump described below is a FRAMO TK4. If another type of pump is on board, then the
particularoperationofthatpumpistobeused.
Therearebasicallythreemaincomponentswhichmakeuptheportablepump.
1Thepumpunit.
2Thestarterheadwithhosesbetweenpumpandhead.
3 Pressure and return hoses between the starter head and the snap on coupling stations on
deck.
Flexible hoses of sufficient length are coupled to the pump to effect the discharge. The length
offlexiblehoseshouldbekepttotheminimumtoreachtheinstalledpipework.
Theportablepumpisloweredintothecargotankbyaslingandnotbythehydraulichoses.
PORTABLEFRAMOTRYOUT
As soon as a new Chief officer/ Pumpman joins he should at the earliest rig up the portable
Framopumpandtryitout.
Neverhookupwithoutaflowcontrolvalveforspeedcontrolandstop/start.
A)Fillupaempty200litredrumwithSWandkeepacoupleoffirehosesstandbytofillitup.
B)Usetripodthesamewayyouwilluseinatank.
C)Beforeconnectinghydhosescloseflowcontrolvalve.
D)Checkforcleanlinessonsnaponcouplings.
E)Alwaysconnectreturnhydhosefirstandopenvalve.
F)Connectpressurehydhoseandopenvalve.
G) Open flow control valve till the required rpm is reached, dont let the drum go dry. If so
thenputdischgbackintothedrum.
H)Probablespecsofaportableframowillbe180bars/70cumperhour/140ltrshydoilper
min
I) After you are satisfied , rinse with FW. Then first shut flow control valve. Make system
pressurezero.
J)Closepressurelinevalvefirstandthenreturn.
K)Alwaysdisconnectpressurehydhosefirstandthenreturn.
7/24
8/15/2016
L)Beforekeepingbackinstorereleasetheoilpressureinsidehydhosesbyremovingabout20
CCofoil,bypushingwithfingers.Otherwiseinanactualemergencyyouwillhavedifficulty
inconnectingthesnaponcouplings.
M)Dontkinkthehosesinthestore.
Portable Framo pump is not used to pump ashore. Rather it is used to pump from one tank
whose pump does not work to another tank of the same grade or empty tank whose pump
works.
If the emergency pump is to be used, then the terminal and chemical operator should be
advised. The terminal should also be aware of any problems anticipated and mutual co
operationisvitalforthesafeandefficientdischargeofthecargo.
Ensurethatonlythelowerhalfofthepumpissubmergedandisloweredasthecargolevelfalls
.
FRAMODEEPWELLPUMPOVERHAULING
MODELS:SD125ANDSD150(designnumber5)
Shutinletvalveofmainhydraulicinletpressureline.
Purgethecofferdam.
TaketheFramotoolboxdown.
Todismantleimpellerandwearrings:
Remove8nosboltstodismantlepumpsupportring.
Liftupthesupportringandtieitupwitharopeaboutonemetrehigh.
Loosen8nosboltsofupperwearringsupport.
Thenloosen2turnsonly6nosallenboltsforimpellerhub(inner).
Turnimpellerclockwiseforeasyaccess.
Pressdowntheboltsandimpeller.
Whenimpellerislooseremovethebolts.
Remove4nosboltsbetweenvolutecasingandcargoleg.
Replace2oftheboltswithlongliftingboltsoneboltoneachleg.
Remove remaining bolts between volute casing and bearing housing of cargo
flange.
Now all volute casing , impeller and suction cover is hanging on lifting bolts
diagonallypositionedoneachcargoleg.
Lowerunitonplasticstrips.
Slidetheunitoutofthewell.
Removeupperwearringandinspectit(whitelargering).
Remove black o ring and small white seal element between impeller and impeller
hub.
Putunitupsidedown
Removenutsbetweensuctioncoverandimpeller.
Inspectwhitewearring.Normalradialclearanceis0.2mm.ifclearancebecomes
greaterthan1mmrenew.
Loosenlockingbracketandremovelockingring.
Fitbackthesuctionbellmouthtoliftupthesuctioncone
Finallyliftuptheimpeller.
Notewearringsusuallylast10yearsforcleanoils.Forsedimentcargoeslikeclay
slurryyouwillhavetorenewoften.
Todismantledoublecargolipsealandcofferdamseal:
Firstdismantle4boltsonthelowerpartofthincofferdamcheckpipe.
Putamirror.
8/24
8/15/2016
Dismantleimpellerhubfromthepumpshaft.
Loosenlockwasher.
Removeboltandpulloutimpellerhub.
Useextractortoremoveimpellerhub.
Dontdamageorringandceramicsleeve.
Putontheassemblingcylindertokeeptheceramicsleeveinplaceandprotectseal
lips.
Pulldownsealringhousingwithcargosseal.
RemovethethinwhiteTeflonsealring.
Remove(thicksmallwithspring)doublecargolipseal.
Removesinglelipcargoseal.
Note:alwayschangesingleanddoublecargolipsealtogetherastheycomeasone
sparepart.
Removeceramicsleeveafterremovingtheassemblingcylinder.
TodismantleMechoilseal:
Mechsealcanbedismantledwithoutdrainingoilfromthehydpumpstack.
Removebearinghousingfrompumpcasing.
Putupsidedownandremoveuppersealringhousing.
Use2liftingboltsandremovemechsealstationarypart(black)andTeflonseal
element.
Use special tool for rotating part of mech sealnever use grease on oring of
stationarysealusesoapwater.
Dismantlepumpshaft,ballbearingandbackstopunit(afterreadingthemanual).
Forhydmotoryoumustdrainouthydoilfrompumpstack.
UseairdrivendrainpumpgivenbyFramo.
LowerhydmotorbyusingFramojack.
Assembling
Assemblingisdonethereversewaythethingscameoff.
Howeverturnceramicsleeveby180degrees.
Groovefromdoublelipcargosealmustbefacingtowardstheimpeller.
Fitretainerringongearedshaftcorrectlyatendofceramicsleeve.
Runningtest:
Pressuretestcofferdamat3barspressure.
Blankcofferdamventpipe.
Unscrewthecompleteairreliefvalveandconnectpressureguage.
Checkforpressuredrop.Pressuremustbestablefor30minutes.
FRAMOHARDWARE
WhenanewdeliveryMasterorChiefEngineergoestotheyardtotakeoveraship,theymust
knowthefollowingminimumessentials.
9/24
8/15/2016
TheymustknowwhichhardwareisyardsupplyandwhatisFramosupply.TheFramosupply
isusuallyperfect,theyardsupplyandtheinterfacingneedstobecheckedingreatdetailthis
iswhytheyaresentbycompanytotheyardwellinadvance.Thenewbuildingsuperintendent
is of course there much before, and he need to read this chapter too. Sometimes for yards
conveniencetheydonotfitFramosupplyhardware,andthismustberectified.
For example, recently when one of our Masters pointed out to the yard, that the Framo air
purge couplings for stripping the stack do not have non return ball valves ( but wrongly fitted
with yard supply shut off cocks ) as is usual for Framo fitted ships as a Framo supply , the
yardinitiallystonewalledbutsincethiswasdoneinwritingwithcopytoFramoandcompany,
theyardwasforcedtorecifyitfreeofcostbeforedelivery.ImagineSulphuricacidsprayingon
thePumpmansface,afterhefinishedstrippingthestack!!.
Look for alien voltage from interfaced equipment prior to working. There must be sufficient
service space and lifting hook pad eyes. Hydraulic oil used must be mineral based and must
haveFPbetween180and230C.Thiswasanothermistakerecentlynoticedtheyardhadto
drain out the cheap quality yard supply hydraulic oil , flush the system and then fill up again
withthecorrectviscocity/FPhydraulicoil,asspecifiedbyFramo.
Anyhydleakspraymustnotcomeincontactwithheatedsurfaces.Checkhydoilconnections,
valvesandflangesifnecessaryputsplashtapesonflanges.IfthepowerpackisintheER
anoilmistdetectorisdesirable.Thisisboundtobearegulationverysoon.
Weldingonframoequipmentinnottobedonewithoutpermission.
Theremustbenopaintonflexiblehosesandrubberdampersasitwillcrackverysoon.
It is important to know the hyd oil conspumption of all cargo pumpsbig and small , ballast
pumps, portable pump, tankcleaning pump etc in litres/ minute. This must be posted at the
remorepanelintheCCR.
Anyconsumerhookedontothecentralhydraulicring,mainsystemcanberun(likecrane)
aslongastheoildeliveryissufficient.TocontrolthespeedofthehydmotoraFCV(oldships
)/STC(allnewships)isfitted.FramodoesnotmakeFCVanymoretheymakeitonly
fortheportablepumps.
Checkthehydraulicoilstoragetankandcleanoildraintank.Bothmusthaveslopingbottoms
away from the suction and towards the bottom drain for efficient water draining. These tanks
areusuallyyardsupplytherestareFramosupply.
In case the power pack is situated outside the ER, the ventilation must be sufficientwithout
ingressofsaltspray.TheadvantageofhavingthepowerpackinthehigherlevelFPstoreisthe
natural head of hydraulic oil afforded , to the mechanical hydraulic oil seal at cofferdam of
submergedcargopump,incasetheJockeypumpfails.
There must be an obstruction free arrangement in case the whole pipe stack and pump head
hastoberemovedfromthetankwithatallcrane.
Thepipestackmustbeparalleltothebulkhead,wherethebracketfortheintermediatesupport
iswelded.
FromFramoCCRcontrolyoushouldbeabletoseemanifoldtheconsoleismadebyyard.
Look for dents on framo pump risers due to incorrect handling by slings or forklift marks
under power pack units ( they must be lifted by 4 hooks ). The risers have concentric pipes
insideinlet/return/cofferdam.
Framopumpsmustbeinstalledonlyaftertheweldingcausingspatter,grinding,picklinginthe
tanksareoverinSStanksorforthematter,paintingincoatedtanks.
10/24
8/15/2016
NoteFramo recommends hyd drums to be stored horizontally when it is kept out doorso
thatthebungsarecoveredbyoiloilcanleakoutbutwatercannotcomein.
Waterhasanegativeeffectonhydoiladditives,whichhavebeenprimarilyputtoimproveoil
quality.
Framodropsmustnotleadtopumpsuctionitmustnothitsteamcoilsmustslipunderneath
andhittheforwardbulkheadfortsunamirecirculation.
FlexiblehosesforstackstrippingwillhaveSSsnaponcouplings,withaNRballvalveateach
end.Thehosewillnotbe>2metreslong,willbeSSbraided,willbeheavydutyandhardto
bend at 180 deg angles. There will be NO jubilee clipsif you notice Jubilee clips it is a
deliberate yard mistake. They have fitted a compressed air outlet valve far away from the
pump,andinsteadofrelocatingtheairvalvetheydidthenextbestinaclandestinemanner
that is, give the ship a longer hose with couplings fixed by jubilee clamps. After stripping the
stacktheremustbenoneedtoshutacockbeforedisconnecting.Cargomustnotingresstheair
flexibleevenifairpressuredropsfrom7kg.
Exhaust traps must have 50 cms clearance to keep a collecting bucket . Cofferdam blow is
done into a compatible bucket and not into the clear sample glass bottle. There must be
differentbucketsfordifferentgradesofcargo.
Theintermediaterisersupportsmustnobeweldedincornersorslopeofcorrugatedsolidsteel
oron2differentbulkheadsatcornersoftank.Framohavecertaincalculationsonwhichthey
decide whether to put one or two intermediate riser supports. Be aware in tanks without
sloshingconsiderationsandlessloaddensity,carriageoffreeflowinghighdensitycargoeslike
sulphuricacidofSG1.85cancausecracks.Mastermustpreventshipfromrollingexcessively
and not trust the Framo calculations to deliver his tanks from cracking danger . Framo
calculationshavenottakenintoaccounttheshipstanksloaddensityifaheavycargoof2.0
SGcanbeloaded98%orpartiallyfull.
Prior pump installation the deck trunk and brackets for intermediate and bottom support have
to be welded into the tank. A good yard will use a Framo provided dummy with laser beam
holestoavoidtemplatingmisalignment.Goodalignmentmeansnocracks.WhiletheJapanese
yards are experts in thisnewly mushroomed yards who have jumped into the fray with the
chemicalType2tankervegoilshippingboom(after1.1.2007)maynotbeso.Insuchyards
theOwnersyardnewbuildingsuperintendentmustcarryhisownlaserpencilbeamavailable
inthemarket.
Weldingseamsofdecktrunksmustnotbefacingtheshipsidewheretheycangetpoundedby
aincompressiblegreenwaterwave.
Ammetersmustbebeprovidedformotors>7.5KW.Agoodchiefengineerwhoknowsabout
swash plate angles of variable displacement Framo power pack pumps will hardly need this
Ammeter.TheratioofcurrenttransformermustbetoldtoFramobyyardifanamperemeter
isrequiredonthehydraulicsystemcontrolpanel.
Cablesformotorheatingelementsandthermistorsmustnotbeinterchangedasvoltage>2.5V
will damage the thermistors. Motor heating elements must be powered up immediately after
installation.
Hydraulicoiltanksmustbeventedindoorsrepeatindoorsandthattoowithanairfilter,notto
outer decks. The storage volume must be min 50% of the total oil volume in the hydraulic
systemtherecommendedis70%.
ThestorageandcleanoildraintankmustbeSStopreventcoatingifnotgritblasttoSA2.5
andgivetwocoatsofhydoilresistantepoxy100micronseach.OnlySSpipesareused,copper
orgalvanizedpipesmustneverbeused.
Manometer test connections must be provided by the yard at both supply and return lines, to
dotroubleshootingandtotestforpressurepeaks.
11/24
8/15/2016
Ventingplugsmustbeatthehighestpointatbothpressureandreturnpipes.
Framodoesnotaccepthydrauliccylindersconnectedtothesystem.Ifacranehastobeused
they recommend a separate hyd system with hyd motor driven from Framo system. But as
longastheCCROOWisawarethatacraneisbeingoperated,hecanbevigilant.
Pipelinesmustnothavetoomuchofpressuredrop(smoothinternalsurface)orairpockets.
FramopressuredropcalculationsarebasedonminimumID.
Unnecessaryflangesmustbeavoidedbyyard.Allpipelinespoolweldsmustbepossibletobe
inspectedfromaflangesayusingavideoscope,attheyard.
Theresilientpipelineclampsmusthave4rubberpadsatall4quadrantsequallycompressed
toabsorbvibrationsandpreventtransmissiontodeckstructures.Theseclampsmustbewelded
torigidstructure.
PipelinebulkheadpenetrationsmustberesilientFramosupply.Theinnerbulkheadmusthavea
protectioncup,,linedwithglasswool.bothyardsupply.
Expansion loops on hyd pipelines must be always horizontalnever vertical. These are for
thermalexpansionandaxialforces/deflectionofshipsstructure.
Water ballast pumps must be connected to different RCV blocksto ensure operation of
ballastsystemifonevalveblockisoutofservice.
Pilot pipes on open decks must be made of SS. Pilot pipes min distance between expansion
loops is 25 metres. If attached to the catwalkexpansion loop must correspond with the
expansion joint. If there are 2 tiers there must be no contact between any pipe and adjacent
flangeflanges can be turned to avoid contact. Only cold bending is permitted.free of
wrinkles on inner side and 7% ovalty. Pipes must be degreased before bending and pickled
afterbending.LowpressurepipeshaveTeflonmandrilinsidethepipes.
TIG welding with Argon gas is recommended for SS. Carbon steel pipes must be coated with
zinc rich epoxy. Neutralization of carbon steel pipes after pickling2% phosphoric acid at 85
deg C for 5 min, the Framo way is wrongNitric acid would have been the best.
NeutralizationofSS(passivation)14%Nitricacidatambienttempfor45min.
Pipe clamps must be welded only AFTER alignment and assembly of pipes. Adjusting spools
aremin2to3metreslongthepipesmustbepulledapartbeforeinsertingtopreventdamage
tospoolOring.UseMolebnenumSulphidegreaseonscrewconnections.
Assoonasyoujointheshipcheckthemanifoldifthemanifoldathwartshippipesareabove
the fore and aft cargo deck lines it simplifies the loading. If it is belowit simplifies the
stripping.ThisknowledgeisvitalwithhighMPcargoesloadedfrombargesinfreezingweather
likePhenolloading/dischginwinter.Ifpipelinesgetfrozenwithtoxiccargoandyouhaveto
putyoucrewindangertounfreezethelinesitisadisgrace.
Ifthemanifoldsareabovedecklinesthenseparatedrainlineshavetobeinstalledforalldeck
pipelines. If the manifold common collector is above the manifold pipelinesthen 2 drain
tanksatthemanifold.
Hyd oil pour point should be around 26 deg C, with viscosity ISO VG46the trade name
whetheritisTELLUSShell/RANDOTexacoorBARTRANBPwillhavethenumber46.
The hyd oil must always be filtered by using the Framo hyd oil transfer unit when the oil is
filledintothesystemfromthestoragetank.Watercontentmustbebelow300ppmor0.03%
Airinthesystemisindicatedby
Backflowintothesystemwhenatstandstill
Greatdifferenceintanklevelatlowandhighsystempressure
Foaming
Discolouredoil
12/24
8/15/2016
Coolingwaterpipelinesarefittedwithflexiblebellowstopreventvibrations.Pipingattheoutlet
sidemustberoutedabovetheoilcoolerandavacuumbreakermustbeinstalled.
The tank risers have concentric hyd pipes for max safety. Framo cofferdam is at atmospheric
pressure,unliketheJapanesedeepwellpumpswhouseairpressurizedcofferdamstomakeup
forthelackofJockeypumpandthattoowithafixedairconnection!
RememberFramocargodoublelipsealfacesonlystaticpressure.Framopumpdesignpermits
dryrunningduringstrippingandtankcleaning.Itfacilitatesintankreplacementofwearandtear
partswithoutinterferingwithhydraulicsection.
Bypurgingonlytheconditionofthedoublesealcargosealisknown,hencereplacebothsingle
lipanddoublelipcargosealstogetheralways.
After fixing the snap on hydraulic couplings of portable framo, secure it with locking ring
onlythenthearrangementissafe.
Portable Framo TK80 usually provided on board EMS ships have a capacity of 90 cum/ hr.
PortableFramoinletpressureisusually180barsandthereturnlinepressure16bars.
Before purging cofferdam drain the compressed air supply line off water. When purging
cofferdam the cofferdam relief valve operates at 3.5 bars. If not, then you get air into the
hydraulicsystemwithoncetheairpressureisgreaterthanthejockeypumppressure,duetoa
blockedcofferdam.
LightcargoeslikeMethanol/Naphthabypasscargosealsandpenetratecofferdamsmoreeasily
thanviscousoneslikeLuboils/Vegoils.Cofferdamingressofcargovolumemeansnothing,if
thetypeofcargopurgedisnotmentioned.
Nonviscouscargoleakage0.5litres/dayisnormal.Oilleakage0.25litres/dayisnormal.
Cargoleakageincofferdamcanbe
Wearonceramicsleeve
Leakingpumpstack/pumpheadseals
Tofillupacofferdampriordischg,forcargoeslikeCausticsoda
Disconnectexhausttrappipingfrompumptopplateuseasuitableadaptorandfillup.allow
airtoescapefromsnaponaircouplinginotherwordsthisisreverseofpurging
Forcontiniouscirculationofwaterwhiledischarging,forcargoeslikeClayslurries:
Same way as you blow the cofferdam. Ensure the hyd return oil pressure is higher than the
cofferdampressure.
If the hyd oil temp is <20C circulate the oil for heating at max 100 bars prior to raising the
pressureto150bars.
Whenusingdeckmountedheatersmakesurethecargoiscirculatingthoughtheheaterbefore
openingsteaminletvalve.Neverheatwithoutnecessarycargoflowthroughtheheatertoavoid
carbonizing. Shut off heating medium before the pump is stopped. For deck mounted heaters
doNOTheatwhiledischargingorcargowillcomebackintothetank.
Jockeypumpalsopreventswaterentryintohydraulicoilfromleakingcooler.
If oil temp is <20C, circulate the oil though the heating/ venting valve with one power pack
running.
Manualoverride:
Modeone1)Sensoronoiltankisindicatingshutdownlevel,andithasbeendeterminedthat
levelisOK
2)Alimitswitchisindicatingclosedvalveandithasbeenverifiedthatthevalveisfullyopen.
13/24
8/15/2016
Mode2forPLCfailure
Coolingwatervalvenforpowerpackisautomatic,50Copen30Cshut
The Framo pumps can be run against a closed cargo valve without any risk of eventual
overheatingasthewearringlossisleddirectlybackintothetank.
PCV is a proportional valve for precise and fast control of pressure. This valve is primarily
usedforremotecontrolofpilotpressuretoaFramohydcontrolvalve.PCVisacompactunit
with integrated electronics and a pressure transducer for controlling the pressure on port A.
whenthecurrenttoPCViszerothespoolisinspringreturnposition.
When the actual pressure at port A is lower than the set pressure, the spool will more so that
portPandportAareconnected,whileportT(totank)willclose.Thevalveistheninsupply
mode.
A limitation is built into the electronics so that the PCV will not open unless the command
signalexceedsapressureof1012bars.Thevalvecloseswhenthecommandsignalgetslower
than 10 bars. When using remote control PCV, the local control valve must be set in max
position and vice versa. Everybody on the ship must know thiswhen a tank is being
dischargedinbulkoratsea,thelocalcontrolvalveSTCmustbefullyopenorfullyclockwise.
Thecommandsignaltothevalveisusuallysetbyapotentiometeratthecontrolpanel.
Emergencyoverride
ThisproceduremustbeknowntoChiefengineer.ReadtheFramomanualassoonasyoujoin,
andfamiliarizehowtodoit,wheretheallenkeyhastobeinsertedandhowithastobeturned
afterlooseningthechecknut.Ifyoudothissimpleprocedurefast,thechiefofficerneednot
rig up the labour intensive portable Framo and end up with ROB and a mandatory and costly
prewash.
IfthevalvehasanelectricalfaultyoucanmechanicallyconnectportPtoportA,andrunthe
cargo pump from local control. Remember to unload local control valve before changing to
manualoverride.Useanallenkeyclockwise.AfteroperationsconnectportAtoportT(tank
)byscrewingcounterclockwise.Fastenthelocknutdontuseforcewithallenkey.
CAPTAJITVADAKAYIL(28YEARSINCOMMAND)
..
PostedbyCapt.AjitVadakayilat12:02:00PM
41 comments:
Rinku January6,2011at2:42PM
Capt,
Veryinformative
14/24
8/15/2016
Thanks
Reply
SHISHIRDUTT February17,2011at11:13AM
DearCapt.Ajit,
Canyouprovidesomedescriptiononthedrawingandfunctionofsuperstripsystem.
rgrds
Shishir
Reply
Capt.AjitVadakayil
February17,2011at11:49AM
sishir,
Superstrip of cargo pipelines , must be done on a chemical tanker after dischg to comply with Marpol
ROBminquantity.
Also in case of inconvenient cargoes like Sulphuric acid , Luboils and high MP cargoes, after
completionofloading.
Basicallyyoushovecargofrominboardsideoftheshutmanifoldvalve,tooutboardshoreside.
Youcantblowcargoinalargediapipelineuphillagainstgravity,(aftofmanifoldwithtrimbystern)from
tanktillmanifold,asairwillskimontopofcargoinsidethepipeline.
Soairisblowninboardofashutmanifoldvalve,toforcethecargotoflowdownhill,totheafttankstack,
and then the cargo is ushered into a small diameter superstip pipeline ( this could be portable if fixed
piggybacksuperstrippipelinesarenotfittedforallafttanks),whichtakesthecargooutboardoftheshut
manifoldvalve,ashore.Aircannotskimontopofcargoinaverysmalldiameterpipeline.
OnmodernChemicaltankers,superstrippipingisavoidedbyraisingtheafttankdeliverypipesupwards,
sothatcargoflowstowardsmanifoldbygravityduetoaslopingpipeline.
This makes sure that after dischg all your cargo goes ashore by gravity. But on the other hand after
completionofloadingyourmanifoldcrosspipesofafttankswillbefullofcargo.Sulphuricaacidsloshing
inrollingduringloadedpassage,candestroyallthebutterflyvalvesatthemanifold,onbothsides.
CAPTAJITVADAKAYIL
..
Reply
sehmus September13,2011at12:29PM
dearcaptain,
we faced with one remark in veetting inspection ..could you pls advise brand of oil mist dedector for
powerpackroomasusedforframosystem...
thanksinadvance,
sehyuc@yahoo.com
Reply
Capt.AjitVadakayil
September13,2011at2:27PM
hi,
youcangoforanyofthethreeOMD
DAIHATSU
GREENINSTRUMENTSAS
QMIMULTIPLEX
15/24
8/15/2016
captajitvadakayil
..
Reply
Hydroponics November17,2011at3:49PM
Pipelines must not have too much of pressure drop ( smooth internal surface ) or air pockets. Framo
pressuredropcalculationsarebasedonminimumID.
AutomatedFeedPumpforGreaseTraps
Reply
MahmoudReda December1,2011at11:18PM
ThanksCapt.AjitVadakayilforinformation
i'mstudentinnavalarchitectandmarineengineeringdep.,PortSaiduniversity,Egypt
andi'mdoingaresearchondifferencesbetweenchemicalandoiltankers.
ineedtoaskaboutsomethingpls
1isthereanyprotectionfordeepwellpumpsincaseoftankloadedwithaggressiveacids?
2canyoutellmewhatisthemaindifferencesbetweenchemicalandoiltankersinpumpingsystem?
thanksinadvance
Reply
Capt.AjitVadakayil
December1,2011at11:46PM
himahmoud,
1)acidsareloadedinstainlesssteeltanks,withstainlesssteeldeepwellpumps,withtefloninserts.epoxy
andzincsilicatepaintscannothandleacids.framodeepwellpumpshaveacofferdamtopreventacidcargo
enteringthehydraulicoilimpellermotordrive.
2)oiltankershavepumproomswithpumpsandalltanksareconnectedatthebottomleveloftank.youcan
preventanoverflowwhileloadingbyopeninganemptytank.
chemicaltankersdoNOThavepumproomasallpumpsaresituatedinsidethetankstopreventhavinga
suction pipe, where all pumping problems lie. this way all tanks are connected above tank level at the
manifold.hereoverflowispreventedwhileloadingbyshuttingthefulltank.
captajitvadakayil
..
Reply
BOSS December12,2011at1:02PM
thanksforprovidedaniceinformation
We Manufacturers and Suppliers of Single Spring Mechanical Seal, Dry Mechanical Seals, Reactor
MechanicalSeal,CartridgeMechanicalSeals,MechanicalShaftsSealManufacturers.
Reply
Sm March12,2012at10:37AM
CaptVadakayil,
Iwassurfingthenetandfoundveryhelpfulinfoofchemicaltankersonyourblog.Excellentdetails.
HaveaquestiontodayoncarriageofFurnaceoilwith2%sedimentsinitforalongvoyageonaIMOII
chemical tanker with Framo deep well pumos. How do you see this as a problem cargo and any risk
associated.
Appreciateyourinput.
16/24
8/15/2016
Manythanks.
SModak.
Reply
Capt.AjitVadakayil
May8,2012at2:20PM
himodak,
itisverydifficulttocleanFOtanksafterdischarge.
thenextcargoCANNOTbeacleanone.thebestnextcargowillbeLDO(NOTthegoldengasoil).
if the charterers push youtake your own sweet time for tankcleaning and ask for enough degreaser
tankcleaningchemicals
dontevergetrushed,fornobodywillgiveyouagoldmedalforbeinganeagerbeaverbutyouwillget
hungifyourshipfailsthenextfirstfoot.
extensive flushing of pipelines with degreaser will be required. the black oil tends to get behind even a
valveseatring.
thefirstprewashcannotbehotasthelightersolventfractionswillevaporate,andthebalancesediments
willinvolvenightmarecleaning..
removecoldinterfacewhileHOTwashing.
captajitvadakayil
..
Reply
alekhyabizconn July3,2012at9:34AM
This blog is good.Ashish Industries inspected in the year 2003. With our consistent performance and
superiorqualityproducts,wehaveestablishedourselvesasarenownedcompanycateringtoourclients
with varied precision mechanical seals solutions. <a href="http://www.globalautomotive
industry.com/productsservices/accessories/ashishindustries/
>SingleSpringMechanicalSeal</a>.
Reply
alekhyabizconn October1,2012at1:44PM
Thanksforeveryotherinformativesite.TheplaceelsemayjustIamgettingthattypeofinfowrittenin
suchaperfectapproach?IhaveaundertakingthatIamjustnowworkingon,andIhavebeenatthelook
outforsuchinformation.AGSFiltrationPvt.LtdisaNativeIndianorganizationofWorldwidereputationin
thefieldofmultipledemandandprogramFiltration.CompressedAirFilte.
Reply
JesusF.Bracho December6,2012at2:35AM
DearCapt.Vadakayil
Regardingframopumpscofferdams,whatcouldbethereasontofillthecofferdamswithwater?,different
fromthereasonofavoidingclogging(molasses,etc).Manythanksinadvance!JBracho
Reply
Capt.AjitVadakayil
December6,2012at8:13AM
hijesus,
cofferdam prevents cargo from entering the hydraulic system and also hydraulic oil from entering the
cargotank.
17/24
8/15/2016
conversely both hyd oil and cargo are expected to ingress in the cofferdam in small quantitiesas this
spaceisalsoaINDICATORwhichtellsyouifthecargooroilsealrequiresrenewal,duetowear.
hencecofferdammustalwaysbeclear.youmustNOTloadcargoinatankwhosepump'scofferdamis
clogged.
there are certain cargoes which will harden inside the cofferdam and hence cannot be purged with air,
beforeloadingthenextcargo.
alsosomeofthesecargoesmaybe"ABRASIVE"(likeclayslurry)anddestroytheceramicsleeveon
whichthecargosealabuts.andsinceclayslurryisINSOLUBLEinwaterandHEAVY,justfillingupthe
cofferdamwillNOTdo.
crystallizingcargoeslikephosphoricacidandcausticsodaarealsoabrasive.
whenthepumpruns,waterhastobecontiniouslyfilledandejectedoutondeck.
TO AVOID INGRESS OF WATER INTO HYD OIL (WHILE RECIRC OF WATER) DO NOT
TRUST THE SMALL PRESSURE EXERTED BY THE JOCKEY PUMP RUN THE FRAMO
SYSTEM,WHENWATERISFILLEDINTHECOFFERDAM.
captajitvadakayil
..
Reply
JesusF.Bracho December7,2012at12:31AM
DearCapt.Vadakayil
Manythanksforyourpromptanswerandhelp!
Verybestregards,
JBracho
Reply
vijaykamal December28,2012at9:12PM
dearcaptain,
Greetings.i have sailed in bulk carrier for two years and i have done single contract as 4/e in bulk
carrier.nowiamgettingaofferfromamaritimeagencytodochemcoandjoinachemicalcarrieras4/ebut
thewagestheygiveis1800$,kindlyadviceonthis.inbulkcarriertheypayme3400$
Reply
vijaykamal December28,2012at9:15PM
dearcaptain,ihavesailedinbulkas4/eandnowiget3400$monthlyandigotaofferfromamaritime
agencytodochemcoandjointheirchemicaltankerfor1800$monthly.ischemicaltankersafetowork
withandalsoiheardlifeishecticatchemicaltankers...kindlyadvise
Reply
Replies
Capt.AjitVadakayil
December28,2012at9:44PM
hivijay,
itisgoodtodochemcoandgetexperienceonachemicaltanker.
negotiateyourwagesandgoforashortcontract.
lifeonchemicaltankersissaferthanonaoldbulkcarrier.
captajitvadakayil
..
18/24
8/15/2016
HarshalDure April20,2013at4:32AM
DEARCAPTAIN...
I HAVE ONE QUISTION AND IAM LOOKING FOR THE ANSWER FROM LONG
TIMECANUPLZANSWERTHIS....
Whatistheprecautiontobefollowedwhenreplacingthemechanicalsealsinacargopumpof
antanker?
PLZSIR,,
Capt.AjitVadakayil
April20,2013at9:23AM
hiharshal,
Thelappedsealfacesarebrittleandmaycrackifdroppedorscratchedagainstotherparts.
Nevertouchsealfaceswithbarehandsusecleangloves.
Neveruseanylubricantonsealfaces,theymustbeassembledcompletelydry,cleanand
dustfree.Cleanthesealfacesusingdenaturedalcohol.
Checkthatoringsforrotatingandstationaryseat,andrubberbellows,areundamagedprior
toinstallation.
Dynamic O ring and static O ring have different surface roughnesscheck value in manula
drawing
Toreducefrictionalforceswheninstallingrotatingseatonshaftorsleeve,thinlylubricatethe
dynamic oring, or shaft/sleeve area for oring with silicone grease. Never use grease
incompatiblewithoringmaterial.
Useapprovedassemblytoolswheninstallingrotatingseatonshaft.
UseLoctite243orequivalentonsetscrews.Setscrewsmustberenewedafterevery
dismounting.
UsetorqueOnscrewsaccordingtotable.
Toreducefrictionduringassembly,wetthestationaryoringandallslidingsurfacesfortheo
ringwithwater.Ifthestationaryseatisimpossibletoinstallusingwater,addsomesoaptothe
water.Useaslittlesoapaspossible.
Thestationaryoringmustneverbelubricatedwithgrease.
When pressing in the stationary seat with oring, make sure that the pressure distribution is
uniformandthattheoringisnotdamaged.
Donotuseanyassemblytoolsagainstsealface.Pressseatintosealhousingbyhandusing
cleangloves.
Onstationaryseatswherenolockringisinstalled,makesurethatapossibletwistedoring
duringassemblyisnotforcingthestationaryseatoutofsealhousingafterassembly.
Whenlookingattheslidingsurfaceoftherotatingseat,arighthandedshaft
requiresarighthandedspringandviceversa.
Whenmountingmechanicalsealswithconical
springs,thespringmustbepushedontothe
shaftwithascrewingmovementidenticaltothewindingdirectionofthespringthiscausesthe
springtoopen.
Ifaprovisionhasbeenmadeforastationary,aswellasarotatingpumpingscrewthespiral
directionofthe
stationarymembermustopposethatoftherotatingpumpingscrew.
19/24
8/15/2016
After installation is finished a pressure test of the mechanical seal should be performed if
possible.
.Fordetailedprocedures,refertothepumpsservicemanualorassemblyinstructions.
Pressuretestwithcleandryair.
Ifthemechanicalsealisusedasoilseal,thereturnchamber,wherethisispossible,shouldbe
pressuretestedto6barfor15minutes.Monitorpressureincofferdamduringtest.
Installrightsideuprotatingandstationaryseats.
captajitvadakayil
..
HarshalDure April22,2013at6:16PM
DearCapt.Vadakayil
Manymanythanksforyourpromptanswerandhelp!
Appreciateyourinput
Manythanx..AGAIN
Reply
KAnand June23,2013at4:06PM
CaptainVadakayil,
Sirwhatarethereasonsforstoppingoverflowonoiltankerbyopeninganemptytankbutshuttingafull
tankonachemtanker/
Reply
Replies
Capt.AjitVadakayil
June23,2013at7:29PM
hika,
punchintogooglesearch
INSTRUCTIONS FOR OVERFLOW PREVENTION ON CHEMICAL TANKERS
VADAKAYIL
oiltankerstanksareconnectedtoeachotheratthebottomofthetanks.
chemicaltankertanksareconnectedtoeachotherabout2metresabovemaindecklevelatthe
manifold(iftheyareconnectedbyspoolsorinternalloopinghoses).
captajitvadakayil
..
Reply
VishwajeetSingh June25,2013at9:35AM
hellosir
readyourextremelyhelpfulblogs..thanksforsharingyourknowledgewithus.
myqueryiswhataretheriskandhazardsassociatedwithframopumpsonachemicaltanker..
Reply
Replies
Capt.AjitVadakayil
June25,2013at10:14AM
20/24
8/15/2016
hivs,
do NOT allow the impeller to work loose . sometimes after changing the cargo seals the
engineerssoapoorjobinboxingback.
leakywearringscanspraycargo.
high MP cargoes the pump and dischg column can freeze . no not allow cold ballast
interface.
captajitvadakayil
..
Reply
PushkarKashikar August6,2013at9:55AM
hellosir,
ijustwouldliketoaskwhatcheckstobecarriedoutbeforedischargingthecargoonfixedframosystem
1.bydeckside
2.byengineside
ifyoucanthenpleaseemailmeon
marinepush@gmail.com
thanksnbrgds
pushkar
Reply
Replies
Capt.AjitVadakayil
August6,2013at11:04AM
hipk,
idoNOTtakesuchcomprehensiveacademicquestionsmeantfororalsandexams,dueto
obviousreasons.
thereismorethanenoughinfoinmyblogpostsonthissubject.
andidoNOTcomeonemail.
CHEMICALTANKERS,DISCHARGEOPERATIONSVADAKAYIL
itgoeswithoutsayingthatengineershavetocheckthehydoillevel,ensurejockeypumpis
running,startcoolingwatersystem,checkoilfilters,startrequisitenumberofgeneratorsand
ventairfromsystemifthereissound.
anddeckofficershavetopurgepumpcofferdams,checkforleaksandtellengineershowmany
powerpackstheywilluse.
Ifthehydraulicoiltemperatureisbelow20C,circulatetheoilforheatingat
maximum100barpriortoraisingthehydraulicsystempressuretomax.
captajitvadakayil
..
Reply
venkatasyamkonidala November15,2013at6:32PM
Dearsir
canyouexplainwhatisthereasonforstartingadditionalfeedpumpbeforestartingpowerpack
Reply
21/24
8/15/2016
Replies
Capt.AjitVadakayil
November15,2013at7:19PM
hivsk,
intheframosystemthefeedpumpiscalledjockeypump
itruns24hrsaday365daysayearNONSTOP.
readitemno3rightontopofthepost.
captajitvadakayil
..
Reply
VenkataSyam November17,2013at12:13PM
Dearsir
Itisunderstoodthatjockey/feedpumprunsallthetimeinframosystem.mydoubtiswhyitisrequiredto
startsecondfeedpumpwhilestartingpowerpack.twofeedpumpswillberunningwhenpowerpackruns
and only one feed pump when powerpack is not running. it is inbuilt system and additional feed pump
startsautomaticallywhenpowerpackisstarted.Canyouexplainthereasonsir.
Bestregards
Reply
Replies
Capt.AjitVadakayil
November17,2013at2:27PM
hivs,
thisdependsontheoperationmanual
maybethehydrauliccircuitisdesignedthatway.
captajitvadakayil
..
Reply
CdtTomAlex November18,2013at7:46AM
DearSir
Thanksforthisinformativearticle.Couldyoupleaseenumerateonhowtogoaboutduringchangeoverof
tanksduringcargodischarge.Dischargingfrom1W,5Wand6W.Iwillliketokeep1Wand6Wrunning
butneedtochange5Wto4W?Thanksinadvance
Reply
Replies
Capt.AjitVadakayil
November18,2013at8:16AM
hita,
idoNOTtakesuchquestionsduetoobviousreasons.
howeveryoucanreadanotherpost
whenyoudothejobpracticallyontheshipbyassistingincargowork,youwillcometoknow.
22/24
8/15/2016
captajitvadakayil
..
Reply
NIKESHPATIL March22,2014at4:13PM
Canyoupleaseadvisemetheexternalinspectionofthedeepwellpumpsinsidethetankstobecarriedout
duringtankinspections.
Thanks,
Reply
Replies
Capt.AjitVadakayil
March22,2014at4:33PM
hinp,
readthepostproperly.
captajitvadakayil
..
Reply
ElinaMaria August22,2014at3:09PM
Niceblog!
Itgivessomegoodandusefulinformationaboutoilequipmentandit'suses.Theequipmentshowninthis
blogisreallygoodandhighquality.
AirOperatedPumps
Reply
SophieTilley August25,2014at3:34PM
Iwentacrossyourblogitisreallygood.Ithasveryimportantandusefulinformation.
WorkshopEquipment
Reply
Search2 July1,2015at4:13PM
Hi,
Thanksfortheniceexplanations,youarereallyworkedhard
towritethiswonderfulpost.
Niceefforts,keepwriting.
Andre
Pumps&ValvesManufacturers
Reply
ChanderJeetSinghBhalla January8,2016at1:44PM
IMUSTSALUTEYOUCAPTAJIT!!!THISISAGREATJOBYOUAREDOINGBYSHARING
YOUREXPERIENCEWITHSHIPPINGFRATERNITY!!
CSBHALLA
Reply
23/24
8/15/2016
Reply
Mastermariner April16,2016at10:10AM
Can you throw more lights on what you have mentioned on wear ring test and other framo pump
performancetests
Thanksinadvance
Reply
Enteryourcomment...
Commentas:
Publish
Selectprofile...
Preview
NewerPost
Home
OlderPost
Subscribeto:PostComments(Atom)
Simpletemplate.PoweredbyBlogger.
24/24

Ajit Vadakayil - Deepwell Pumps On Chemical Tankers - Capt Ajit Vadakayil

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ajit Vadakayil - Deepwell Pumps On Chemical Tankers - Capt Ajit Vadakayil

Uploaded by

Copyright:

Available Formats

8/15/2016

DEEPWELL PUMPS ON CHEMICAL TANKERS CAPT AJIT VADAKAYIL

Blog Arc hive

You might also like