Heavy Fuel Oil supply unit

Quick start guide

Heavy Fuel Oil supply units

INTRODUCTION

TABLE OF CONTENTS

This instruction manual is intended for training and marketing purposes only.

1. Activating pump shaft seal lubrication (Seal Guard).....................4 2. Inspecting fuel valve positions....................................................5 3. Venting suction filters.................................................................6

The instruction manual delivered with each unit is the only correct instruction manual to be used. Auramarine Ltd. assumes no liability for any damages resulting from inaccurate information found in this instruction manual.

4. Inspecting instrument valves......................................................7 5. Activating fuses and thermal relays.............................................8 6. Starting feeder/supply pumps.....................................................9 7. Venting the deaeration tank......................................................10 8. Checking suction and feed pressure.........................................11 9. Starting the booster/circulation pump.......................................12

Warning!

Note!

Orange boxes contain warnings and reminders.

Blue boxes contain comments and user instructions.

10. Checking booster/circulation and outlet pressure gauges...........13 11. Adjusting viscosity....................................................................14 12. Checking the steam/thermal oil regulator valve..........................15 13. Testing equipment and alarms..................................................16 14. Starting and running the engine on MDO..................................17 15. Switching to the use of HFO.....................................................18 16. Switching to the use of MDO.....................................................19 17. Shutting down the system.........................................................20

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1. Activating pump shaft seal lubrication (Seal Guard)

2. Inspecting fuel valve positions

• Ensure that Seal Guard has a functional gas cartridge and oil.

• Ensure that the heating media is not turned on.

• Activate the pump lubricator (Seal Guard) 24 hours before starting for the first time by turning the switch to 9. • Not all pump models come with Seal Guard – if you are using one without Seal Guard, please go straight to Section 2.

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If Seal Guard is not activated in time, it may cause the pump shaft seals to leak.

• Open the required fuel valves according to the PI diagram. • Select MDO.

There are also inlet and outlet valves on the outside of the unit. Start-up and testing are done using MDO.

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3. Venting suction filters

4. Inspecting instrument valves

Figure 1

Figure 2

• Open the venting screw (Figure 1) and ensure that the oil is flowing. • The suction pressure gauge (Figure 2) should read > 0 bar (usually 0 –1 bar).

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Remember to vent all suction filters and then close them after venting.

• Open the air valves and ensure that there is adequate air pressure. • Check the automatic filter air pressure gauge to see whether the air pressure rises to approximately 4 bar. (Note! Not all filter models come with a pressure gauge.)

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5. Activating fuses and thermal relays

6. Starting feeder/supply pumps

1 Figure 1

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Figure 2 3

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• Ensure that the main switches are set to zero – otherwise, the cabinets will not open (1). • Activate the electrical cabinet fuses (2) and thermal relays (3). • Ensure that the drive switches are set to zero (4). • Turn on the power with the main switch (5). • Reset the alarms.

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Ensure that all drive switches are set to zero before switching on the main power. After resetting, one of the alarms may still be active – this is normal. The lights should go off when the unit is started.

t • Ensure that MDO is flowing into the pump (see Section 3). • Test run the electric pumps. Ensure that the motors are rotating in the right direction. If the rotation direction is wrong, contact an electrician. • If the rotation direction is right, leave one of the pumps running.

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Ensure that the electric motor is rotating in the right direction (always clockwise). Never run the pump ”dry”.

8. Checking suction and feed pressure

7. Venting the deaeration tank

Figure 1

A. Automatic venting • Low level alarm sounds – venting starts. • If you have this type of device, venting will run automatically. B. Manual venting (pictured) • Low level alarm sounds – the tank is vent by opening the valve.

When manually venting the deaeration tank, the valve is opened only when the low level alarm sounds. Otherwise, the valve must stay closed.

Figure 2

• Open all gauges by turning the yellow tip. • The suction side pressure should drop to approx. 0 bar (Figure 1). • The feed pressure should rise to 3 – 5 bar (Figure 2). • If the connections are wrong, the feed pressure gauge (Figure 2) will not display any values.

• When the alarm shuts off, close the valve. (The deaeration tank may only be checked during the initial pump start-up.)

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Parallel feeder and booster pump pairs are connected from different cabinets. One pump is in standby mode. Remember to test both pumps. Never touch the pump relief valves! If necessary, pressure can be adjusted using the pressure regulator valve downstream from the pumps, not with the relief valves!

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9. Starting the booster/circulation pump

10. Checking booster/circulation and outlet pressure gauges

t • Ensure that oil return circulation is allowed to the unit deaeration tank. • Test run the electric pumps. Ensure that the motors are rotating in the right direction. If the rotation direction is wrong, contact an electrician.

Ensure that the electric motor is rotating in the right direction.

• Vent the unit’s external fuel system. • The ship’s diesel engine fuel feed pressure should be the same as the unit’s outlet pressure. • Also ensure that the fuel flow returns to the unit.

• If the rotation directions are right, leave one of the pumps running.

Never touch the pump relief valves! Outlet pressure is adjusted with the pressure regulator valve located outside the unit, not the pump relief valves! Turn the switches for feeder and booster pumps being shut down to the standby position.

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11. Adjusting viscosity

12. Checking the steam/thermal oil regulator valve

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• Activate the viscometer on the control panel (1) and select Adjust viscosity (2). Also turn on the automatic filter (3). • Check the display to ensure that the viscosity is 4 – 8 cSt. Note! The display can also be placed outside the unit (engine control room).

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There is a 3 – 6 min time delay between manual flushings of the automatic filter!

• Ensure that the steam/thermal oil regulator valve is closed or the electric heaters are switched off. • Ensure that the heat tracing valves are closed or electric tracing is shut off. • If the regulator valve is open, contact an electrician, who will switch the feed phases. • Temperature regulation is a safety function, which is only available with HFO.

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Heat tracing must not be on when using MDO!

13. Testing equipment and alarms

14. Starting and running the engine on MDO

• Test equipment and alarms.

• Ensure that heat tracing is not on for unit outlet and inlet pipelines.

• Test functions according to the alarm panel; also test remote control.

• Start the engine.

• Also ensure that the alarms are being sent to the engine control room.

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Ensure that heat tracing is not on for unit outlet and inlet pipelines.

15. Switching to the use of HFO

16. Switching to the use of MDO

• Open the valve for the unit’s external heat source. • Open the valves (steam/thermal oil) for the heat exchanger in use. Use only one heat exchanger. • Switch the change-over valve to HFO. The switch to HFO may take around 1 – 3 hours. • Viscosity will be automatically set to the setpoint value. Check this value against the motor’s technical specifications (10–20 cSt). Regulation of the value may take several hours. • Open the unit’s external fuel line heat tracing valves.

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Be careful of hot surfaces – use protective safety gear.

• Turn off heat tracing for the unit’s outlet and inlet pipelines. • Switch the change-over valve to MDO.

The viscosity alarm monitors the setpoint. It is ± 3 cSt of the selected setpoint. The low viscosity alarm will be triggered when switching to HFO. This is normal. The oil temperature will rise to approx. 135 – 150°C. 19

A rise of more than 50°C in MDO temperature may damage the system.

17. Shutting down the system

Notes

• It is possible to shut down the ship’s diesel engine when viscosity decreases. The unit may also be shut down after this.

If the unit must be shut down when using HFO, turn on the unit’s heat tracing!

The system should always be shut down when using MDO – never HFO. Switching too quickly may damage the unit pumps.

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IMPORTANT POINTS TO REMEMBER – PLEASE READ! Pumps The pumps are equipped with mechanical shaft seals. The mechanical seals must leak to operate properly. The mechanical seals consist of two highly polished, very flat surfaces. The surfaces may not run dry, as they will otherwise fail very quickly. Therefore, they are designed to allow a very thin film of liquid to exist between them. Some of the liquid will leak out of the seal. When pumping HFO, the leaking HFO will visibly accumulate on the pump. This is normal and does not indicate a manufacturing defect. It is not a guarantee issue. A leakage rate of 10 drops of oil per hour or less is considered normal. Please note that seals will sometimes require a “run in” period, with leakage gradually diminishing over several hours of operation after the initial start-up. Start-ups can be particularly hard on mechanical seals. Never start a pump without priming. Always make sure that the Seal Guard lubricator is activated, if the pump is equipped with one. Automatic filter During the initial start-up of the fuel system, the automatic filter may get clogged. This does not indicate a defect in the automatic filter. The tanks and pipes of the fuel oil system contain a lot of dirt and debris. The automatic filter will catch the dirt, but there may be so much of it that the filter cannot clean itself anymore. The clogging of the filter will also depend on the quality of the oil. Poor quality oil contains particles, tar, paraffin and

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other impurities, and tends to clog the filter elements. As a result, the automatic filter will need to be stripped and the filter elements cleaned, in some cases repeatedly. When the dirt has been flushed from the system, the automatic filter will operate normally. This is all normal and not a guarantee issue. Viscometer During the initial start-up of the fuel oil unit, the viscometer may indicate an unexpected viscosity. Should this happen, the value will tend to be too high. This is typically caused by a dirty sensor, i.e. the pendulum. Poor quality oil will worsen this, thus requiring a cleaning of the pendulum. Flush the pendulum with diesel oil or a mild detergent. Be extremely careful when handling the pendulum, as it is a sophisticated instrument. Guarantee Although all Auramarine fuel booster unit contracts offer a guarantee of quality, normal wear parts are not included in the guarantee. The following are considered wear parts: • Mechanical shaft seals of the pumps • All gaskets, rubber pistons and o-rings • Filter candles and elements • Couplings and coupling elements • Ball bearings for pumps and electric motors

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QUICK VIEW 5

1. Activating pump shaft seal lubrication (Seal Guard)

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2. Inspecting fuel valve positions 3. Venting suction filters

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4. Inspecting instrument valves

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5. Activating fuses and thermal relays

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6. Starting feeder/supply pumps 7. Venting the deaeration tank

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8. Checking suction and feed pressure

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9. Starting the booster/ circulation pump 10. Checking booster/circulation and outlet pressure gauges 11. Adjusting viscosity

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12. Checking the steam/thermal oil regulator valve

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13. Testing equipment and alarms 14. Starting and running the engine on MDO 15. Switching to the use of HFO 16. Switching to the use of MDO 17. Shutting down the system

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Auramarine After Sales is much more than just a quick spare parts supplier. Our mission is to bring in new cost and energy-saving solutions for our customers and solve challenges together in a competitive business situations. Auramarine After Sales services include: • basic support for unit installation • spare part sales with fast delivery times worldwide • unit commissioning and field maintenance • performance optimization • component and unit design upgrades • fuel cooling systems and Marine Gas Oil -conversions

Auramarine Original Spare Parts available for your equipment, with fast delivery times and competitive prices. Stop losing money and start earning it now! The first step in improving your situation is to find out where to save. Fuel is a shipowner’s primary cost and giving a fuel system a trial is the most effective way to achieve major savings. A trial will provide reliable information as well as give you a rough idea as to what your return on investment will be. Just send us an email and get off to a perfect start! For questions concerning trials, our products, Spare parts and After Sales services, please contact our After Sales team at after.sales@ auramarine.com

We help you reduce your operating costs Besides the conventional spare part sales, we can offer you, for example, high performance fuel consumption monitoring systems, which will help the vessel to reduce its actual operating costs. We can also offer you inclusive modernization packages for measurement of the fuel booster viscosity and control systems for improving and ensuring more accurately-controlled combustion cycles in your engines. All in all, Auramarine After Sales can effectively update your auxiliary systems to the level of the newest and most modern units, with greater reliability, higher engine performance and lower fuel consumption. Worldwide presence Auramarine spare parts, After Sales services and technical support are globally available for all your installations through our global Auramarine After Sales organization. Your personnel can easily contact our technical sales engineers with standard spare part enquiries or any other operational and technical questions. We have an excellent selection of 26

Close to you all over the world Auramarine has two extensive spare part facilities: one in Europe and the other in Asia. In addition to this, we have representatives in 30 countries, so customer support and service is always nearby. 27

gadfhsfgjhsfghsdfghnsfghn Auramarine HFO (Heavy Fuel Oil supply units) HFO unit series, which offers easy accessibility and service, meets the increasing demand to minimize the amount of space required for anything other than passengers or cargo. Auramarine MGO (Marine Gas Oil handling unit) Auramarine offers fast and reliable solutions when needing to switch to low sulphur fuel. The unit works seamlessly with the AMB and all other HFO units. Auramarine After Sales Auramarine’s primary task is to ensure the continuous and flawless operation of your ships. This is why our After Sales service is available 24/7. In addition to this, we maintain a global dealer and agent network. Under normal circumstances, the required assistance or spare part is dispatched to the ship within 24 hours and delivered in 2 – 3 days.

THIS PUBLICATION IS DESIGNED TO PROVIDE AS ACCURATE AND AUTHORITATIVE INFORMATION REGARDING THE SUBJECTS COVERED AS WAS AVAILABLE AT THE TIME OF WRITING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS AND THE DESIGN OF THE SUBJECT AND PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CANNOT TAKE ANY RESPONSIBILITY OR LIABILITY FOR ANY ERRORS OR OMISSIONS IN THIS PUBLICATION OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER AND COPYRIGHT OWNER SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES, FOR ANY CONSEQUENTIAL, SPECIAL, CONTINGENT, OR INCIDENTAL DAMAGES OR INJURY, FINANCIAL OR OTHERWISE, SUFFERED BY ANY PART ARISING OUT OF, CONNECTED WITH, OR RESULTING FROM THE USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED THEREIN. COPYRIGHT © 2013 BY AURAMARINE LTD. ALL RIGHTS RESERVED. NO PART OF THIS PUBLICATION MAY BE REPRODUCED OR COPIED IN ANY FORM OR BY ANY MEANS, WITHOUT PRIOR WRITTEN PERMISSION OF THE COPYRIGHT OWNER.

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Auramarine  –  Number one expertise on the seven seas. Auramarine has been the world’s leading manufacturer of fuel oil supply systems for over 30 years. We have wideranging experience in liquid flows and this craftsmanship is also utilized in design and manufacture of cooling water and lubrication oil units. With over 12,000 skid mounted auxiliary units, Auramarine has superior experience in fuel systems.

AURAMARINE LTD P.O. Box 849 FI-20101 Turku, Finland Tel. +358 204 86 5030 Fax +358 204 86 5031 [email protected] www.auramarine.com