Framo SubmergedCargoPumps

No.100000104
Rev.I08Jun04/AGAa

PurgingInstruction

CONTENTS
1 2 3 4 5 6 Howtopurgethecofferdam Purgingintervalsloggingofpurgingresult Evaluationofthepurgingresult Troubleshooting Precautionstobetakenwhenhandlingspecialtypesofcargoes Exampleofpurgingform

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Thisproceduredescribespurgingofsubmergedcargo pumpswithdrycofferdam.(Forsubmergedcargopumps withliquidfilledcofferdam,refertoinstruction100001024.) Thecargopumpcofferdamisessentialforsegregationof thepumphydraulicsectionfromthecargoandforseal monitoring.Purgingtobecarriedoutatregularintervalsfor thepurposeof: Leakageratedetection Conditionmonitoringoftheshaftsealsystem Avoidthatleakagesareblockingthecofferdam

1HOWTOPURGETHECOFFERDAM
CAUTION: Exhaustgasandliquidmaybehazardous. Wearsafetygearandavoidcontactwithdrainfromexhaust trapandventingline.

Preparation:
1) Placeasuitablecontainerunderneaththeexhausttrapto collecttheleakage. 2) Checkthatdrainvalveatbottomofexhausttrapisnot blocked. 3) Drainthepurgingmediumsupplylineforcondensed water. 4) Connectpurginghose(max.supplypressure7bar).

Purging:
5) Startthepurgingbyopeningthevalveatpurgingmedium supplyline.

Note! Areliefvalveisfittedatcofferdampurgingconnection.This issetat33,5bartolimitthepurgingpressureforprotection ofthepumpseals.Asmallleakagefromthereliefvalveis normalwhenliquidispurgedfromcofferdam.Thevalvewill alsoopenifthecofferdamisblocked.

6) Checkthatexhaustgasiscomingoutoftheexhausttrap ventline(toverifythatcofferdamisopen).

CAUTION! Exhaustgasandliquidwatchout!
7) Purgecofferdaminseveralsequencesifrequired. Drainexhausttrapbetweeneachsequence. 8) Disconnectpurginghose. 9) Closeexhausttrapdrainvalve.
Fig.1

10)Logtheamountofleakage,evaluatetheresult.

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Note! Forhandlingspecialcargoes,ref.chapter5.

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2PURGINGINTERVALS,LOGGINGOFPURGINGRESULT
LOADING 1. Shortlybefore loading. VOYAGE 1. 12daysafterloading. 2. Ifnoleakageatstep1,purgeevery fortnight. 3. Ifleakageisdetectedatstep1,orata laterstageduringthevoyage,purgethis pumpeveryday. 4. Ifpumpsareusedforcargocirculation duringthevoyage,thecofferdammust bepurgedbeforestartandafterstop. DISCHARGE 1. Shortlybefore discharging. 2. Shortlyafter discharging.

Note! Neglectingofpurgingcanresultinablockedcofferdamandlackofleakagecontrol.
Thepurgingformshouldbefilledinwiththeresultsfromeverypurgingoperation.Eachhorizontalline intheformrepresentsonecargoinonetankfromloadingtilldischarging.Ifashiploadsand dischargessometanksmorefrequentlythanother,anextraformshouldbefilledinforthosetanks.

ExampleofFRAMOpurgingform

FilledinpurgingformtobesenttoShipownerandtoFramo(purging@framo.no). (Greencopyfortheship,redcopyfortheShipownerandwhitecopyforFramo.)

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Shipscrewtoevaluatethepurgingresultsandtotakenecessaryactionhoweverincasethe shipscrewneedsadvice,contactaFramoServiceStation.

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3EVALUATIONOFTHEPURGINGRESULT 3.1Cargoleakage
Asmallleakagerateofuptoabout0.5l/day (andhigherwithlightcargoes)duringpump operationisnormal. Acceptableleakageratedependsonthetypeof cargoandpossibleconsequencesincaseof leakage. Riskforcloggingofpumpcofferdam Cargoeslikenaphtha,condensateetc. penetratestheshaftsealsmoreeasilythan lubricatingoils,vegetableoilsandotherviscous cargoes. Itisthereforerecommendedtocarefullymonitor theleakagerateoveraperiodoftime, preferablewithdifferenttypeofcargoes. Forcriticalcargoes,whentheleakagerateis about2litres/dayorhigher,thepumpmustbe purgedacoupleoftimesdailyandservice (pressuretestrepair)carriedoutatfirst opportunity. Intensifythepurgingiftheleakagerateis exceedingacceptablelimits.Ifthisisnot sufficienttokeeptheleakageundercontrolit must,dependingonthenatureofthecargo,be consideredtodischargethetankusingthe portablepump. Cargoleakagetocofferdamnormallyindicates shaftsealleakage.Buttheleakagemightcome fromflangeconnectionsordamage(cracks/pin holes)inpump/pipestack(ref.chapter4, Troubleshooting). Thedevelopmentofacargoleakagecanbe monitoredifpurgingisdoneaccordingto instructions.Therebymaintenanceworkcanbe planned,andunexpectedshutdowndueto leakagecanbeavoided.

3.2Hydraulicoilleakage
Hydraulicoilinthecofferdamnormally indicatesshaftsealleakage,butmightcome fromflangefacesealsinpipestack/pump headordamageinthepipestack/pump head. Asmallleakagerateintothecofferdamupto about10ml/h(0.25l/day)fromthe mechanicaloilsealorlipsealduringpump operationisnormal.Forshortperiodsoftime, higherleakagepeakscanoccur. Iftheleakagerateisincreasingabove acceptablelevel,thepumpmustbepurgeda coupleoftimesdaily,andinspectedassoon aspossibletofindthereasonfortheleakage. Intensifythepurgingiftheleakagerateis increasingabovetheacceptablelevel.Ifthis isnotkeepingtheleakageundercontrol, closethehydraulicservicevalve.Depending ofthenatureofthecargoconsidertousethe portablepumptodischargethecargo.

3.3Blockedcofferdam
Ingeneralwedonotrecommendtooperate thecargopumpwithblockedcofferdam. Foradvice,dependingoftypeofcargoetc., contactaFramoServiceStation.

Note! Alwaysremembertopressuretestthecofferdamwith3bartolocatetheleakagepriortoany dismantlingofthecargopump.

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4TROUBLESHOOTING
Warning: Topreventdamagefromhazardouscargoes,takenecessaryprecautions,wearsafety gearandavoidcontactwithspray/gases.
Symptom:
Notpossibletopurgethe cofferdam(noair,inert gasorliquidcomingoutof thecheckpipewhen purging) (Seealsochapter1)

POSSIBLEREASON:
a) Noorinsufficient purgingmediumsupply b) Blockedcofferdam system

Remedy:*)
a) Checkvalves,hoseconnectionsand purgingmediumreliefvalve(openat approx.3bar). b) Checktheexhausttrapandthepipingon deckforblockage.Openifpossible. b1)Disconnectcheckpipefrompumpunit (lowersealhouse)watchoutforpossible pressurizedliquidincofferdam!! Bycarefullypurgingcheckiftheblockageis locatedinthecheckpipeorinthepump/ pipestackcofferdam. Dependingonthenatureofthemedium blockingthecofferdamsystemusesteamor solventtodissolvetheblockage. Dismantlingofpumpmightberequired.

Note! Incasesteamisusedin attempttoclearablockage inpumpcofferdamsystem payspecialattentionnotto overpressurizethe pump/pipestack

Note!Pressuretestpumpafterassembly.
Cargoleakagetopump cofferdam. (Seealsochapter1) General Pressuretestpumpcofferdamsystematapprox. 3bar. Checkforleakageifrequiredspraywithsoapy watertolocatetheleakage.

Note! Alwayspressuretestpump priortoandafter dismantling.Thisisrequired tolocatepossibleleakage andtoconfirmnoleakage uponcompletionofrepair.

a)Replacecargosealset. a)Worncargoseal Also,carefullycheckceramicsleevefor NoteIfnoleakageis possibledamagewear. detectedbypressuretest itislikelythatthecargo leakagetocofferdamis causedbyworncargo seal.(theupperseallipis sealingwhenpressurizing cofferdam). b)Leakingsealelementin flangeconnection b)Checkforlooseboltsandforpittingcorrosion insealfacesincaseofcorrosionrepairis required. Whenassemble,renewdamagedseal element. c)ContactaFramoServiceStation.

c)Crack/pinholeinpiping
*)Ref.instructionformaintenanceandrepairforactualpump.

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Symptom:
Hydraulicoilleakageto pumpcofferdam. (Seealsochapter1)

Possiblereason:
General

Remedy:*)
Drainthepumpreturnsidepriortodismantling. Disconnectpumphead/unitfrompipe stack/casing. Pressurizepumpunitreturnsideatapprox4bar andcheckforleakagetocofferdamside. Pressuretestpumppipestack/casingatmax7 baroncofferdamsideandcheckforleakageto returnside. a)Replaceshaftseal(replacedsealtobe reconditionediffeasible) b)Checksealingsurfaceforpossibledamage repairifdamaged. Whenassemble,renewdamagedseal element. c)ContactaFramoServiceStation.

a)Leakingshaftseal b)Leakingsealelementin flangeconnection.

c)Crack/pinholeinpiping
*)Ref.instructionformaintenanceandrepairforactualpump.

Note! Evaluateifchangedpartsassleeves,mechanicalsealsetc.arepossibletorecondition. SendthesepartstoaFramoServiceStationandaskforanevaluation.

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5PRECAUTIONSTOBETAKENWHENHANDLINGSPECIALTYPESOF CARGOES
Themainruleistohavethecofferdamclean,dryandventedtoatmospherethroughtheexhausttrap ventline,inordertodetectleakageseasily.However,whenhandlingcertaingroupsofcargoesitmay beanadvantagetofillthecofferdamwithliquidtoimprovetheseallifetimeandtoavoidsolidifying cargoblockingthecofferdam.Recommendedtypeofliquidtobefilledintothecofferdamforsome groupsofcargoesisgivenbelow. Thisisageneraladvice,onlyexperiencecandefinewhichliquidgivesthebestresultforthegreat numberofdifferenttypesofcargoes.

Acidcargoes
Afterdischargingandpurgingisfinished,it maybeanadvantagetocirculatefresh waterthroughthecofferdamtoremoveall residuesafteraleakage.

Phenol,causticsodaetc.
Acirculationofhotwaterthroughthecofferdam canavoidclogging.

Note! Rememberthatsomeofthesetypesof cargoesareveryhazardous. Heatedoilproducts(fueloil,crudeoil)

Fillcofferdamwithdieseloil/whitespirittokeep anyleakageintocofferdaminliquidform.(Thisis especiallyimportantafterstrippingandduring tankcleaning.)

Polymerisingcargoes.(TDI,MDI)
Fillcofferdamwithdioctylphthalate(DOP) tolimittheriskofblockingthecofferdam.

Crystallizingcargoes(molasses,etc.)
Fillcofferdamwithfreshwater.The cofferdammayalsobearrangedwitha smallwatercirculation.

Filling
Tofillliquidinthecofferdam,disconnectthe exhausttrappipingfromthepumptopplate.Using asuitableadapter,filltheliquidthroughthe cofferdamcheckpipe.Openthepurging connectiontoventilatethecofferdamduringfilling. (Connectanopenfemalecouplingorsimilar).
Fig.2

Circulation
Acirculationofliquidthroughthecofferdamcan bearrangedinthefollowingway: Connectliquidsupplytothepurgingconnection. Thesupplylinemustalsobeequippedwitha valvetoregulatetheliquidflow. Opendrainvalveontheexhausttrap,and collectthereturnliquidhere.

Note! Whenfillingorcirculatingliquidinthecofferdam, itisimportantthatthehydraulicoilreturnpressure alwaysishigherthanthepressureinthe cofferdam.Thisisespeciallyimportantonhydraulic systemswithnonpressurisedreturnline.

Fig.3

Solidifyingcargoes(incargotankswithheatingcoils)

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Topreventthecargotogetsolid(freeze)insidethesuctionwell,circulatethecargoatintervalsby startingthecargopump.

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6EXAMPLEOFPURGINGFORM