FRAMO Mounting Instruction

Framo Mounting Instruction

Main contents1 2 3 4 5 6 8 9 Introduction Location on board Equipment handling - Storage at yard Installation of submerged cargo pumps Installation/Storage of portable equipment Installation of submerged ballast pumps Installation of hydraulic power unit, closed loop system Installation of electrical equipment 1401-0001-401 1401-0002-401 1401-0003-401 1401-0004-401 1401-0005-401 1401-0006-401 1401-0034-4 1401-0009-401 1401-0010-401 1401-0012-401 1401-0026-4 1401-0017-401 1401-0018-401 1401-0019-401 1401-0020-401

10 Yard equipment 12 Installation of deck mounted cargo heat exchangers 14 Installation of submerged tank cleaning pumps 17 Hydraulic piping 18 Cargo piping 19 Hydraulic oils - Oil filling - Flushing 20 Framo commissioning - Testing

June 2003


No. 1401-0001-4Feb-2000

IntroductionCONTENTS1 Framo documentation 2 Ordering new parts - Return of parts 3 Addresses

Framo Mounting Instruction INTRODUCTION

No.1401-0001-4 Feb-2000 Page 2 of 4

1 FRAMO DOCUMENTATIONThe 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 cooperation 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 180-230C, 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.


No.1401-0001-4 Feb-2000 Page 3 of 4

Documentation for yards design and installation is supplied to the yard shortly after receiving the order, and contains the following:

FRAMO MOUNTING INSTRUCTION

FRAMO DRAWINGS PUMPING SYSTEM

FRAMO DRAWINGS PIPING SYSTEM

General recommendations and requirements for design, handling and installation of the Framo cargo pumping system.

General Arrangement Framo specification Equipment drawings Technical data System drawings

Piping specifications Layout drawings Component drawings Supplied only if hydraulic piping system is included in Framo supply

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 SERVICE MANUAL PUMPING SYSTEM

FRAMO SERVICE MANUAL PIPING SYSTEM

Technical data Initial start up Operation Maintenance Drawings - Part lists

Piping specification Layout drawings

Supplied only if hydraulic piping system is included in Framo supply

2 ORDERING NEW PARTS - RETURN OF PARTSWhen 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 Hardangerveien 150 N-5226 NESTTUN


No.1401-0001-4 Feb-2000 Page 4 of 4

3 ADDRESSES Sales DepartmentFRANK MOHN A/S P.O. Box 98 Sltthaug N-5851 BERGEN, Norway Telephone: Telefax: E-Mail: Internet: (47) 55 99 90 00 (47) 55 99 93 80 [email protected] www.framo.com

Project ManagementThe 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 the Piping 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.

Contact addresses:Project DepartmentFRANK MOHN FUSA AS P.O. Box 10 N-5641 FUSA, Norway Telephone: Telefax: E-Mail: (47) 55 99 96 00 (47) 55 99 97 84 [email protected]

Piping DepartmentFRANK MOHN FLATY A/S Flaty N-5918 FREKHAUG, Norway Telephone: Telefax: E-Mail: (47) 55 99 94 00 (47) 55 99 95 84 [email protected]

Service DepartmentFRANK MOHN SERVICES AS P.O. Box 44 Sltthaug N-5851 BERGEN, Norway Telephone: After 1600 hrs.: Telefax: E-Mail: (47) 55 99 92 00 (47) 90 99 00 06 (47) 55 99 93 82 [email protected]


No. 1401-0002-4Rev. B Dec-2001

Equipment - Location on board

CONTENTS1 Framo cargo pumping system 2 Location in general 3 Submerged cargo pumps 4 Submerged ballast pumps 5 Location of other equipment 6 Framo control system 7 Hydraulic power units 8 Hydraulic transmission equipment 9 Hydraulic oil storage / Clean oil drain tank

Framo Mounting Instruction EQUIPMENT - LOCATION ON BOARD

No.1401-0002-4 Rev.B Dec-2001 Page 2 of 8

1 FRAMO CARGO PUMPING SYSTEMThe 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 the motor 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.

Fig. 1 Framo cargo pumping system

2 LOCATION IN GENERALThe 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



3 SUBMERGED CARGO PUMPSNote! 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).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

Flexible clamp

Cargo pipe

Cargo valveStripping pipeStripping valve

Exhaust trap Service valves Local control valve High pressure pipe Low pressure pipeDrop line

Valve for drop line

C L pipestack

B

h ulk

ea

dPipestack parallel to bulkhead

Location of bracket for intermediate support

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.

Location of brackets for lower support ring

Position of suction well

Clearance between suction bellmouth and well

Suction well Cargo tanks should be designed with suction wells for optimal : - Cargo pumping - Stripping - Service access For further information see section 4.

Fig. 2



4 SUBMERGED BALLAST PUMPSSubmerged 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 The header tank must have free access for inspection and filling. For further information see section 6.

Fig. 3 Arrangement of ballast pump in tank



5 LOCATION OF OTHER EQUIPMENTHydraulic driven pumps on deck, see section 7. Hydraulic driven thruster motor, see section 11. Deck mounted cargo heat exchangers, see section 12. Submerged cargo heat exchangers, see section 13.

6 FRAMO CONTROL SYSTEMThe Framo cargo pumping system is normally operated/monitored from the Framo control panel, consisting of hydraulic system control panel and cargo pump control panel. The control panel should be installed in the cargo control room or other indoor location where living quarter conditions can be kept. It should also be sufficiently illuminated and arranged for good contact/communication to the cargo manifold area to ensure a proper and safe cargo handling. The panels are sometimes designed for installation in yards console, but the above recommendations still apply. The control system may also be interfaced with, and operated from vessels integrated control system. Local panels / motor starters should be installed in the vicinity of the controlled equipment.

Emergency stop arrangementFramo supplies three emergency stop buttons as standard. One to be located close to the power pack room, and two for location on deck, normally installed close to manifold.

7 HYDRAULIC POWER UNIT (HPU)Location of the hydraulic power unit (HPU) must be considered in an early stage of the ships planning, and one has to take into consideration: Minimum noise level in accommodation area Minimum noise emitted from the ship Optimum pipe routing Easy access for maintenance

Generally, HPU room location is recommended as shown below. For further information, see section 8.

Fig. 4 Location of hydraulic power unit



8 HYDRAULIC TRANSMISSION EQUIPMENTLocation of electrical equipment shall comply with degree of protection by enclosure (IP). Electrically operated hydraulic control valves supplied by Framo must be installed in safe area: - Electrical/hydraulical remote control assembly for the hydraulically driven pumps, controlling the pump speed, (normally installed on main deck level). - Thruster pilot control valve assembly, must be installed as close to the thruster motor as possible. For more details, see section 11. Separately supplied pilot filter for these valves must be located as close to the valves as possible.

Fig. 5 Location of hydraulic transmission equipment



9 HYDRAULIC OIL STORAGE / CLEAN OIL DRAIN TANKThe hydraulic oil storage / clean oil drain tank incl. necessary equipment is yard supply. Design requirements are described in section 10. Framo recommend to install the storage/clean oil drain tank below the HPU, either as two separated tanks, or as a combination tank for storage- and clean oil drain. With this location, eventual overflow from the system tank and drainage from the HPU will gravitate down to the clean oil drain tank. The storage tank/clean oil drain tank must be installed in-door, and the ship bulkhead or shell plating must not be part of the tank. This to avoid condensation and water in the hydraulic oil due to temperature differences. Neither must heated surfaces with temperature above 60C be part of the tank, (fuel tanks etc.). The transfer unit must be located close to the storage/clean oil drain tank to minimise the suction side pressure drop.

Fig. 6 Separate storage- and clean oil drain tank



Fig. 7 Combined storage- and clean oil drain tank


No. 1401-0003-4Feb-2000

Equipment handling - Storage at yard

CONTENTS1 Goods receival 2 Preservation, packing and marking 3 Handling of Framo equipment3.1 3.2 3.3 3.4 Handling of power units Handling of submerged cargo- and ballast pumps Handling of heat exchanger Handling of portable equipment

4 Storage at yard4.1 Storage in dry and clean conditions 4.2 Warehouse storage 4.3 Outdoor storage

Framo Mounting Instruction EQUIPMENT HANDLING - STORAGE AT YARD

No.1401-0003-4 Feb-2000 Page 2 of 9

1 GOODS RECEIVALImmediately 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 PreservationStainless steel components are pickled, cleaned and ready for installation. Mild steel components are protected against corrosion by means of priming or painting outside and protecting 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 markingGenerally 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 against moisture. 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.

Framo Mounting Instruction EQUIPMENT HANDLING - STORAGE AT YARDDispatch documents are - Packing list: - Packing specification: - Container specification:

No.1401-0003-4 Feb-2000 Page 3 of 9

Address and dispatch information in addition to the listed items Case- and pallet number Container-, case- and pallet number if shipped in containers

These documents are packed with the components. For further information see below:

Packing list Contents FM order no. Customer Dispatch information Item Item details

See Framo specification * Package no., Identification no., quantity, description etc.

* Every component is marked with an item number according to the packing list. Packing specification Contents FM order no. Packages no. Packages details

Every case or pallet is marked with packages no. Dimension and weight

Container specification If the equipment is shipped in containers, the content in each container is given in this specification. Contents FM order no. Packages no. Packages details

Dimension and weight


No.1401-0003-4 Feb-2000 Page 4 of 9

3 HANDLING OF FRAMO EQUIPMENTEven 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 unitsGeneral infoThe 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 containerNormally 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.


No.1401-0003-4 Feb-2000 Page 5 of 9

3.2 Handling of submerged cargo- and ballast pumpsThe pumps are designed to withstand flexing and bending of the vessels structural members (bulkheads etc.). For this reason the pump bend easily, but as long as this bending is well within the elastic limits, it will do no harm to the pump. Incorrect and careless handling might, however, put undue strain on the pumps, causing permanent damage. The only acceptable way to lift pumps out of the wooden racks is to lift each pump/pump section separately.

Fig. 2

The pumps shall under no circumstances be lifted like this:

Fig. 3

Note! Damage to pump due to incorrect lifting and handling will not be covered by Framos guarantee.


No.1401-0003-4 Feb-2000 Page 6 of 9

If the pumps have been shipped in a closed container, they have to be pulled out as shown below. The following equipment is necessary for unpacking and lifting (Framo supply): - Two softslings. Minimum working Load Limit (WLL): 5 000kg. Length: 18 meters - Four softslings. Minimum working Load Limit (WLL): 1 000kg. Length: 2 meters 1. Four pallets in a good condition (yard supply) to be placed as shown in fig. 4 - 6.

Fig. 4

2. The two softslings (L = 18m) must be fastened on the horizontal beam of the transportation frame and to a forklift. To pull the transportation frame out of the container the forklift must have a constant tension on the softslings. Pull load is approximately 60% of transportation frame and pumps weight.

Fig. 5

3. The other two pallets must be placed as shown in fig. 6. They must not interfere with the lifting points.

Fig. 6


No.1401-0003-4 Feb-2000 Page 7 of 9

Softslings Minimum WLL= 5000 kg Minimum lenght = 18 m

Max. 30

o

Warning !Avoid contact

For securing and roping only !Do not hook any lifing arrangement to this frame construction.

Lifting point

Softslings Length = 2m

Fig. 7 Lifting of pumps on a transportation frame.

3.3 Handling of heat exchangerHandle the equipment unpacked in the packages supplied from Framo. If they are delivered in wooden rack like the cargo pumps (fig. 3) use instructions from chapter 3.2 for handling.

3.4 Handling of portable equipmentHandle the equipment unpacked in the packages supplied from Framo.


No.1401-0003-4 Feb-2000 Page 8 of 9

4 STORAGE AT YARDGenerally 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, sandblasting, 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 conditionsAll electrical components must be stored in a dry, clean room where temperature is kept steady above 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 storageThe 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. Flexible hoses. Mild steel pipes.


No.1401-0003-4 Feb-2000 Page 9 of 9

4.3 Outdoor storageFollowing equipment may be stored outdoor, provided it is properly protected with tarpaulin to protect it from iron dust from grinding, welding spatter, sea water spray, sand and bird droppings. (Stainless steel may corrode if surface is polluted) Cargo coolers/heaters. Deck trunks in stainless steel, (flange protection must be kept on). Pump supports. Stainless steel pipes. Submerged cargo pumps and ballast pumps.

Submerged cargo pumps and ballast pumps must be stored with their axis in a horizontal position, preferably in the same wooden rack as they were received. If the pumps have to be removed from the rack, they should be supported in at least three points as shown below. Note! The pumps must not be in direct contact with mild steel.

TarpaulinCargo pumpSupported in three points

Fig. 8

Oil in drums.To prevent water from leaking into the hydraulic oil, the drums have to be stored horizontally and in such a way that the drum bungs are wet by the oil. The hydraulic oil is mixed with special additives, which improve the oil quality. If the oil is mixed with water, the additives may lose effect, or in worst case, give negative effect. Corrosion will occur and abnormal wear will lead to breakdown of the system.

Fig. 9


No. 1401-0004-4Feb-2000

Installation of submerged cargo pumpsCONTENTS1 General 2 Orientation in tank2.1 Arrangement on top plate 2.2 Nozzle loads 2.3 Location of brackets for intermediate support(s)

3 Installation of deck trunk and brackets for intermediate and bottom support3.1 3.2 3.3 3.4 3.5 Framo dummy Deck trunk Bracket for bottom support Bracket(s) for intermediate support Recommendation for welding stainless steel to carbon steel

4 Prefabrication of deck piping 5 Assembling of pipe stacks 6 Installation of pumps in tank6.1 Installation of SD100/125/150/200/250 6.2 Installation of SD3000/350 6.3 Additional information for pumps above 20 meter

7 Pump with cofferdam header tank

Framo Mounting Instruction INSTALLATION OF SUBMERGED CARGO PUMPS

No.1401-0004-4 Feb-2000 Page 2 of 22

1 GENERALFigures in this instruction are made for all cargo pumps. It is supposed that a dummy equipment package intended for the pump type to be installed, is available. For further information, see drawings for the actual cargo pump, deck trunk, support, suction well and dummy.

(Speed Torque Controller)

STC

The Framo hydraulically driven submerged cargo pump consists of three main parts:

Top plateTop plate Resilient top plate connection

Deck trunk

The cargo pump is supported by a deck trunk welded to the deck. A special gasket and a resilient bolt arrangement will prevent noise and cargo leakage.

Pipe stackPipe stackIntermediate supportCargo pipe Cofferdam pipe Hydraulic return pipe Hydraulic pressure pipe Cargo stripping pipe Cofferdam check pipe

The pipe stack connects the pump head to the top plate. Dependent on pump length, the pipe stack is supported by intermediate support(s).

Pump headThe pump head is welded or flanged to the pipe stack and supported by the bottom support.

Pump head Bottom support

The cargo tank should be designed with suction well for optimal tank emptying. It should be installed at the aft end of each tank and preferably with tank top sloping towards the suction well. Prefabricated suction well can be quoted for on request.

Suction wellFig. 1


No.1401-0004-4 Feb-2000 Page 3 of 22

2 ORIENTATION IN TANKNote! 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). The overview below indicates how the orientation of the pumps affects location of the suction well, location of pipe stack support(s) (if any) and location of the cargo line and hydraulic line connections.Cargo stripping line Cargo discharge valve Two first clamps resilient mounted

Pilot line Stripping valve Alternative orientation of STC

Cargo line

Cofferdam connection

Service valves Spools to be removed for service

Drop line

C L pipestack

B

h ulk

ea

d

Intermediate support

Bracket for intermediate support

C L

C L Centerline (C L ) to be parallel to bulkhead where the bracket for intermediate support is welded

Bottom support Suction well

Alternative orientation of suction well

Space for service. See dimensional drawing for suction well.

Fig. 2


No.1401-0004-4 Feb-2000 Page 4 of 22

2.1 Arrangement on top plateValves must be placed in areas which are easily accessed by pump operator.Air/inert gas supply for purging of cargo and cofferdam pipe1/2 closing valve with snap-on coupling (1 coupling included for each pump) Free area for service, installation/lifting of pump Air/inert gas supply pressure 6-7 bar Flex. hose with snap on couplings (normal length 2m)

Min. 2000

Cofferdam venting pipe ND15, stainless steel

Purging connection (purging of cofferdam pipe)

Exhaust trap500 500

Drain valve

Purging connection (purging of cargo pipe)

Min. 500

Min. 1500

Fig. 3

2.2 Nozzle loadsTo ensure proper installation and avoid leakage between pump top plate and deck trunk the maximum allowable nozzle loads for the cargo pumps are given below:)25&(6020(17 DSSUR[ [ $3, 6' 6'

($&+ 12==/( )

6'

6'

6'

6'

6'

81,7 N1 N1 N1 N1P N1P N1P

) )

0 0 0

Too high nozzle loads will give leakage, and noise will be generated by mechanical contact between top plate and deck trunk. Nozzle loads on cargo pumps have no influence on rotating parts of the pumps.

Z MZ Y F Z MX MY X FY F X

Fig. 4


No.1401-0004-4 Feb-2000 Page 5 of 22

2.3 Location of brackets for intermediate support(s)Bracket is part of the ship design and supplied by yard. It is important that the yard is aware of the forces acting in the tank area (sloshing, structural deflection etc.). Brackets to be designed according to forces shown in table below:

Centerline to be parallel to bulkhead3803 7N1@ ) >N1@

F2 F1

6' 6' 6' 6' 6'

Fig. 5

High stress concentration

High stress concentration

Acceptable solutionsFig. 6

Not acceptable solutions

Supports for all cargo pumps except SD300 and SD350 may enter the cargo tank through standard man-hole openings. Due to the size the supports of SD300 and SD350 must be placed in tank before the deck is closed. All welding on suction well and deck trunk has to be finished before installation of the brackets.


No.1401-0004-4 Feb-2000 Page 6 of 22

To find pump lenght (L) and location for the bracket(s) relative to the suction well, following calculation(s) has to be done:

Pump length: L = TB + S - C

Lower edge of top plate

2QH LQWHUPHGLDWH VXSSRUW +HLJKW >PP@ $ N [ /

)DFWRU N N

7ZR LQWHUPHGLDWH VXSSRUWV +HLJKW >PP@ $ N [ /!

)DFWRUV N N! !

"

N N "

$ N [ /"

L = S = C = A1 = A2 = H = TB =

Pump length [mm] Gasket, approx. 2 mm. Pump clearance, see page 12 Intermediate support height [mm] Intermediate support height [mm] Deck trunk height [mm] * Height from bottom of suction well to top of deck trunk [mm] * Standard deck trunk height, 500 mm. (High deck trunks complicate cleaning work.)

L

Intermediate support

Approx. 50-100 mm

Deck trunk

Lower edge of intermediate support

H

Final figures (A1, A2 and L) to be sent to Framo as soon as possible.C

A1

A2

TBSuction well bottom

Fig. 7

S


No.1401-0004-4 Feb-2000 Page 7 of 22

3 INSTALLATION OF DECK TRUNK AND BRACKETS FOR INTERMEDIATE AND BOTTOM SUPPORTPrior 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, bottom support brackets and bracket(s) for intermediate support. The following installation procedure is based upon use of Framo dummy.

3.1 Framo dummyThe 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.Laser Top plate dummyLabel ( length of dummy)

Brackets for location of flange connections Adjustment screws for deck trunk height Support dummy

Measuring pipe (one or several sets)

Pipe no.2 (Marked with two white tape rings) Tape rings to be of equal color Pipe no.1 (Marked with one white tape ring)

Support dummy Distance plate

Measuring tape

Fig. 8a Framo dymmy

Fig. 8b Assembling of measuring pipe

LD

Make sure that rubber element is installed.

Framo Mounting Instruction INSTALLATION OF SUBMERGED CARGO PUMPS Calibration of laserThe laser is to be controlled before use to detect any inaccuracy during transportation. Control and adjust the laser as follows: - Grease the laser flange to make turning of the laser easier. - Locate the laser on the top plate dummy installed on the deck trunk. See fig. 16. - Turn the laser on. Mark the spot where the centre of the beam hits the suction well. - Turn the laser 90 and mark where the centre of the laser beam now hits the target. - Repeat the turning in steps of 90 until a full circle is completed, and mark the spots for each step. - The collection of spots should be within a circle of =20 mm. - If not all spots are within this circle, adjust the laser by the two adjustment screws, using a screwdriver. - After the adjustment, re-check the laser as described above. - Continue the above procedure until the accuracy of the laser is as specified above.LaserOFF ON

No.1401-0004-4 Feb-2000 Page 8 of 22

Battery 1,5 volt (Size C)

Adjustment screws

Laser flange

The collection of spots to hit within a circle of =20 mm 20 mm

Mark the spots

CAUTION! Avoid staring straight into the laser beam.

Fig. 10


No.1401-0004-4 Feb-2000 Page 9 of 22

3.2 Deck trunkNote! It is important that the deck trunks are welded into the ship at the latest possible stage to ensure correct pump clearance C, according to page 12.

1

a) Mark pump center b) Cut hole in deck for deck trunk.

b) Position of cargo and hydraulic flange connections for the pump, see pumps dimensional drawing.Edges parallell to centre line C L

Y

X

Position of hydraulic valve

Pump center line

Position of cargo flange Centre line C L

through centre of cargo line and hydraulic flange connections

Fig. 13

Suction wellFig. 11

Y

X

c) If the pump has intermediate support(s):Edge parallel to bulkhead where the intermediate support bracket shall be welded Adjustment screws

Position for laser Holes for measuring pipe

2

When connecting the top plate dummy to the deck trunk, please note: a)Sealing surface has to be protected in order to avoid scratches.

Trunk

Deck trunk

Welding seam must not be orientated in ship's transverse direction

Fig. 14

Fig. 12


No.1401-0004-4 Feb-2000 Page 10 of 22

3

Trunk alignment Laser

4

Height adjustment 8 mm distance plate in the suction well

Adjustment nuts

Position of measuring pipe: Highest point in bottom of the suction well

PUMP SD 100 SD 125 SD 150 SD 200 SD 300 SD 350

230 230 230 300 350 400

Laser beam

5

Spot welding

Spot weld the deck trunk to deck

Pump center

Laser beam

20

Approx. 0,5mmFig. 16

Laser beam to hit within: =20 mm

Measuring pipe not to touch distance plate


No.1401-0004-4 Feb-2000 Page 11 of 22

6 WeldingRemove adjustment screws

7 Checking

Ruler

Laser

R

The trunk is to be welded according to classification requirements.

After finishing the installation of the first trunk, measure the distance TB in 0O, 90O, 180O, 270O at a distance R from the center line with the supplied calibrated measuring tape. Flat bar to be locked to measuring tape.

TB

PUMP SD 100 SD 125 SD 150 SD 200 SD 300 SD 350

R 115 115 115 150 175 200

0

90 1800

0

0

0

Check for correct height and straightness, by using the measuring pipe and laser.

R

270

0

Fig. 17


No.1401-0004-4 Feb-2000 Page 12 of 22

8

Adjustment of procedure. After measuring the first trunk in accordance with 7 , proceed with the next trunk and adjust procedure according to the table below if necessary. The number listed in the table below includes gasket and cargo pump tolerances. Proceed with welding of trunks until recommended height is reached.

6'

6' 6'

6'

6'

6'

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PLQ

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! + -

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&PLQ

7% LV WKH PLQLPXP YDOXH RI 7% / LV WKH VSHFLILHG OHQJWK RI WKH FDUJR SXPS

Ruler

Gasket Approx. 2 mm

Important:R

Install the deck trunk in correct height relative to the suction well. Too low clearance: - Service impossible Too high clearance: - Unacceptable cargo residue.L

TB

Fig. 18

C

(L)


No.1401-0004-4 Feb-2000 Page 13 of 22

3.3 Brackets for bottom supportAll welding on suction well and deck trunk has to be finished before installation of the bottom support brackets.

1

2a SD125/150

Support dummy Brackets

Laser beam

2b SD100/200/300/350

Support dummy

Pump center

3a SD125/150Laser beamBlue tape

3b SD100/200/300/350Laser beamMirror Adjust brackets before welding

0O

Blue tape

0O Mirror

Mark Bolts

Mark

90

O

Bolts

90

O

a

Fig. 19


No.1401-0004-4 Feb-2000 Page 14 of 22

3.4 Bracket(s) for intermediate support

1

2

Laser beam to hit dummy center 0O Bolts

Laser beam

Measuring pipe

90

O

Mirror Blue tape Mark

3C L C L

Pump center

Centerline C L must be parallel to the bulkhead where the intermediate support shall be welded.

Fig. 20

3.5 Recommendations for welding stainless steel to carbon steelSometimes it becomes necessary to weld stainless steel to carbon or low alloyed steel. A typical example is stainless steel wells welded into carbon steel tanks. The dilution of the weld metal by the base material must then be considered to avoid the formation of hard brittle structures. This is done by using a welding consumable with different composition to both base materials. Carbon steel filler metal will result in a high alloyed martensitic microstructure on the stainless steel side of the weld. Filler metal of the same composition as the stainless steel will result in the same microstructure on the carbon steel side. This microstructure will result in extensive cracking, often very difficult to observe. The correct filler metal shall instead be overalloyed stainless steel or Ni-based alloys to secure a ductile weld metal. These filler metals will tolerate a substantial dilution from the carbon steel without hardening. The composition should be specially balanced to ensure that the total alloy content is adequate to accommodate dilution effects and which have a ferrite content sufficient to provide high resistance to hot cracking. Preheating shall not be performed on austenitic stainless steel, since this will promote carbide precipitation in the grain boundaries and the formation of sigma-phase (a hard and brittle phase that dramatically increases the risk of cracking).


No.1401-0004-4 Feb-2000 Page 15 of 22

4 PREFABRICATION OF DECK PIPINGWhen the trunk is installed, the top plate dummy can be used for adjustment/prefabrication of the piping. - Remove the laser from the top plate dummy. - Assemble the brackets for the current connections. - Bolt the top plate dummy to the trunk in correct position (see dimensional drawing for top plate). The dummy can now be used for adjustment of the piping by fixing the pipe flanges to the relevant positions/brackets on the dummy.

Hydraulic piping Cargo pipe Connections for other pipes

Fig. 21

Be careful not to damage the sealing surface on the deck trunk and protect the seal faces by the supplied plywood after this operation.

5 ASSEMBLING OF PIPE STACKSThe pump is to be assembled in a horizontal position. Every pump part is to be supported in at least two points. Note! The pumps must not be in contact with carbon steel.Pump no. Pump no.

Fig. 22

Check that pump no. on all the pump parts are identical. Pump no. is placed on top plate and flange for volute casing. Locate the pump parts in correct positions one after another.

Framo Mounting Instruction INSTALLATION OF SUBMERGED CARGO PUMPSNote ! All pipes must be checked for foreign bodies before connection. Any parts left in the pipes (screws, nuts, plastic bolts rags, etc.) may cause serious damage to the pump. Clean all o-ring grooves and seal faces with a dry rag. Check all seal elements, back-up rings, grooves and seal faces. Pay special attention to the teflon rings and be absolute sure of no deformation nor radial grooves. Never install damaged seal elements. Assemble connection pipe and seals on the flange of lower part. Guide the two parts together. Be careful when the connection pipe enter the hydraulic pressure pipe. Assemble bolts and nuts. Tighten the bolts according to the table below.

No.1401-0004-4 Feb-2000 Page 16 of 22

Bolt, washer and nut Seal rings

Connection pipe

Circlip O-ring Back-up ring O-ring Back-up ring

Fig. 23Cargo stripping pipe -bolts -washers -nuts -seal ring Bracket Cofferdam check pipe -socket bolts -seal ring Option temp. sensor -bolts -washers -nuts -seal ring Hydraulic pipes -bolts -washers -nuts -seal rings -connection pipe -circlip Option vacuum drain -bolts -washers -nuts -seal ring Cargo pipe -bolts -washers -nuts -seal ring

Fig. 24 Split flanges

All screws and nuts have to be assembled with specified torque. If no torque is specified, use the following torque: ACID RESISTANT BOLTS AND NUTS, QUALITY A4-80 M6 9.2 Nm M8 22.3 Nm M10 44.2 Nm M12 76.2 Nm M16 190 Nm M20 370 Nm

Acid resistant bolts are to be coated with Molybdenum disculphide (Molycote) or similar on threads and under bolt heads/nuts prior to assembling.


No.1401-0004-4 Feb-2000 Page 17 of 22

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. Blank off cofferdam check pipe (see fig. 25). The blank flange is a part of the Framo supplied standard tool.Cofferdam check pipe Blank off cofferdam check pipe Air pressure or nitrogen

Relief valveFig. 25 Pressure test of pump

Unscrew the complete relief valve and connect a manometer to the G1/4 connection (not Framo delivery). Connect air/nitrogen supply to the snap-on coupling on the purging connection (flex. hose with snap on couplings is Framo delivery), and increase pressure to max. 3 bar. Stop the air/nitrogen supply and observe the pressurized volume for 15 minutes. Flush the split flanges with soapy water to be sure of no leakage. Reinstall the complete relief valve and assemble the blank flange on the outlet from cofferdam check pipe.


No.1401-0004-4 Feb-2000 Page 18 of 22

6 INSTALLATION OF PUMPS IN TANKThe Framo cargo pumps have two different resilient arrangements on top plate. Installation of each arrangement is described separately.

Preparations: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. PicklingPickling 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 manufacturers procedure for pickling before starting the work.

Blank flangesBlank flanges and seals on top plate shall be left until connection of the pump to the vessels piping systems. The blank flanges on the pumps suction opening and the protection around the pump shaft shall be removed only by the Framo service engineer before water is filled into the tank.

Transport securing (Only on pumps with vacuum stripping pipe)The steel wire on lower vacuum stripping pipe shall also be removed 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 before the pump. Tighten upper nuts and lock nuts to 174 Nm (Fig. 26). If coated surfaces on bracket for support: 1) Assemble upper nut, use 174Nm torque. 2) Retighten to specified torque. 3) Assemble lock nut, use 174Nm torque.Support ring Framo supply Fasteners : Yard supply Material : Stainless Quality : A4-80 Flat washer Support bracket Yard supply Coating touch up Flat washer Upper nut (Torque 174 Nm) Lock nut (Torque 174 Nm)

Deck trunkRemove the flange protection and inspect the sealing surface on the deck trunk flange. Required surface roughness is Ra 1,6 m. If the sealing surface has been damaged (scratches, grooves) during transport or installation, the damages must be removed by careful grinding/ polishing by abrasive paper. Note! If grinding/polishing is required, this must be done according to figure below.

Fig. 26 Bottom and intermediate support

Never grind across seal face

Correct grinding direction

Fig. 27 Sealing surface - deck trunk


No.1401-0004-4 Feb-2000 Page 19 of 22

6.1 Installation of SD100/125/150/200/250Clean the gasket groove in the top plate. Stretch the gasket over the top plate, -take care not to damage the gasket. Install the gasket carefully in gasket groove while the pump is still lying on the ground. Install two guide pins in top plate (180 apart). Install lifting tool on the top plate (supplied by Framo in the toolbox)Two guide pins

Fig. 28

Lift the pump to a vertical position. Preferably two cranes should be used for this operation, one to keep the pump clear of the ground and the other for lifting. The pump shall not be allowed to slide along the ground during lifting. All pumps above 12 metres should be lifted by using a snatch block together with the crane on the lower part of the pump. Minimum length of the wire through the snatch block = 2 x length of the lower part of pump.

Snatch block

Lower part

Upper part

Split pump above 20 meters. See chapter 10.3

Fig. 29

Lower the pump until the top plate rests on the deck trunk. Be careful when the guiding pins enter the deck trunk holes.

Fig. 30

Install rubber bushings and hexagon head bolts under the trunk flange. Use Loctite on the bolts. Tighten bolts in a diagonal sequence to 44 Nm. Remove the two guide pins, and install the two remaining rubber bushings and bolts. Tighten bolts to 44 Nm.

Gasket

Rubber bushing

When pump installation is completed:Check that the distance from pump suction opening to the suction well bottom is according to the table on page 12. Remember: Dont remove any blank flanges.Fig. 31Hexagon head bolt


No.1401-0004-4 Feb-2000 Page 20 of 22

6.2 Installation of SD300/350Clean the gasket groove in the top plate. Stretch the gasket over the top plate, -take care not to damage the gasket. The gasket has to be greased with teflon grease before installation in the top plate. Gasket and grease are supplied by Framo. Install the gasket carefully in gasket groove while the pump is still lying on the ground. Install lifting tool on top plate (supplied by Framo in the toolbox). Lift the pump to a vertical position. Preferably two cranes should be used for this operation, one to keep the pump clear of the ground and the other for lifting. The pump shall not be allowed to slide along the ground during lifting. All pumps above 12 metres should be lifted by using a snatch block together with the crane on the lower part of the pump. Minimum length of the wire through the snatch block = 2 x length of the lower part of pump.

Snatch block

Lower part

Upper part

Split pump above 20 meters. See chapter 10.3

Fig. 32

Two guide pins

Lower the pump until the top plate rests on the deck trunk. Use 2 guiding pins to get the correct position.

Fig. 33

Remove the guiding pins. Assemble bolts, nuts, washers and bushings and tighten bolts in a diagonal sequence to 44 Nm.

When pump installation is completed: Check that the distance from pump suction opening to the suction well bottom is according to table on page 12. Remember: Dont remove any blank flanges.Fig. 34


No.1401-0004-4 Feb-2000 Page 21 of 22

6.3 Additional information during installation of pumps above 20 meterNote ! The pump has to be pressure tested after assembling and installation in tank. That demand an arrangement in tank which give access to the split flanges. Lower the lower part of the pump until the top is approx. 0.5 m from deck trunk.

Fig. 35

Place the installation tool on the deck trunk (see actual tool drawing). Continue lowering until the pumps lower part is resting on the tool. Remove the ring screw and lifting plate. Clean all o-ring grooves with a dry rag, and assemble parts shown in fig. 23 and 24 Before lifting upper part of the pump, assemble guiding bolts on top plate (see fig. 27). Lift the upper part of the pump in position above deck trunk, remove blind flanges and clean the flanges with a dry rag. Continue the lowering and guide it in correct position. Be careful when the connection pipe enter the high pressure pipe. Before connecting lower and upper part of the pump the gasket between top plate and deck trunk must be placed upon the deck trunk. Use the procedure described on page 18 for pressure testing of the pump.

Fig. 36


No.1401-0004-4 Feb-2000 Page 22 of 22

7 PUMP WITH COFFERDAM HEADER TANKPermanent liquid filled cofferdam is used when the submerged cargo pump is handling only one type of cargo (oil production & storage vessels).

Filling of cofferdam- Fill the cofferdam through the headertank until the liquid level stabilises just above low level mark on the sight glass. - Use a ISO VG10 hydraulic oil in the cofferdam. (DIN51524 (1) HL, for instance Shell Morlina Oil 10). Due to expansion and air in the system, the level will stabilize between 2 to 7 days after filling. - The cofferdam volume depends on pump size and pump length. The following formulas give approx. volume required to fill the cofferdam to header tank low level mark : (volume in litres)Header tank

S D 100 SD 125/150 S D 200 S D 250 S D 300 S D 350

(L x 0,6) + 3 (L x 0,6) + 12 (L x 3,7) + 8 (L x 3,7) + 14 (L x 4,3) + 13 (L x 5,1) + 19Fig. 37

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


No. 1401-0005-4Rev. A Mar-2003

Installation/storage of portable equipment

Framo Mounting Instruction INSTALLATION OF PORTABLE EQUIPMENT

No.1401-0005-4 Rev. A Mar-2003 Page 2 of 3

1 STORING ON BOARD

The portable pumping equipment must be stored easy accessible in a clean and dry area. The concentric hose can be stored on brackets on the bulkhead (see fig.1), or on a suitable hose reel, or lying in a shelf. The cargo hose and extension hoses can be stored on a suitable hose reel, or lying in a shelf. The pump and hoses must always be safely supported and fastened in order to avoid wear or damages due to ship movements. It is especially important that the hoses are not hanging or laying over sharp edges, or that sharp objects are placed upon them. The bending radius for the hoses during storage must be according to dimensioning drawings. For TK150 / TK6 control valve + snap-on couplings are delivered in an equipment box. For TK80 control valve is connected to pump, while snap-on couplings are delivered in an equipment box. Equipment boxes are delivered with bracket for installation in fixed location together with the portable pump.Fig. 1

Fig. 2

Portable winch: The portable winch must be safely supported and fastened in order to avoid wear or damages due to ship movements.

Framo Mounting Instruction INSTALLATION OF PORTABLE EQUIPMENT

No.1401-0005-4 Rev. A Mar-2003 Page 3 of 3

2 COUPLING STATIONS FOR PORTABLE EQUIPMENTThe portable pump includes hydraulic hoses with a control valve either connected to the end of the hose(concentric hose) or separately delivered. Standard length of this hoses are 10 and 18 m. Separate extension hoses must be connected between the control valve and the coupling stations (standard length of extension hoses is 10 and 18 m). The hydraulic ring line must be equiped with coupling stations (pressure and return) for connection/ operation of the portable pump. Each coupling station consist of a ball valve with blind flange for pressure connection, and a nonreturn valve with blind flange for return connection. Snap-on couplings are delivered separately in an equipment box, and are only mounted by ship crew when pump is connected for use. The number and location of coupling stations must be selected so that the portable pump can be used in every tank. A coupling station should preferably also be located close to the pump storage, to simplify testing of pump. Installation of coupling stations in hydraulic ring line must be according to figures below. This to avoid extra bending forces from the extension hoses on the coupling stations.

h = sufficient height above ship deck to avoid exceeding the allowable bending radius of the extension hoses, and give easy access for connection of the extension hoses.Fig. 3


No. 1401-0006-4Rev.B Jan-2003

Installation of submerged ballast pumpsCONTENTS1 General 2 Arrangement and orientation in tank2.1 Pump casing 2.2 Location of bracket for intermediate support(s) 2.3 Arrangement on top plate 2.4 Evacuation system

3 Installation requirements 4 Example of pump installation with Framo dummy4.1 4.2 4.3 4.4 Framo dummy Pump casing Bracket(s) for intermediate support(s) Deck trunk

5 Assembling of pipe stacks 6 Installation of pumps in tank6.1 Additional information for pumps assembled during installation in tank 6.2 Filling of liquid in cofferdam

Framo Mounting Instruction INSTALLATION OF SUBMERGED BALLAST PUMPS

No.1401-0006-4 Rev.B Jan-2003 Page 2 of 23

1 GENERALFigures in this procedure are made general for all types of submerged ballast pumps. It is assumed that a dummy equipment package intended for the pump type to be installed, is available. For further information, see drawings for the actual ballast pump, deck trunk, intermediate support and dummy. The Framo hydraulically driven submerged ballast pump consists of: - Pump casing/ Air separator - Pump head - Pipe stack - Top plate - Evacuating system

Pump casing/ Air SeparatorThe pump casing is bolted to a foundation. An ejector is connected at the suction side.

Pump headThe pump head is mounted inside the pump casing.

Pipe stackThe pipe stack consists of a hydraulic pipe stack and an arrangement with pipe and cable for the evacuating system. The hydraulic pipe stack connects the pump head to the STC-valve. Supports on the pipe stack prevent horizontal movement and allow for vertical expansion.

Top plate/ Control valvesThe pipe stack penetrates the top plate. A sealing device (bellow) between top plate and pipe stack allows the pipe stack to expand. The evacuation control system is attached to the top plate.Fig. 1



2 ARRANGEMENT AND ORIENTATION IN TANK

Fig. 2

The suction/discharge flange position has to be informed to Framo as soon as possible making it possible to finalize the manufacturing drawings. See pump dimensional drawing.



2.1 Pump casingNozzle loadsTo ensure good installation and to avoid high tensile forces on pump casing, the maximum allowable nozzle loads to be as follows:MAX. ALLOWABLE FORCES/MOMENT (approx. 2 x API 610) EACH NOZZLE Fx [kN] Fy [kN] Fz [kN] Mx [kNm] My [kNm] Mz [kNm] SB200 8"Discharge

SB300 10" 12"Discharge



24"Suction

Suction

Suction

Suction

5,0 4,0 3,2 3,6 1,8 2,6

6,8 5,4 4,5 5,0 2,5 3,8

8,0 6,7 5,4 6,1 3,0 4,6

9,0 7,2 5,8 6,4 3,2 4,8

10,2 8,5 6,7 7,4 3,7 5,4

11,6 9,8 7,6 8,3 4,2 6,1

12,9 11,1 8,5 9,3 4,8 6,8

15,6 13,8 10,2 11,1 5,9 8,2

Fig. 3



2.2 Location of bracket for intermediate support(s)Bracket is part of the ship design and supplied by yard. It is important to be aware of the forces acting in the tank area (sloshing, structural deflection etc.). Brackets to be designed according to forces shown in table below:

PUMP TYPE SB200 SB300 SB400 SB600

F1 [kN] 7 7 11 11

F2 [kN] 12 12 18 18

Fig. 4

Fig. 5

Supports for all ballast pumps may enter the ballast tank through standard manhole openings.



To find the pump length (L) and location of the bracket(s), following calculations have to be done:

One intermediate support A1 = 0,4 x L +/- 500

Two intermediate supports A1 = 0,3 x L +/- 500 A2 = 0,6 x L +/- 500

Tree intermediate supports A1 = 0,25 x L +/- 500 A2 = 0,5 x L +/- 500 A3 = 0,7 x L +/- 500

L = Pump length [mm] A1-A3 = Intermediate support height [mm] H = Deck trunk height [mm]

Final figures (L, A1 and A2 ) to be sent to Framo as soon as possible.

Fig. 6



2.3 Arrangement on top plateTrunk on deck

Fig. 7

Trunk in void space

Fig. 8



2.4 Evacuation system

Fig. 9

The start and stop of the ejector is controlled by two electric level switches located in the pump casing. The signal goes to a solenoid valve(Exi) connected to the PLC. The solenoid valve controls a pneumatic valve for start and stop of the ejector. Note! In order to protect the pneumatic valves it is necessary to place a filter/water trap in the air line.



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 check the tolerances. For height control see fig. 11.

Fig. 10



LD

= Height from top of pump casing to top of deck trunk

AD1- = Intermediate support height. AD3 Height from top of pump casing to lower edge of intermediate support dummy.

Fig. 11



4 EXAMPLE OF PUMP INSTALLATION WITH FRAMO DUMMYThe 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 help you 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 dummyNote! 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.

Fig. 12

Framo Mounting Instruction INSTALLATION OF SUBMERGED BALLAST PUMPS Calibration of laserThe lasers is to be controlled each time before use to detect any inaccuracy during transportation. Control and adjust the lasers as follows: - Grease the laser flange to make turning of the laser easier. - Locate the laser on the top plate dummy installed on the deck trunk. - Turn the laser on. Mark the spot where the centre of the beam hits the target. - Turn the laser 90 and mark where the centre of the laser beam now hits the target. - Repeat the turning in steps of 90 until a full circle is completed, and mark the spots for each step. - The collection of spots should be within a circle of =20 mm. - If not all spots are within this circle, adjust the laser by the two adjustment screws, using a screwdriver. - After the adjustment, re-check the laser as described above. - Continue the above procedure until the accuracy of the laser is as specified above. CAUTION! Avoid staring straight into the laser beam.


Fig. 13



4.2 Pump casing 1Pilot hole

2 Pump casing- Place the pump casing in the center marked. - Fasten the laser to the pump casing dummy and place it on top of the pump casing. - Turn the pump casing dummy in steps of 90 until a full circle is completed as described on page 12. The collection of spots should be within a circle of = 20 mm. - If necessary tilt the pump casing until the laser beam hits the center of pilot hole. - Drill holes in foundation and fasten the pump casing with counter nuts.

- Mark the center of the pump casing. - Measure the distances from this center to the bulkhead/frames (x,y). - Use these distances (x,y) to find the center of the deck trunk in the deck. - Cut a pilot hole 250 for the deck trunk. - Calibrate the laser according page 12.

Fig. 14

Fig. 15



4.3 Bracket(s) for intermediate support(s) 3 Adjustment and weldingNote! Pump casing has to be protected against weld spatter, sand blasting and painting. - Connect the intermediate support dummy to the bracket. - Alignment (by use of mirror) - Height adustment

Fig. 16



4.4 Deck trunk 4 Final hole for deck trunkConnect the top plate dummy with plexiglass to the deck trunk. Adjust trunk until the laser beam hits the center marked on plexiglass. Mark outside diameter of deck trunk. Cut final hole in deck for deck trunk. Position of deck trunk The deck trunk must be connected to the top plate dummy with connections for STC valve in correct position, see dimensional drawing of pump.

Fig. 17

Fig. 18

5 Adjustment- Move the laser to the top plate dummy and calibrate the laser (ref. page 12). - Trunk alignment - Height adjustment - Spot welding

6 Welding and controlThe trunk is to be welded according to classification requirements. Frequently check the position/alignment during welding.

Fig. 19

Fig. 20

According to practical experience the distance between the top flange of deck trunk and the deck will normally be reduced about 3-5 mm caused by the added heat when welding. If such a reduction is expected, this must be taken into consideration.



5 ASSEMBLING OF PIPE STACKPumps delivered in two parts have to be assembled in a horizontal position. Every pump section is to be supported in at least two points. Note! All ballast pumps type SB400 and SB600 delivered in two or three parts and SB200/SB300 pumps with total length above 20m have to be assembled during installation, see chapter 6.1.

Fig. 21

Note! The pumps must not be in contact with mild steel during assembling. Check that the pump no. on all the pump sections are identical. Pump no. is placed on top plate and pump head flange. Place the pump sections in correct positions one after another.

Framo Mounting Instruction INSTALLATION OF SUBMERGED BALLAST PUMPSNote ! All pipes must be checked for foreign bodies before connection. Any parts left in the pipes (screws, nuts, plastic bolts, rags, etc.) may cause serious damage to the pump. Clean all o-ring grooves and seal faces with a dry rag. Check all seal elements, back-up rings, grooves and seal faces. Never install damaged seal elements. Assemble connection pipe and seals on the flange of lower part. Guide the two parts together. Be careful when the connection pipe enter the hydraulic pressure pipe. Assemble bolts and nuts. Tighten the bolts according to the table below.


Fig. 22

All screws and nuts have to be assembled with specified torque. If no torque is specified, use torque according to following: ACID RESISTANT BOLTS AND NUTS, QUALITY A4-80 M6 9.2 Nm M8 22.3 Nm M10 44.2 Nm M12 76.2 Nm M16 190 Nm M20 370 Nm

Acid resistant bolts are to be coated with Molybdenum disculphide (Molycote) or similar on threads and under bolt heads/nuts prior to assembling.

Framo Mounting Instruction INSTALLATION OF SUBMERGED BALLAST PUMPSLevel switch cable:


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. 23

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 sufficient margin. Remount the cap.

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 pressure to 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



6 INSTALLATION OF PUMPS IN TANK Preparations:Note! Welding, sandblasting grinding and coating must be finished and tank must be properly cleaned before installation of pump in tank.

PicklingPickling is 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 manufacturers procedure for pickling before starting the work.

Blank flangesBlank flanges and seals on top plate flanges shall be kept on until connection of the pump to the vessels piping systems.

Special tools required for installation are supplied by Framo in the tool box.See tool list for descriptions.

Intermediate support(s)Install the support(s) on the bracket(s) before installation of pump. 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 trunkRemove the flange protection and inspect the sealing surface on the deck trunk flange. Install two guide pins in top plate (180 apart). Locate the sealant joint on the deck trunk flange (ref. fig. 32b).

Fig. 26

Pump casingRemove protections from top flange, ejector pipe and level switch pocket. Inspect the sealing surfaces. Install two guide pins (180 apart) and 10 stud bolts. Put the gasket on the top flange.

Regarding SB200:Remove the anodes in pump casing before installing the pump (fig. 27).Fig. 27



Lifting of pumpsPumps shipped as one complete unitLift the pump to a vertical position. Preferably two cranes should be used for this operation, one to keep the 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

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 the pump. Length of the wire through the snatch block = 2 x length of the lower part of pump.

Fig. 29

All SB400/SB600 (regardless of pump length) and SB200/SB300 with total length above 20mEach section has to lifted separately. See chapter 6.1 for installation in tank.

Fig. 30

Framo Mounting Instruction INSTALLATION OF SUBMERGED BALLAST PUMPS- 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

- Remove transport bracket (belonging to toolbox) - 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. 32a

Fig. 32b

Note! Transport bracket and guide pins should be included in toolbox when installation is completed.

Framo Mounting Instruction INSTALLATION OF SUBMERGED BALLAST PUMPS- Remove the cap on evacuating control unit. - Connect cables according to el. diagram. - Remount the cap.


Note! When pump installation is completed. Do not remove any blank flanges before final connection to the piping system.

Fig. 33

6.1 Additional information for pumps assembled during installation in tankNote ! The pump has to be pressure tested after assembling and installation in tank. This requires an arrangement in tank which gives access to the flange connections in pipe stack. Lower the lower part of the pump until the top is approx. 0.5 m from deck trunk.Fig. 34

Install the installation tool on the deck trunk (see actual tool drawing). Continue lowering until the pumps lower part is resting on the tool. Secure the lower part before removing the lifting tool. Clean all o-ring grooves with a dry rag, and assemble parts shown in fig. 22. Before lifting upper part of the pump, assemble guiding bolts on top plate (see fig. 32a). Lift the upper part of the pump in position above deck trunk. Remove blank flanges and clean the flange connections with a dry rag. The gasket between top plate and deck trunk must be placed upon the deck trunk. Continue the lowering until the distance between the flanges is 50-100 mm. Install lifting bolts (toolbox) and lift the lower part by using the lifting bolts. Be careful when the connection pipe enters the high pressure pipe. For assembling of flanges, see page 17. Regarding the level switch cable, see chapter 5. Pressure test the pump.Fig. 36 Fig. 35



6.2 Filling of liquid in cofferdamAll the SB-pumps have liquid filled cofferdam. - Cofferdam liquid: Ethylene glycol or propylene glycol* : 50-60 % Use pure glycol without additives. Commercially available automotive anti-freeze should never be used. Some of the additives in anti-freeze tend to form deposits on seal parts and thereby causing failure on the seals. Corrosion inhibitor (Rocor NB Liquid or equal) : 0.9% (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. Demineralised water: Freezing point Freezing point ~ - 35C < - 40C 40-50% v. 50% glycol v. 60% glycol

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

Filling:- Install the drain tool and unscrew the drain plug. Connect a hose to the drain tool. It is then possible to fill the cofferdam through the hose while venting at the header tank. Fill the cofferdam until liquid level stabilises at max. level mark on the sight glass.Fig. 37

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

The cofferdam volume depends on pump type and pump length. The following formulas give approx. volume (in litres) required to fill cofferdam to low level mark in header tank:

Pump type SB200 SB300 SB400 SB600

Pump head 2,5 80 95 125

Pipe stack L x 0,5 L x 3,5 L x 3,5 L x 3,5

Header tank 2,5 10 10 10

Total 5 + (L x 0,5) 90 + (L x 3,5) 105 + (L x 3,5) 135+ (L x 3,5)

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

* Other names for ethyleneglycol: monoethyleneglycol, 1.2 ethanediol, ethanediol. Other names for propyleneglycol: monopropyleneglycol, 1.2 propanediol, propanediol.

Framo Mounting Instruction Installation of hydraulic power unitClosed loop system

No. 1401-0034-4Rev.B Jan-2003

CONTENTS 1 2 3 4 5 6 7 8 9 General Arrangement Service space and lifting arrangement Ventilation and heat dissipation Foundation and mounting Cooling arrangement Cable/starter cabinet for electric equipment Starting system for diesel engines Fuel system

10 Exhaust

Framo Mounting Instruction INSTALLATION OF POWER UNIT, CLOSED LOOP


1 GENERALThe hydraulic power unit (HPU) delivers oil to the main pressure line and consists of the following main parts: - Electric driven hydraulic power packs - Diesel driven hydraulic power packs - Main hydraulic oil filter - Hydraulic oil cooler - Common foundation - Enclosure for separating high pressure hydraulic oil from hot surfaces. A hydraulic power pack consists of a hydraulic pump with a built on pulsation damper, either driven by an electric motor or a diesel engine. Each hydraulic power pack is resilient mounted and exhaust, fuel and water connections are delivered with flexible connections. The auxiliary hydraulic unit consists of a hydraulic system tank and electric driven feed power packs.

Fig. 1 Hydraulic power unit (HPU) with 2 diesel driven and 2 electric driven hydraulic power packs.

Normally the hydraulic power units are supplied as shown in fig. 1, but they may also be delivered with the auxiliary unit as a separate item or with the auxiliary unit, power packs and filter/cooler unit delivered separately.


No.1401-0034-4 Rev.B Jan2003 Page 3 of 14

2 ARRANGEMENTNormally 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 room and diesel engines/electric motors will be located in the engine room. 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.

Fig. 2 Recommended HPU room arrangement

Note! High pressure piping/flanges to be segregated from ignition sources (exhaust, electric starters, etc.) 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 a higher deck level but not more than 8 meters above the hydraulic power unit. This is limited by the maximum allowable drain oil pressure.

Fig. 3 Auxiliary unit located above the hydraulic power unit



3 SERVICE SPACE AND LIFTING ARRANGEMENTService spaceTo have access for service, a minimum free space is required around: Filter Hydraulic oil cooler Hydraulic pumps Electric motors/diesel engines

Please note that the required dimensions for service space shown in the dimensional drawings are absolutely minimum.Fig. 4 Service space

There must also be space for:Correct location of ventilation ducts Cable trays Lifting tools Electric starters Local control panel

Ref. fig. 6, 8, 9 and 10.

Fig. 5 Service space

Framo Mounting Instruction INSTALLATION OF POWER UNIT, CLOSED LOOP Lifting arrangement


Lifting arrangement is yard responsibility and must be installed above each power pack and the hydraulic oil cooler. Monorail is recommended above the diesel engines and electric motors. Approximately weights of the major components: Electric motor: Diesel engine: 2000 kg 2500 kg Hydraulic pump (single): 400 kg Hydraulic oil cooler: 1400 kg

Fig. 6 Space for lifting

4 VENTILATION AND HEAT DISSIPATIONIt is important that the power unit gets sufficient air supply according to motor size and number of motors. Yard is responsible for: - Sufficient ventilation capacity - Correct direction of air flow - Acceptable air temperature - Clean and water free air

CapacityCalculation of necessary ventilation capacity is yard responsibility, but approximate air consumption is given in fig. 7. For calculation of radiated heat see technical data. This curve is based on temp. increase T = 10C. Example: 3 x Diesel engines 400 kW 2 x Electric motors 400 kW Total 1200 kW Total 800 kW Total : 9 m3/s : 4 m3/s : 13 m3/s

Required air flow - Power Unit RoomInstalled power P (kW) 3500 3000 2500 2000 1500 1000 500 0 04

Electric motors

Diesel engines with water cooled manifold. Cooling and combustion air

5

9

10

15

20

25

Required air flow V (m3/s)

Fig. 7

Framo Mounting Instruction INSTALLATION OF POWER UNIT, CLOSED LOOP Air distribution


The air should be distributed to all parts of the room to avoid pockets of stagnant hot air and any oil vapour from crankcase ventilation. Arrangement for separating the hydraulic side from motor side with ventilation ducts on both side is shown fig.8. When arranged like this, the ventilation capacity for the hydraulic room will be reduced.

Fig. 8 Ventilation/Service arrangement

Alternative location of venting duct for correct air flow:

Fig. 9 Totally enclosed electric motor

Fig. 10 Open drip proof electric motor

Framo Mounting Instruction INSTALLATION OF POWER UNIT, CLOSED LOOP Noise reduction


To avoid noise transmission to surrounding areas, some basic requirements to the power unit room must be fulfilled if the HPU is installed in critical interface area. Key items are: - Hydraulic room (with entrance of double door type). - Noise trap on in- and outlet of ventilation in order to achieve effective absorption of high frequency noise. - Flexible and air tight penetrations for pipes and cables. - Critical interface areas such as bulkheads against accommodation areas should be covered completely by noise absorbing material. Ref. fig. 11.

Fig. 11 - Noise reduction



5 FOUNDATION AND MOUNTINGThe hydraulic power unit foundation to be welded (only outside) to a rigid deck structure and filled with concrete to prescribed level. Gutter and drain possibility is recommended (Yard supply). Yard extension of shield is shown in fig. 12.

Fig. 12

Framo Mounting Instruction INSTALLATION OF POWER UNIT, CLOSED LOOP 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 are supplied 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.



6 COOLING ARRANGEMENTThe hydraulic oil is cooled by sea water or fresh water automatically controlled by an electrically operated on-off valve. The valve is operated from the Framo PLC (Programmable Logic Control). The cooling water flow and max. pressure must be in accordance with the technical data given for the system. Note! - Too low water flow through the cooler may cause corrosion/fouling problems. - Too high flow may cause erosion problems.

The water flow is controlled by means of orifices at the water inlet and outlet side of the hydraulic oil cooler. This orifice is calculated and delivered by Framo. To verify that the flow is correct, differential pressure between the two test points must be measured. If differential pressure is out of the tolerances given in technical data, Framo must be contacted.

Fig. 14 Cooling system arrangement

When the power unit is installed above sea water level and sea water is used as cooling medium, piping at the outlet side must be routed above oil cooler and a vacuum breaker must be installed. Sea water piping should have sufficient zinc anodes.



7 CABLE/STARTER CABINET FOR ELECTRIC EQUIPMENTRecommended cable routing:

Fig. 15

The hydraulic power packs are resilient mounted and therefore allowed to move relatively to the foundation. Accordingly, cable trays and their supports must be connected to the foundation and not to the hydraulic power packs. Welding on electric motors are prohibited. The cables should be arranged to allow for removal of electric motors. The starter cabinet should be located outside the hydraulic room (ref. fig.8).

Wiring between hydraulic power unit and local diesel engine control panelTo secure optimal performance and running conditions of the diesel engine, following details must be noted (ref. fig. 8): - Individual screened cables to be used for pick-up and actuator. - The screens to be terminated to dedicated terminals, not to ground. - Max. cable length and min. cross section to be respected.

8 STARTING SYSTEM FOR DIESEL ENGINESAir startingThe piping from the reduction valves to the starter shall be as short as possible in order to limit pipe losses. Starter motor is supplied with a flexible hose. All connections should be made up with Loctite pipe sealant or equivalent. Teflon tape should not be used in starting air systems. Design the piping to ensure that drain does not enter the starter motor. Install a drain valve at lowest point (see fig.16).Fig. 16

Framo Mounting Instruction INSTALLATION OF POWER UNIT, CLOSED LOOPElectric starter:


- Only starter type battery should be used in order to provide sufficient starting current with limited internal voltage drop. Refer to technical data for the project regarding recommended battery capacity. - Installation and charging of batteries must comply to class requirements with respe

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FRAMO Mounting Instruction