HFO Feeder 3.0

Operation Manual
HFO Feeder 3.0

Document ID DBAE136813b
Date of issue 18.08.2017
Status Approved
Classification Confidential
INSTRUCTIONS
© Copyright by Wärtsilä Finland Oy
All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior
written permission of the copyright owner.
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 EVENTUAL 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 PARTY ARISING OUT
OF, CONNECTED WITH, OR RESULTING FROM THE USE OF THIS PUBLICATION OR THE INFORMATION
CONTAINED THEREIN.
Operation Manual
Table of Contents
1. About this manual........................................................................................................................................ 1-1

1.1. Product identification............................................................................................................................... 1-1
1.2. Objective.................................................................................................................................................. 1-1
1.3. Use of symbols........................................................................................................................................ 1-1
1.4. Preconditions........................................................................................................................................... 1-2
2. Safety notes.................................................................................................................................................. 2-1

2.1. General safety notes................................................................................................................................ 2-1
2.2. Elementary plant safety........................................................................................................................... 2-1
2.3. Safety notes for maintenance work......................................................................................................... 2-2
3. System descriptions..................................................................................................................................... 3-1

3.1. Overview of the fuel feeder...................................................................................................................... 3-1
3.2. Fuel system.............................................................................................................................................. 3-1
3.2.1. Safety shut-off valves........................................................................................................................ 3-3
3.2.2. HFO feeder pumps............................................................................................................................ 3-3
3.2.3. Automatic filter.................................................................................................................................. 3-4
3.3. Compressed air system........................................................................................................................... 3-4
3.3.1. Instrument air filter............................................................................................................................ 3-4
3.4. Sludge system......................................................................................................................................... 3-4
3.5. Trace heating........................................................................................................................................... 3-5
3.6. Control system......................................................................................................................................... 3-5
3.7. Manual valves and indicators in the fuel feeder (single).......................................................................... 3-6
3.8. Manual valves and indicators in the fuel feeder (double 8.5 and 15 m³/h).............................................. 3-8
3.9. Manual valves and indicators in the fuel feeder (double 36 m³/h)......................................................... 3-10
4. Start and stop............................................................................................................................................... 4-1

4.1. Preparing the fuel feeder for start............................................................................................................ 4-1
4.1.1. Starting after a prolonged stop......................................................................................................... 4-2
4.1.2. Starting after maintenance work....................................................................................................... 4-2
4.2. Starting the fuel feeding........................................................................................................................... 4-3
4.2.1. Starting the HFO feeder.................................................................................................................... 4-3
4.3. Shutting down the fuel feeder.................................................................................................................. 4-4
4.3.1. Stopping for maintenance work........................................................................................................ 4-4
5. Operation...................................................................................................................................................... 5-1
5.1. Normal operation and supervision........................................................................................................... 5-1
5.1.1. Supervising pumps........................................................................................................................... 5-1
5.2. Regular inspections................................................................................................................................. 5-1
5.2.1. Performing the daily inspections....................................................................................................... 5-1
5.2.2. Performing the weekly inspections................................................................................................... 5-2
5.3. Abnormal operating situations................................................................................................................. 5-2
5.3.1. Overflow and leaks............................................................................................................................ 5-2
5.3.2. Emptying the drip pan of the fuel feeder........................................................................................... 5-2
5.4. Alarms and fault finding........................................................................................................................... 5-3
5.4.1. Pump and motor overload alarms..................................................................................................... 5-3
5.4.2. Suction pressure low, HFO feeder pump.......................................................................................... 5-3
5.4.3. HFO feeder pressure deviation......................................................................................................... 5-3
5.4.4. High differential pressure, fuel filter.................................................................................................. 5-4
5.4.5. High differential pressure, bypass filter............................................................................................. 5-4
5.4.6. Sludge pump malfunction................................................................................................................. 5-4
5.4.7. Quick-closing valve closed............................................................................................................... 5-4
DBAE136813b Confidential i
Operation Manual
6. Maintenance................................................................................................................................................. 6-1
6.1. Maintaining the fuel feeder...................................................................................................................... 6-1
A. Technical specifications............................................................................................................................. A-1
ii Confidential DBAE136813b
Operation Manual 1. About this manual
1. About this manual
1.1 Product identification GUID-0BB44107-C5C0-467F-B355-573C37234A6F
This manual deals with the HFO Feeder 3.0 which is used for transferring heavy fuel oil
(HFO) from the fuel storage system to the fuel circulation system of the engines.
The HFO Feeder uses electrical trace heating or steam trace heating depending on the plant
heating type. The manual covers the following models:
HFO Feeder 3.0 Single A feeder unit with one feed pump
HFO Feeder 3.0 Double A feeder unit with two feed pumps
Table 1-1 Reference documents
Model Flow diagram Dimensional drawing Device list

Double 8.5 m³/h DBAC827706a DBAC834454b DBAC827705a
Double 36 m³/h DBAC207946h DBAC210409f DBAC208054l
Single 36 m³/h DBAC223268h DBAC230463e DBAC223273k
1.2 Objective GUID-5DFA6976-F7C0-4C91-BA0F-5130F2DE2C03
This manual is aimed at the operating personnel of the plant. The purpose is to ensure that
the operators have all the information necessary to safely run the fuel feeder in normal
operating conditions.
The operating procedures for the fuel feeder are part of the overall procedures for the plant.
The instructions given in this manual only cover procedures related to the fuel feeder. The
design and function of the connected systems must be considered when applying the
information.
Detailed information about single components is given in the documentation issued by the
original equipment manufacturers.
1.3 Use of symbols GUID-7CCEB85B-87B1-4B4A-B618-FD8B38F102A6
This manual includes different kinds of notes emphasized with a symbol. They are meant to
draw the reader's attention to possible dangers involved or other things to take into
consideration when performing an operation.
The following notes and warnings are used:
NOTE
Note is used in the text for highlighting important information or requirements.
DBAE136813b Confidential 1-1

1. About this manual Operation Manual
WARNING
Warning is used in the text whenever there is a risk of personal injury.
WARNING - ELECTRICITY
The electricity warning is used in the text when there is a risk of personal injury
due to electrical shocks.
CAUTION
Caution is used in the text whenever there is a risk of damaging equipment.
1.4 Preconditions GUID-67C2D2FC-AC9D-4F37-889F-2D19209B6D81
Properly trained and experienced personnel must be available to perform the actions
required in the instructions. All tools and equipment used must be in good condition.
The equipment described in this manual must not be used for any other purpose than it was
designed for, and it must not be modified in any way without the supplier’s written
permission. The information in this manual is no longer valid if modifications are made to
the equipment.
Wärtsilä accepts no responsibility for situations arising from unintended use or unauthorized
modifications to the equipment, or from work performed by untrained personnel.
1-2 Confidential DBAE136813b

Operation Manual 2. Safety notes
2. Safety notes
For detailed information about plant safety, first aid and actions in emergency situations,
refer to the separate plant safety instruction documents. All personnel working in the plant
must read the safety instructions and be familiar with the safety routines.
2.1 General safety notes GUID-B2F39505-B588-4D24-9B53-5874E70B9D0C
Only persons with adequate training are allowed to operate the equipment in the plant.
Before starting to operate the plant, read the manuals provided by the component
manufacturers. Read and obey the safety instructions provided by the equipment
manufacturers and the material safety data sheets for the chemicals handled in the plant.
Observe the warning signs on the equipment. The signs must not be removed.
To prevent injury, be aware of moving parts. Never run the engine or any auxiliary
equipment without having the covers and protective shields properly mounted. Before
starting any maintenance work, adjustments or inspection, take the necessary precautions
to prevent accidental starting of the equipment.
WARNING
Electromagnetic fields. Electrical or mechanical equipment in this power plant
may interfere with the operation of a pacemaker or other implanted devices that
are sensitive to electromagnetic fields. Check with your doctor or other
physician/specialist before entering this facility to reduce the risk of serious
health consequences.
2.2 Elementary plant safety GUID-5DE929B3-C253-4A74-9499-08E3F98206A1
Handling of chemicals
Before using a chemical, study the material safety data sheets (MSDS) provided by the
supplier of the chemical. Any chemical should be considered potentially hazardous unless it
is known to be harmless. When handling chemicals, contact with skin and eyes must be
avoided. Protective clothing has to be used, including safety glasses and impermeable
gloves. Also respiratory protective equipment may be required. The chemicals must be kept
in a well ventilated place. Do not eat or drink while handling chemicals. Spills must be
properly collected and the chemicals disposed of in accordance with local regulations.
Risk of ignition
Pay attention to the risk of ignition, as the equipment may contain combustible gases or
liquids.
● Do not light matches or open flames in the vicinity.
● Prevent sparks from occurring. Be aware that sparks may occur due to static electricity.
● Check that the area is free of combustible gases and liquids before using any power
tool.
In case of fuel leaks, actions must be taken immediately.
Electrical safety
Only authorized electricians may perform work on electrical equipment. To prevent
electrical shocks, do not open electrical cabinets during operation. Do not touch any
electrical wiring or components until the main switch has been switched off and secured.

2. Safety notes Operation Manual
Burning or splashing hazard

When the plant is in operation, some of the pipes and components contain hot liquids, and
the surface may be hot. Before dismantling or opening any process equipment, consider
what the system may contain and take the necessary precautions to avoid burns, exposure
to hazardous substances, spills or splashing. All components should be allowed to cool
down before performing any maintenance work on them. Remove the pressure from the
system before opening any part of it. Opening a pressurized vessel that contains a hot
liquid may cause splashing.
Pressurized air
Be aware of the power of pressurized air. The pressure in the compressed air system is very
high. Look out for jets of pressurized air. If inspection, maintenance or adjustments will be
performed on a unit that uses compressed air, the compressed air supply should normally
be switched off to prevent personal injury. Do not open any component or unit before
ensuring that it is not pressurized. If a part of the compressed air system is isolated for
maintenance work, the valves must be locked and properly tagged out in order to prevent
accidental opening.
Protective clothing
To prevent injury to the personnel, protective clothing must be used when working in the
plant. Use overalls made according to safety regulations, protective gloves, safety glasses,
safety footwear, ear protection and hard hat. The protective gloves have to be strong and
heat resistant. Respiratory protective equipment must be used whenever there is a risk of
hazardous fumes.
Clean working space

The working space should always be kept tidy. Wipe up oil spills and dispose of all debris
that might cause accidents.
Working in confined spaces

Before working in a confined space, all inlet and outlet valves to the space must be closed
and properly locked. If the space has contained chemicals that may produce vapours, it
must be properly vented and the air tested. Two people should be assigned for hole watch
and remain stationed outside the space where they can observe the workers inside. Test
the air again at the beginning of each shift.
2.3 Safety notes for maintenance work GUID-42DFB1C2-416A-4B61-A8DB-9CD7CA39B522
Related topics
Maintenance......................................................................................................................... 6-1
To prevent personal injury, proper safety precautions must be taken when performing
maintenance work on the unit.
● To prevent accidental starting, any component that is to be serviced must be properly
locked and tagged out, along with the related inlet and outlet valves.
○ The components must be disconnected from the power supply and any other energy
sources, such as compressed air or steam.
○ If the maintenance involves the electrical system, the main switch must be turned off
and secured.
● The unit must be allowed to cool down before opening any components or pipes for
maintenance or inspection. Most of the pipes in the unit contain hot liquids or steam,
and are hot during operation.

Operation Manual 2. Safety notes
● Before starting the maintenance work, the pressure must be released. Note that
pressurized liquid, air or steam may be trapped between the closed valves when
isolating part of a system.
● Protective clothing must always be used when opening any part of the unit, as well as
when venting or draining a system.

2. Safety notes Operation Manual
This page has intentionally been left blank.

Operation Manual 3. System descriptions
3. System descriptions
3.1 Overview of the fuel feeder GUID-EDD22980-FAEF-4455-8D8E-B1DD1DA3DA18
The fuel feeder provides heavy fuel oil (HFO) at the correct pressure to the fuel circulation
system of the engines. The feeder pumps are mounted on a steel frame together with the
necessary piping, valves, instrumentation, etc., forming a compact unit.
The fuel feeder unit contains the following main components (see Fig 3-1):
● Safety shut-off valve (1)
● Feeder pump (2)
● Fuel filter (3)
● Control panel (4)
● Sludge tank (5)
● Sludge pump (6)
● Compressed air bottle (7)
● Instrument air filter (8).
4
3
5
6
1
Fig 3-1 Fuel feeder GUID-C9CED413-A2F6-47C0-A50C-A2852C44D5F1 v1
3.2 Fuel system GUID-9221B170-CAE0-4358-8A4A-8759B310180D
The fuel feeder transfers fuel from the storage system to the fuel circulation system of the
engines. The feeder pumps maintain the correct pressure in the fuel supply lines.

3. System descriptions Operation Manual
A safety shut-off valve is installed at each fuel inlet. The fuel feeder also includes an
automatic filter, equipped with a sludge tank and an air-driven sludge pump.
Excess fuel returns to the fuel storage system through an overflow valve. Alternatively, the
excess fuel can be directed back to the feeder pump inlet by means of a manual valve.
The feeder includes gauges and sensors for monitoring the fuel pressure. A temperature
sensor is installed at the outlet of the pumps.
(A) HFO inlet

(B) HFO outlet
(E) HFO return to storage system
(1) Safety shut-off valve (5) Sludge tank
(2) Suction strainer (6) Sludge pump
(3) HFO feed pump (7) Overflow valve
(4) Automatic filter
Fig 3-2 HFO feeder (single) GUID-2EB32820-AD86-42BF-B534-BC808EC37354 v1
(A) HFO inlet

(B) HFO outlet
Fig 3-3 HFO feeder (double 8.5 and 15 m³/h) GUID-77707F50-49B4-4456-9DA3-0D348C4AF1D1 v1

(A) HFO inlet

(B) HFO outlet
Fig 3-4 HFO feeder (double 36 m³/h) GUID-4DDFAE4F-8D5D-4359-AB1D-3F153E4D9FC6 v1
3.2.1 Safety shut-off valves GUID-6317F50B-47BE-4114-87AD-7D924C239AAD
The safety shut-off valves are installed to instantly cut off the fuel supply when required for
safety reasons. The valves can also be closed manually from the control panel in
emergency situations.
The electropneumatic valves are equipped with a small air bottle, to keep the valves open in
case of short disturbances in the compressed air supply. If there is a loss of air pressure,
the valves close and stop the fuel supply. The valves are closed also if the control voltage is
lost due to an emergency stop or a power failure.
Each valve is equipped with a limit switch for position indication.
3.2.2 HFO feeder pumps GUID-EDF21800-B2F3-497E-9409-88B59123EEE5
Related topics
Starting the HFO feeder........................................................................................................4-3
The HFO feeder (double) includes two electrically driven screw pumps, connected in
parallel. One of the pumps is normally on standby while the other one is running.
The pumps have built-in safety valves and they are protected from impurities by suction
strainers. A non-return valve prevents the fuel from flowing in the wrong direction. The
pumps are also equipped with manual inlet and outlet valves.

The pumps are controlled by frequency converters. The frequency converter regulates the
speed of the feeder pump to maintain the correct pressure in the outlet line. Pressure
transmitters are installed on the inlet and outlet sides of the pumps, together with gauges
for local monitoring. The speed control is primarily handled by a pressure transmitter
downstream of the filter in the feeder line. Another pressure transmitter between the pumps
and the filter provides backup control if the main sensor fails. The standby pump is started
automatically if the feeder pressure drops too low, indicating a failure of the main pump.
An overflow line secures that the feeder pressure is kept stable at sudden changes in the
fuel consumption. If the pressure rises too high, the excess fuel is released to the pump
inlet side or to the fuel storage system through an overflow valve. The overflow valve is
equipped with a bypass pipe, which prevents underpressure by continuously leading a
small fuel flow to the overflow line.
3.2.3 Automatic filter GUID-6474D33C-A323-47D3-ADA7-28AF32C1C9D9
In the automatic filter, the oil is filtered by candle elements. The filter elements are cleaned
automatically by back-flushing using compressed air.
The automatic filter includes two filter chambers. One filter chamber is always held in
reserve, allowing cleaning of the filter elements without causing any interruption in the
filtration process. A high differential pressure across the filter initiates the filter chamber
change-over and back-flushing.
The filter unit is equipped with a bypass filter, a differential pressure indicator and an
electronic controller.
3.3 Compressed air system GUID-5E3E6359-1175-4B4D-AB71-729D29B8FAA9
Compressed air is used by the pneumatic valves and by the air-driven sludge pump. The
operation of the pneumatic components requires a reliable supply of compressed air.
The compressed air system in the fuel feeder consists mainly of piping and valves for
distribution of air from the externally installed compressors. A filter at the compressed air
inlet improves the quality of the instrument air.
The air line to the sludge pump includes a pressure regulator. An air bottle secures that the
safety shut-off valves in the fuel lines are kept open in case of minor disturbances in the
compressed air supply.
3.3.1 Instrument air filter GUID-004A91BC-B309-4452-9310-5CBB42BA5D3F
The coalescing filter separates liquid and solid particles from the compressed air.
The air is filtered by a pleated multi-layer filter fabric with an incorporated drainage layer.
The filter includes an automatic drain and a differential pressure indicator.
3.4 Sludge system GUID-ABE2EEA7-9731-43E1-A9F0-C2F9CC68752E
The sludge system collects and disposes of the sludge from the automatic fuel filter.
The back-flushing oil from the fuel filter flows to a collecting tank, which is emptied by an
air-driven pump. The sludge tank is equipped with a level switch for automatic start of the
emptying pump. When the level switch indicates that the tank needs emptying, the pump is
started and runs for a preset time. The pump can also be used for emptying the drip pan.
The pump is equipped with inlet and outlet valves, as well as a non-return valve.
The compressed air line to the pump includes a solenoid valve for pump control, as well as
a pressure regulator. The solenoid valve is equipped with a manual bypass valve, enabling
the pump to be run in manual mode if necessary.

3.5 Trace heating GUID-D6E90826-D3DA-4D49-B69F-019C7B0DDCB0
The HFO and sludge pipes in the fuel feeder are trace heated, to compensate for heat
losses. The trace heating keeps the fuel heated if the flow in the system is stopped, and
must always be activated when the system is filled with HFO.
If electrical heating is used, the pipes are trace heated by a heating cable installed along the
pipes. The heating power of the self-regulating cable depends on the pipe temperature.
When the pipe temperature drops, the trace heating power increases.
If steam heating is used, a steam tube for trace heating is mounted on the pipes. The
heating effect is determined by the dimensions of the trace heating tube, and no
temperature control equipment is installed. The trace heating system comprises two
separate heating circuits: one for the HFO pipes and the fuel filter, and another one for the
sludge system. The steam circuits are equipped with manual shut-off valves for enabling
and disabling the trace heating.
3.6 Control system GUID-016E53B6-7909-4F27-A80E-1D238E3E0214
The fuel feeder is controlled by the central control system of the plant. The feeder is
connected to the plant control system through the electrical cabinet of the unit. The front
panel of the electrical cabinet includes switches for selecting the pump control modes and
controlling the safety shut-off valves, as well as indication lamps for monitoring the status of
the components. The automatic fuel filter has a separate control box, which is also
connected to the plant control system for remote monitoring.
The pumps are normally set for operation in automatic mode. In the automatic mode, the
pumps are controlled according to the operation of the engines or signals from local
instrumentation equipment. The manual mode is mainly used for test runs and
maintenance.
NOTE
The control functions for the fuel feeder partly depend on the plant-specific
control system configuration.

3.7 Manual valves and indicators in the fuel feeder

(single) GUID-E5A0336E-23E7-488D-8237-F1A9FB59D5AC
P007
P006
P004
T003
P005
P003
V011
V019 V065
V063 V021
V064
V062
V052 V020
V070 V050
V071
Fig 3-5 Manual valves and indicators in the fuel feeder (single) GUID-65CFD58D-72FB-444E-AB5E-
EE641617083F v1
Table 3-1 Manual valves in the fuel feeder (single)
Normal
Valve Description
position
V011 Closed [1] HFO overflow to pump suction side
V019 Open [1]

HFO overflow to storage system
V020 Open Sludge pump outlet
V021 Open Sludge pump inlet (from sludge tank)
V050 Open Compressed air inlet
V052 Open Compressed air to safety shut-off valve
V062 Closed Compressed air to sludge pump (manual operation)
V063 Open HFO inlet
V064 Open HFO outlet
Continued on next page

Normal
Valve Description
position
V065 Closed Sludge pump inlet (from drip pan)
V070 Open Steam to trace heating
V071 Open Condensate from trace heating

[1]
If the HFO from the overflow line is to be directed back to the pump inlet side, valve V011 should
be open and valve V019 closed.
Table 3-2 Sensors and local indicators in the fuel feeder (single)
Indicator Description
P005 Suction pressure of HFO feeder pump
P006 Pressure after HFO feeder pump
P007 Pressure after HFO filter
Sensor Description
P003 Suction pressure of HFO feeder pump
P004 Pressure after HFO feeder pump
T003 Temperature after HFO feeder pump


(double 8.5 and 15 m³/h) GUID-ED1520F7-924A-44DE-B04E-E5516600B0B9
P003
V005
P004 V004
T001 P002
P001
P014
P007
V006 V052
V002
V011
P008 V063
V064
V170
V067 V019
V021
P015
V062
V020
V171
V071
V050
Fig 3-6 Manual valves and indicators in the fuel feeder (double 8.5 and 15 m³/h)
GUID-0721FA8F-F5F7-4534-B2E5-B1E00FC08943 v1
Table 3-3 Manual valves in the fuel feeder (double 8.5 and 15 m³/h)
Normal
Valve Description
position
V002 Open HFO feeder pump D001 inlet
V004 Open HFO feeder pump D001 outlet
V005 Open HFO feeder pump D002 outlet
V006 Open HFO feeder pump D002 inlet
V011 Closed [1]

HFO overflow to pump suction side
V019 Open [1] HFO overflow to storage system
Continued on next page

Normal
Valve Description
position
V063 Open HFO inlet
Trace heating of HFO return pipe, and sludge pipes and tank (steam
V070 Open
heated models)
Condensate from trace heating of HFO return pipe, and sludge pipes
V071 Open
and tank (steam heated models)
V170 Open Trace heating of HFO pipes and fuel filter (steam heated models)
Condensate from trace heating of HFO pipes and fuel filter (steam
V171 Open
heated models)
[1]
Table 3-4 Sensors and local indicators in the fuel feeder (double 8.5 and 15 m³/h)
P001 Suction pressure of HFO feeder pump D001
P003 Pressure after HFO feeder pumps
Sensor Description
P004 Pressure after HFO feeder pumps
T001 Temperature after HFO feeder pumps


(double 36 m³/h) GUID-8D3C18CF-A351-426A-812A-8A8401EE5EB4
P007 P106
P006 P004
P003 T002
T001
P107
P005
P001
V011
V019
V063
V064
V021
V065
V121
P105
P002
V164 V111
V163 V062
V165
V119
V152 V162
V120
V020
V170
V171 V050
V071
V052 V070
Fig 3-7 Manual valves and indicators in the fuel feeder (double 36 m³/h) GUID-C2093CDD-
F0F8-4A49-A73F-68C5FF3577C7 v1
Table 3-5 Manual valves in the fuel feeder (double 36 m³/h)
Normal
Valve Description
position

Manual valves for HFO feeder line with pump D001

Normal
Valve Description
position
V063 Open HFO inlet
Manual valves for HFO feeder line with pump D002

Normal
Valve Description
position
V163 Open HFO inlet

[1]
Table 3-6 Sensors and local indicators in the fuel feeder (double 36 m³/h)
P006 Pressure after HFO feeder pump D001
P007 Pressure after HFO filter (HFO feeder pump D001 line)
P107 Pressure after HFO filter (HFO feeder pump D002 line)

Sensor Description
T001 Temperature after HFO feeder pump D001
T002 Temperature after HFO feeder pump D002

Operation Manual 4. Start and stop
4. Start and stop

The measures to take at startup depend on the state of the equipment. If the engines are
stopped for a brief period only, some of the auxiliary units may be kept in automatic
operation during the stop. Starting after a prolonged stop requires more preparations and
manual operation. The following main operating states are distinguished:
In operation The plant is in operation or on standby, controlled by the control

system. The engines may be running or temporarily stopped. When
the engines are stopped, the auxiliary systems remain filled and are
ready for engine startup.
Maintenance The plant or part of it is stopped for maintenance. The state of the
stop process equipment depends on the nature of the maintenance work
that is to be performed. Some units may be kept in operation if they
are not affected by the maintenance. The fuel supply is typically
stopped for safety reasons.
Prolonged stop The plant is shut down for a prolonged time. The fuel supply system
is emptied. The units are disconnected from the power supply and
the control system.
4.1 Preparing the fuel feeder for start GUID-7ADFCBC4-1F6D-40BD-B2F0-FFC1F154303C
Related topics
Starting the HFO feeder........................................................................................................4-3
The actions to take when starting the fuel feeder largely depend on the state of the
equipment and the length of the shutdown period. Special carefulness is required when
preparing the unit for start after a prolonged stop or after maintenance work.
Procedure
1 Inspect the fuel feeder unit visually to ensure that all systems are in working order.
2 Check the condition of the filters.

Clean or change the filter elements if necessary.
3 Prepare the compressed air system for operation.
a Check the compressed air supply.

Make sure that the pressure is sufficient.
b Drain any condensate from the system.
c Open the shut-off valves in the air distribution lines to the pneumatic components.
4 Check the fuel supply.
5 Check the steam supply (if steam heating is used).
6 Turn on the power supply with the main switch on the control panel.
7 Fill the fuel lines.
8 Put the HFO feeder in operation when a fuel change-over from LFO to HFO is to be
performed.

4. Start and stop Operation Manual
4.1.1 Starting after a prolonged stop GUID-A153AE3F-99B7-4353-BA17-F744FA3D0268
When starting the unit for the first time or after a prolonged stop, inspect the equipment
thoroughly to verify that all components are in working order and ready for startup.
Consider also the instructions in the manuals issued by the original equipment
manufacturers.
● Inspect the unit visually.
a Check for loose or damaged components.
b Check the electrical connections for broken cables, insulation damage or loose
contacts.
c Check the pipes, pipe connections and shaft seals for signs of leakage.
d Retighten or change seals as necessary.

Be careful not to overtighten.
WARNING
Do not use the unit if it appears damaged.
● Inspect all filters and strainers.

It is recommended to always change the filter elements after a prolonged shutdown.
● Operate all valves and grease exposed moving parts.
● Inspect and test all instrumentation and control equipment.
● Fill and prime the pumps.
CAUTION
Never start a pump without filling it first, and never let a pump run dry.
4.1.2 Starting after maintenance work GUID-8EFD3E50-ED93-4C18-8D97-9CE77A51ED1F
Related topics
Maintenance......................................................................................................................... 6-1
When starting after maintenance work, make sure that all units that have been serviced
during the stoppage are correctly assembled and ready for operation.
● Check that all covers are properly mounted.
● Check that all tools and loose parts have been removed.
● Check that no components are still locked or tagged out for maintenance.
● Check the rotation direction of electric motors and pumps if the power supply
cables have been disconnected during the stoppage.

4.2 Starting the fuel feeding
4.2.1 Starting the HFO feeder GUID-36423A6B-C4C9-4C15-939A-DBB5A3CD0F8F
Related topics
HFO feeder pumps............................................................................................................... 3-3
Procedure
1 Check the positions of the manual valves in the HFO feeder system.
a Open the shut-off valves in the feeder lines, to enable free flow through the system.
Also the valves of the standby pump must be open.
b Check that the manual valves in the overflow line are in the correct position.
Normally, valve V011/V111 is closed and valve V019/V119 is open, directing the return
fuel back to the storage system.
2 Open the safety shut-off valve with the switch on the control panel.
3 Fill and vent the fuel lines.

Make sure that the feeder pumps are properly filled.
4 Activate the trace heating.
5 Put the sludge pump in operation.
a Open the manual valve (V020/V120) in the sludge disposal line.
b Open the manual valve (V021/V121) on the inlet side of the pump to draw sludge
from the tank.
c Check that the manual bypass valve (V062/V162) of the pump control valve is
closed.
d Check that the pressure control valve (V056/V156) is correctly adjusted.

A moderate air pressure should be used, to avoid excessive use of compressed air.
e Set the pump for automatic operation with the switch on the control panel.
6 Put the fuel filter in operation.
a Check that the fuel flow is directed to the automatic filter.
b Switch on the automatic filter from the filter control box.
7 Set the feeder pumps for automatic operation with the switch on the control panel.
8 Check the operation of the feeder.
a Check the pressure readings and verify that the pump speed control operates
correctly.
If the pressure does not rise to the normal level, make sure that the overflow valve is
correctly adjusted.
b Check that there is no abnormal noise, vibration or leakage.

4.3 Shutting down the fuel feeder GUID-C6706D11-81C0-4E5E-93F9-9135C9E9D8B0
Prerequisites
Before shutting down the fuel feeder, all engines supplied by the feeder must be stopped.
The actions to take when stopping the fuel feeder depend on the purpose of the shutdown
and the length of the shutdown period.
NOTE
If the engines are stopped only for a short time, the fuel feeder can be kept
activated during the stop.
Procedure
1 Switch off the feeder pumps from the control panel.
2 Switch off the automatic fuel filter from the filter control box.
3 If necessary, drain the fuel lines and stop the trace heating.
NOTE
The trace heating must not be stopped when the system is filled with HFO.
4 Switch off the sludge pump from the control panel.

If the fuel lines are drained, do not switch off the sludge pump before the automatic filter is
completely drained.
5 Close the safety shut-off valves from the control panel.
6 Close the manual shut-off valves as applicable.
4.3.1 Stopping for maintenance work GUID-1DC624ED-7AD7-460B-887E-E94DDF129E50
Related topics
Maintenance......................................................................................................................... 6-1
The actions to take when stopping for maintenance are largely dependent on the nature of
the maintenance work that is to be performed. During a short stop, some units may be kept
in operation if they are not affected by the maintenance.
● Switch off all units in the system that is to be serviced.
● Stop the fuel supply.
● Disconnect the equipment that is to be serviced from all energy sources.
a Disconnect the power supply.
b Stop the compressed air supply.
c Stop the steam supply (if steam heating is used).

● Empty the systems as necessary.

Before emptying a circuit, the pumps and other equipment in the system must be
switched off.
NOTE
The HFO and sludge lines must be emptied if the trace heating is stopped.
● Let the components cool down after stopping the system.

Make sure that the temperature and pressure are on a safe level before opening any part
of the system.
● Lock and tag out the equipment properly before starting any maintenance or
adjustment work.
Make sure that the equipment to be serviced cannot be accidentally started during the
maintenance.


Operation Manual 5. Operation
5. Operation
5.1 Normal operation and supervision GUID-5C1A947E-454C-4B7E-8A0A-B07AD7DCA2C5
The systems are designed to operate automatically once they are properly started, provided
that the units are set for automatic operation. Normal operation includes mainly supervision
and log keeping.
On the daily inspection tours, the operator should take readings, make measurements and
perform other inspection routines. It is of great importance that all actions are carefully
recorded in the logbook. Note deviating values along with the possible cause. To utilize
trend information, a continuous record is essential.
Although some values can be read from the terminal of the control system, the readings
should be checked from the local gauges and indicators, if installed. At the same time, take
the opportunity to check the unit visually and ensure that the sensors and transmitters are
functioning properly.
5.1.1 Supervising pumps GUID-87E97F8A-7982-458C-9479-8F3AEEE32B4E
Inspect the pumps regularly for excessive leakage (a few drops per hour may be normal).
Excessively leaking shaft seals must be changed without delay. When inspecting the
pumps, also check for abnormal noise or vibration.
Pay attention to loss of pump capacity (reduction in flow or pressure), which may indicate
wear.
5.2 Regular inspections GUID-2E9B876E-03BB-48AA-8630-2678B8E87DE7
5.2.1 Performing the daily inspections GUID-E0D2F365-07FA-4988-9FA2-8FF9E6ED894C
The daily inspections are performed to check that the unit operates correctly and identify
possible operating problems at an early stage.
● Check the fuel pressure and temperature readings.
● Check the pumps and motors for abnormal sounds, smells, vibration, etc.
● Inspect the whole unit – especially the pumps – for leakage.
● Check the operation of the fuel filter.
a Check the pressure drop over the filter.
b Check the number of back-flushing operations from the control unit.

An increased back-flushing frequency indicates a deterioration in the condition of the
filter elements.
● Check that the level in the sludge tank is normal and that the sludge pump
operates correctly.
● Check the operation of the compressed air system.
a Check the pressure drop over the instrument air filter.
b Drain any condensate from the air bottle.

5. Operation Operation Manual
5.2.2 Performing the weekly inspections GUID-CCB408D1-828C-48F4-BDF2-A1548B7EB44D
The weekly inspections are performed to verify that all equipment is in good condition.
● Inspect the piping for leaks, insulation damage, broken or loose flanges, etc.
● Operate valves and grease exposed moving parts as necessary.
● Check all electrical connections for insulation damage or loose contacts.
● Check the operation of all instrumentation equipment.
● Check the condition of the filters.
Clean or replace the filter elements if necessary.
● Test-run units that have not been in operation during the week.
5.3 Abnormal operating situations GUID-A487A91A-B94A-4FB6-8E36-EA10523647B9
During operation, pay attention to any indications of operating problems, such as:
● leakage
● emerging smoke
● excessive vibration
● strange sounds or smells.
If any abnormal operating conditions are detected, stop the system as soon as possible and
investigate the cause. Continued operation with malfunctioning components may result in
extensive damage.
5.3.1 Overflow and leaks GUID-5D515806-0AD2-4470-B127-4DF9EB240D9F
It is very important that actions are taken immediately in case of abnormal leakage from any
unit, tank or pipes. The leakage must be stopped immediately and the cause of the situation
investigated. Any abnormal leaks, even small ones, should be repaired as soon as possible.
The drip pans must be checked frequently and emptied whenever necessary, to prevent
overflow.
5.3.2 Emptying the drip pan of the fuel feeder GUID-3B50D729-A25B-4592-A6B2-F2654CE71AEF
The drip pan collects leak fuel and must be emptied regularly to prevent overflow. The drip
pan can be emptied using the sludge pump.
Fig 5-1 Sludge pump and related valves GUID-44A0D0EC-2D00-4224-AB97-812FB692ED85 v1
Procedure
1 Close the shut-off valve (V021/V121) on the line from the sludge tank.

2 Open the shut-off valve (V065/V165) on the line from the drip pan.
3 Check that the shut-off valve (V020/V120) in the sludge disposal line is open.
4 Start the pump manually by opening the bypass valve (V062/V162) in the compressed
air line.
If the pump does not start or the pumping is inefficient, check that the air supply pressure is
sufficient and the pressure reducer is correctly adjusted.
5 When the drip pan is empty, stop the pump by closing the bypass valve in the
compressed air line.
6 Set the shut-off valves back in position for pumping sludge from the sludge tank.
5.4 Alarms and fault finding GUID-658F7B85-D842-4889-989F-60174CA2B637
The control system of the plant includes alarm functions for notifying the operator of
deviating process conditions that require swift actions. If an alarm is activated, the reason
for the alarm situation must be investigated immediately and corrective actions taken.
Alarm conditions can be caused by equipment failure or abnormal measurement values. An
alarm is generated if an analogue value exceeds the alarm limits or if a binary alarm signal is
received.
The plant should be closely monitored during operation, as this enables the operator to
detect and correct possible deviations before they develop into alarm situations.
5.4.1 Pump and motor overload alarms GUID-A55C30AB-EBBB-490A-87FE-A64F615C8DBD
The overload alarm indicates that the overload protection relay has tripped and that the
pump or motor has stopped. The reason may be that a motor protection switch has tripped
or that a motor bearing is damaged. The overload alarm may also be activated if the
viscosity of the pumped liquid is too high or the pump is mechanically blocked.
If no apparent reason for the alarm is found, the cable connections should be checked to
ensure that they are not loose or faulty. If a pump is overloaded, check that the valves in the
system are in the correct positions and that the pressure regulating valve is correctly
adjusted. Also check that the motor protection switch is correctly adjusted.
5.4.2 Suction pressure low, HFO feeder pump GUID-7B7FF924-1B74-450F-A57D-5B326FBC3E9D
The normal suction pressure of the feeder pump is approximately 0 bar, depending on the
level in the upstream fuel tank. A suction pressure below −0.5 bar may be an indication of
blockage in the fuel line, for instance a partially closed valve or a clogged strainer. Check
the level and temperature in the fuel tank, and have the tank filled if necessary.
The HFO feeder can be kept in operation while a dirty suction strainer is cleaned, by
performing a switchover to the standby pump. The stopped pump must be disabled and
isolated from the fuel flow before starting the service work.
5.4.3 HFO feeder pressure deviation GUID-F26810D8-3F30-40AA-B848-81230969D58A
The normal HFO feeder pressure is about 6.5 bar , and it is controlled by the automatic
speed regulation of the feeder pumps. An abnormally high or low feeder pressure indicates
a malfunction of a frequency converter, a pressure sensor or other control equipment. Make
sure that the pumps are set for automatic speed control with the correct pressure setpoint,
and check the setting of the overflow valve. The overflow valve for overpressure prevention
is normally set to open at approximately 8 bar , but may have to be adjusted if the feeder
pressure setpoint is changed. If necessary, the feeder pump can be run with a manually
entered frequency setting until the problem has been found and corrected.

The standby feeder pump starts automatically if the outlet pressure decreases due to a
failure of the main pump. To enable the standby function, the pump must be set for
automatic control and the shut-off valves must be fully open. If the standby pump has
started, inspect the main pump and the whole feeder system to find out the cause.
● Check the operation of the frequency converter of the main pump. Also inspect the
pump and the motor for damage.
● Check that the inlet and outlet valves of the main pump are fully open.
● Check the temperature of the fuel. Insufficient heating may cause pumping problems in
consequence of the high viscosity.
● Check the pressure in the fuel inlet line of the feeder.
5.4.4 High differential pressure, fuel filter GUID-281F8C0B-DFCD-4B7B-AFD2-C738AFF34C3A
The fuel filter is cleaned during operation by automatic back-flushing. An alarm is activated
if the differential pressure continues to rise despite the regular back-flushing, indicating that
the filter candles are clogged.
If the differential pressure alarm is activated, initiate a manual back-flush from the filter
control box. If this does not help, the filter must be shut down for manual cleaning or
replacing of the filter candles. Inspect and clean the filter candles according to the
instructions in the filter manual. The automatic filter can be serviced during operation of the
fuel system by temporarily directing the fuel flow to the bypass filter.
If the filter is not clogged, check the operation of the pressure switch.
5.4.5 High differential pressure, bypass filter GUID-A7BCB474-F045-4A90-9974-974BC117419F
A high differential pressure alarm from the bypass filter indicates that the filter elements are
clogged and must be cleaned or replaced. If the main filter is in working order, put it back in
operation to avoid stopping the fuel system for the time of the bypass filter maintenance.
The bypass filter shall be serviced as soon as possible, to ensure that it is available if the
main filter needs to be taken out of use again.
5.4.6 Sludge pump malfunction GUID-EFB4483B-05BD-4A3F-9A64-457E8C5155D4
A sludge pump malfunction may be caused by incorrect valve positions or by problems in

the compressed air supply.
● Check that the manual shut-off valves in the compressed air line and the sludge disposal
line are fully open.
● Check that the pump control valve in the compressed air line is not bypassed.
● Check that the valves on the suction side of the pump are in the correct positions
(normally drawing sludge from the filter).
● Check the setting of the air pressure reducer. If the air supply pressure is insufficient,
check also the pressure drop over the air filter to verify that the filter is not clogged.
Make sure that the trace heating of the sludge line is in operation. Failure of the trace
heating may cause pumping problems due to the increased viscosity.
5.4.7 Quick-closing valve closed GUID-34DB89DE-9DE2-4181-AFD7-FBAA4AB7341C
An alarm is activated if the limit switch indicates that the quick-closing valve in the fuel line
is in the closed position. The valve must be open to enable the fuel supply.
Check that the control switch of the quick-closing valve is in the correct position. If the
valve fails to open, check the compressed air supply. Make sure that the control air

pressure is sufficient, that the shut-off valves in the air supply line are fully open and that
there is no other blockage (such as a clogged air filter).
If no other reason for the valve malfunction can be found, inspect the quick-closing valve
for damage. Also check the limit switch and the electrical connections.


Operation Manual 6. Maintenance
6. Maintenance
Related topics
Safety notes for maintenance work...................................................................................... 2-2
Starting after maintenance work...........................................................................................4-2
Stopping for maintenance work........................................................................................... 4-4
The maintenance comprises regular inspections, preventive maintenance and replacement

of worn or damaged parts. The maintenance must be carefully done at the right intervals,
which partly depend on the running time and other operating conditions. All maintenance
activities shall be recorded along with the reason for the maintenance.
NOTE
For information about maintenance intervals and instructions on performing the
maintenance tasks, refer to the plant maintenance manual for auxiliary
equipment and to the manuals issued by the original equipment manufacturers.
6.1 Maintaining the fuel feeder GUID-C3AF326E-164A-4DBA-8E2B-F42237018D3C
The fuel feeder is essential for the operation of the engines, and major maintenance of the
unit typically requires that the engines be stopped, unless a backup unit is installed. To
minimize the stop time, the maintenance of the fuel feeder should be performed in
connection with the engine maintenance stops when possible.
Most of the equipment in the fuel feeder is in continuous operation when the engines are
running. The fuel supply must never be interrupted when an engine is in operation. Some
components are provided with bypass or standby means, allowing minor maintenance work
to be performed without shutting down the feeder completely. The automatic fuel filter can
be serviced by temporarily directing the fuel flow to the bypass filter. One of the parallel
HFO feeder pumps can also be taken out of use for maintenance.
Some maintenance tasks require that the system be drained. The HFO lines must always be
emptied if the trace heating needs to be stopped.

6. Maintenance Operation Manual

Operation Manual A. Technical specifications
A. Technical specifications
NOTE
For detailed technical data, refer to the device list and the dimensional drawing
of the unit.
HFO feeder pump

8.5 15 36
Capacity 8.5 m3/h 15 m3/h 36 m3/h
Motor power 4 kW 5.5 kW 15 kW
Sludge pump
Capacity 3 m3/h
Sludge tank
Volume 36 l
Air bottle
Volume 15 l
DBAE136813b Confidential A-1

A. Technical specifications Operation Manual
A-2 Confidential DBAE136813b

Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets.
By emphasising technological innovation and total efficiency, Wärtsilä maximises the environmental
and economic performance of the vessels and power plants of its customers. Wärtsilä is listed on the
NASDAQ OMX Helsinki, Finland.
See also www.wartsila.com
WÄRTSILÄ® is a registered trademark. © 2017 Wärtsilä Corporation.
Wärtsilä Services Main Office Vaasa, Finland

Switchboard +358 10 709 0000
Find local offices at www.wartsila.com/contact

HFO Feeder 3.0 - Operation Manual - EN

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HFO Feeder 3.0 - Operation Manual - EN

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Operation Manual

Date of issue 18.08.2017

1. About this manual........................................................................................................................................ 1-1

2. Safety notes.................................................................................................................................................. 2-1

3. System descriptions..................................................................................................................................... 3-1

4. Start and stop............................................................................................................................................... 4-1

A. Technical specifications............................................................................................................................. A-1

1. About this manual

1.1 Product identification GUID-0BB44107-C5C0-467F-B355-573C37234A6F

Table 1-1 Reference documents

Model Flow diagram Dimensional drawing Device list

1.2 Objective GUID-5DFA6976-F7C0-4C91-BA0F-5130F2DE2C03

1.3 Use of symbols GUID-7CCEB85B-87B1-4B4A-B618-FD8B38F102A6

DBAE136813b Confidential 1-1

1.4 Preconditions GUID-67C2D2FC-AC9D-4F37-889F-2D19209B6D81

1-2 Confidential DBAE136813b

2.1 General safety notes GUID-B2F39505-B588-4D24-9B53-5874E70B9D0C

2.2 Elementary plant safety GUID-5DE929B3-C253-4A74-9499-08E3F98206A1

DBAE136813b Confidential 2-1

Burning or splashing hazard

Clean working space

Working in confined spaces

2.3 Safety notes for maintenance work GUID-42DFB1C2-416A-4B61-A8DB-9CD7CA39B522

2-2 Confidential DBAE136813b

DBAE136813b Confidential 2-3

This page has intentionally been left blank.

2-4 Confidential DBAE136813b

3.1 Overview of the fuel feeder GUID-EDD22980-FAEF-4455-8D8E-B1DD1DA3DA18

Fig 3-1 Fuel feeder GUID-C9CED413-A2F6-47C0-A50C-A2852C44D5F1 v1

3.2 Fuel system GUID-9221B170-CAE0-4358-8A4A-8759B310180D

DBAE136813b Confidential 3-1

(A) HFO inlet

Fig 3-2 HFO feeder (single) GUID-2EB32820-AD86-42BF-B534-BC808EC37354 v1

(A) HFO inlet

Fig 3-3 HFO feeder (double 8.5 and 15 m³/h) GUID-77707F50-49B4-4456-9DA3-0D348C4AF1D1 v1

3-2 Confidential DBAE136813b

(A) HFO inlet

Fig 3-4 HFO feeder (double 36 m³/h) GUID-4DDFAE4F-8D5D-4359-AB1D-3F153E4D9FC6 v1

3.2.1 Safety shut-off valves GUID-6317F50B-47BE-4114-87AD-7D924C239AAD

3.2.2 HFO feeder pumps GUID-EDF21800-B2F3-497E-9409-88B59123EEE5

DBAE136813b Confidential 3-3

3.2.3 Automatic filter GUID-6474D33C-A323-47D3-ADA7-28AF32C1C9D9

3.3 Compressed air system GUID-5E3E6359-1175-4B4D-AB71-729D29B8FAA9

3.3.1 Instrument air filter GUID-004A91BC-B309-4452-9310-5CBB42BA5D3F

3.4 Sludge system GUID-ABE2EEA7-9731-43E1-A9F0-C2F9CC68752E

3-4 Confidential DBAE136813b

3.5 Trace heating GUID-D6E90826-D3DA-4D49-B69F-019C7B0DDCB0

3.6 Control system GUID-016E53B6-7909-4F27-A80E-1D238E3E0214

DBAE136813b Confidential 3-5

3.7 Manual valves and indicators in the fuel feeder

Table 3-1 Manual valves in the fuel feeder (single)

V019 Open [1]

V020 Open Sludge pump outlet

V021 Open Sludge pump inlet (from sludge tank)

V050 Open Compressed air inlet

V052 Open Compressed air to safety shut-off valve

V062 Closed Compressed air to sludge pump (manual operation)

V063 Open HFO inlet

V064 Open HFO outlet

Continued on next page

3-6 Confidential DBAE136813b

V070 Open Steam to trace heating