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Startt-Stop instru

uctions
s
Viscoo Boosster Unit
U

Project: YZJ2013-1
1091

Customer: Jiangsu N ew Yangzi Shipbuilding


S Co.,
C Ltd.

Document No.: 1.451.323 .175 VBU start-stop

WS Order N
No.: 1.451.323 .175

GE
EA Mechan
nical Equip
pment / GE
EA Westfallia Separa
ator Group
p
WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

CONTENT:
- Start-up Instructions (filling, flushing, adjustments)
- Start-up Instructions DO Operating Mode
- Start-up Instructions MGO Operating Mode
- Start-up Instructions HFO Operating Mode
- Shutting Down the Complete Fuel Supply Modul (HFO => MDO)
- Shutting Down the Complete Fuel Supply Modul (HFO => MGO)
- Shutting Down the engines without Switching Over from HFO to MDO/MGO
- HFO => MDO switch over procedure
- MDO => HFO switch over procedure
- HFO => MGO switch over procedure
- MGO => HFO switch over procedure
- MDO => MGO switch over procedure
- MGO => MDO switch over procedure
- Emergency Operation MDO/MGO-Pump

Content 1 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Start-up Instructions (filling, flushing, adjustments)


This chapter describes the initial flushing of the VBU with MGO/MDO, checkpoints and
adjustments
This chapter describes the initial flushing of the VBU with MDO, checkpoints and
adjustments
Set control switches 1S1/ 2S1 (control switch feed pump) to “OFF” position.
Set control switches 1S3 / 2S3 (control switch booster pump) to “OFF” position.
Set the additional DO/MDO pump(s) switch(es) to “0” position.
Set the pre-selection switch local/remote to “local” position.
Switch on the main switches 1S0 / 2S0 on the control cabinet.
Fuel type
Bring the 3/2-way flange valve 10-7-007 to “MDO” position.
Push the MDO key at the control unit
Bring the 3/2-way flange valve (10-7-001) to “MDO/MGO” position. just for information
Check the position at control cabinet display. If no limit switch is activated a time
delayed alarm signal will occur. The VBU will operate in HFO-mode!
All error messages could be acknowledged.
Close all shut-off valves. Open the pressure gauge cocks of the pressure gauges to flow
to monitoring device.
Automatic filter
Open valves to supply automatic back flushing filter (10-4-003) with compressed air!
During initial start the automatic filter must be activated on operator panel.
Switch over the indicator filter 99-4-001/002/003/004 to one filter position. Pay attention
to the position of the arrow marked on the top of the filter.
Switch over the automatic back flushing filter (10-4-003) to the bypass filter. Pay
attention to the position of the arrow marked on the top of the filter.

Feeder part
Close shut-off valves 10-7-011/012 at the fuel oil consumption meter 10-9-011 and open
bypass valve 10-7-013
Close shut-off valves at the remaining fuel oil consumption meters. (10-9-024,12-9-001)
Open bypass valve (10-7-028, 12-7-006).
Open shut-off valves on the suction and discharge side of the feed pumps.
Fill the pipes on the suction side with oil. Vent the piping system via pressure switch
cock 10-7-030, if necessary (located on delivery side of feed pumps)!
(Safety pre-caution: Be sure to avoid dry running of the feed pumps!!!)
Open vent screw at pump housings until fuel is visible
Feeder pump start manually: Set switch 1S1 (control switch feed pump) to “ON”
position.
Check the pressure regulating valve (10-7-006). Close connection to mixing tank or wait
until mixing tank is filled and pressure rises up. Check the pressure regulating valve
(PCV) by reading off the pressure on the pressure gauge on the control cabinet
(pressure setting, see set point list).
If the pressure regulating valve needs re-adjustment, follow the instructions in
the instruction manual of the supplier.
Filling the mixing and degassing tank. (Check of level switch)
Wait until the indication lamp LSL (10-9-012) tank at the control unit display continuously
lights.
Then close solenoid valve 08-7-002, open vent valve 11-7-001 again. Compressed air
conditions see set point list. The conditions for automatic degassing of the system are
now met.

Booster part
Close the feed and discharge shut-off valves 10-7-018/019/020/021 of the heavy fuel oil
preheaters (safety check).
Open the shut-off valve 10-7-022 of the bypass line of the preheaters.
Open shut-off valves on the suction and discharge side of the booster pumps and fill the
pipes with oil. Vent the piping system via pressure switch cock 10-7-031, if necessary
(on delivery side of circulation pump)!
Open vent screw at pump housings until fuel is visible
(Safety pre-caution: Be sure to avoid dry running of the booster pump!!!)
Open shut-off valves of the fuel cooler 10-5-005

Flushing 2 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Booster pump start manually: Set switch 1S3 (control switch booster pump) to “ON”
position.
Open shut-off valve 10-7-029 mounted in the supply line to the compensation damping
pressure tank(s) 10-2-002
Flush the system for approx. 30 min.

Flushing 3 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Booster part fuel cooler 10-5-005


Open shut-off valves before and after the viscosity measuring device and close the
bypass line to activate the fuel cooler control (min. viscosity)
- Open fuel 2-way valves at cooler 10-7-008/009
- Close fuel 2-way valve 10-7-010 cooler bypass
- Cooling water flow must be initiated after fuel has been switched over to
cooler completely
- a message on PLC will indicate the necessity to open cooling water
valves. STEPWISE
- Too quick valve action could lead to fuel-temperature shock at
engine

Open shut-off valves of fuel oil consumption meter 10-9-024


Switch back to the automatic back flushing filter. Pay attention to the position of the
arrow marked on the top of the filter.
Flush the system for approx. 3-4 hours.
While flushing all standby/bypass parts must be flushed. (approx. 1 minute)
a) Switch back from bypass to automatic back flushing. Pay attention to the position
of the arrow marked on the top of the filter.
b) Fuel oil consumption meter, open shut-off valve of the bypass line and close shut-
off valves of the main line.
(at all fuel oil consumption meters)
c) Viscosity meter, open shut-off valve of the bypass line and close shut-off valves of
the main line.
d) Fuel oil preheaters, switch over to stand by preheaters
e) Fuel oil preheaters, after preheaters have been flushed open shut-off valve of the
bypass line and close shut-off valves of the main line.
Open shut-off valves 10-7-011/012 of fuel oil consumption meter 10-9-011 and close
bypass 10-7-013
Open shut-off valves 10-7-026/027 of fuel oil consumption meter 10-9-024 and close
bypass 10-7-028
Open shut-off valves 12-7-004/005 of fuel oil consumption meter 12-9-001 and close
bypass 12-7-006
Push the active pump keys at control unit to switch off all pumps and switch over the
pump control switches to "0" position.
Clean all strainers (Y-strainers, duplex filter, bypass filer, indicator filter)

Emergency DO-system
Open shut-off valves from DO daytank to pump
Check fuel return from engine (correct day tank!)
Fill the pipes on the suction side with oil. Vent the piping system via 3-way ball cock 20-
7-030, if necessary (located on delivery side of feed pumps)!
Safety pre-caution: Be sure to avoid dry running of the DO pumps!!!
Flush emergency MDO/MGO-pump/system with DO/MGO:
Flush emergency MGO-pump/system with MGO:
- Open shut-off valves from DO pump to engine
- Switch on DO-pump 20-3-001 and flush for 30 minutes
Switch off DO pumps
Clean all strainers in DO-sytem

Flushing 4 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Start-up Instructions DO Operating Mode


This chapter describes the VBU start up in DO operation mode.
PROVIDED THAT THE VBU HAS BEEN FLUSHED / FILLED ACCORDING TO THE
FLUSHING CHAPTER. MAKE SURE THAT ALL STRAINERS/FILTERS ARE CLEAN
AND ALL PIPES ARE COMPLETELY FILLED UP/VENTED.
Make sure that the emergency DO-pump is ready for operation
Make sure that bypass filter of automatic back flushing filter 10-4-003 is clean.
Set control switches 1S1/ 2S1 (control switch feed pump) to “OFF” position.
Set control switches 1S3 / 2S3 (control switch booster pump) to “OFF” position.
Set the additional DO/MDO pump(s) switch(es) to “0” position.
Set the pre-selection switch local/remote to “local” position.
Close shut-off valves for the trace heating from and to the machine. (module trace
heating off).
Close trace heating steam/thermal oil valve 06-7-001
Switch on the main switches 1S0 / 2S0 on the control cabinet.
Fuel type
Push the MDO key at the control unit
Bring the 3/2-way flange valve 10-7-007 to “MDO” position.
Bring the 3/2-way flange valve (10-7-001) to “MDO/MGO” position. just for information
Check the position at control cabinet display. If no limit switch is activated a time
delayed alarm signal will occur. The VBU will operate in HFO-mode!

Automatic filter
Open valves to supply automatic back flushing filter (10-4-003) with compressed air!
Switch over the indicator filter 99-4-001/002/003/004 to one filter position. Pay attention
to the position of the arrow marked on the top of the filter.
Switch over from bypass filter to automatic back flushing filter (10-4-003). Pay attention
to the position of the arrow marked on the top of the filter.

Feeder part
Open shut-off valves on the suction and discharge side of the feed pumps.
Fill the pipes on the suction side with oil. Vent the piping system via pressure switch
cock 10-7-030, if necessary (located on delivery side of feed pumps)!
(Safety pre-caution: Be sure to avoid dry running of the feed pumps!!!)
Feeder pump start manually: Set switch 1S1 (control switch feed pump) to “ON”
position.

Filling the mixing and degassing tank. (Check of level switch)


Wait until the indication lamp LSL (10-9-012) tank at the control unit display continuously
lights.
Close vent valve 11-7-001, open compressed air shut-off valve 08-7-001 on top of the
mixing tank and wait until the indication lamp LSL Tank 10-9-012 on the control unit
display goes off. Solenoid valve 08-7-002 to be opened locally or at touch panel
Then close solenoid valve 08-7-002, open vent valve 11-7-001 again. Compressed air
conditions see set point list. The conditions for automatic degassing of the system are
now met.

Booster part
Close the feed and discharge shut-off valves 10-7-018/019/020/021 of the heavy fuel oil
preheaters (safety check).
Open the shut-off valve 10-7-022 of the bypass line of the preheaters.
Open shut-off valves on the suction and discharge side of the booster pumps and fill the
pipes with oil. Vent the piping system via pressure switch cock 10-7-031, if necessary
(on delivery side of circulation pump)!
(Safety pre-caution: Be sure to avoid dry running of the booster pump!!!)
Pre-select the booster pump 1 to "automatic" position and push the booster pump 1 key
via the control unit, to switch on the booster pump 1. Pre-select the booster pump 2 to
"0” position.
(Safety check!!!) Pay attention, start of booster pump in “automatic mode” is only
possible when LSL level switch 10-9-012 of the mixing tank is activated!

DO 5 of 22 VBU Start-Stop_2015.xlsm
WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Open shut-off valve 10-7-029 mounted in the supply line to the compensation damping
pressure tank(s) 10-2-002
Booster part fuel cooler 10-5-005 ACTIVATION
Open shut-off valves before and after the viscosity measuring device and close the
bypass line to activate the fuel cooler control (min. viscosity)
If fuel vsicosity is below MIN-setpoint the fuel cooler has to be activated
- Cooling water flow must be initiated after fuel has been switched over to
cooler completely
- a message on PLC will indicate the necessity to open cooling water
valves. STEPWISE
- Too quick valve action could lead to fuel-temperature shock at
engine

Open shut-off valves 10-7-011/012 of fuel oil consumption meter 10-9-011 and close
bypass 10-7-013
Open shut-off valves 10-7-026/027 of fuel oil consumption meter 10-9-024 and close
bypass 10-7-028
Open shut-off valves 12-7-004/005 of fuel oil consumption meter 12-9-001 and close
bypass 12-7-006

Switch all pumps and valves to "AUTO"-mode


The VBU is now working in DO-mode.
All standby components and bypass-pipes have to be flushed with MDO. (feeder
pumps, booster pumps, pre-heaters, strainers, etc.)

DO 6 of 22 VBU Start-Stop_2015.xlsm
WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Start-up Instructions MGO Operating Mode


This chapter describes the VBU start up in MGO operation mode.
PROVIDED THAT THE VBU HAS BEEN FLUSHED / FILLED ACCORDING TO THE
FLUSHING CHAPTER. MAKE SURE THAT ALL STRAINERS/FILTERS ARE CLEAN
AND ALL PIPES ARE COMPLETELY FILLED UP/VENTED.
Make sure that the emergency DO-pump is ready for operation
Make sure that bypass filter of automatic back flushing filter 10-4-003 is clean.
Set control switches 1S1/ 2S1 (control switch feed pump) to “OFF” position.
Set control switches 1S3 / 2S3 (control switch booster pump) to “OFF” position.
Set the additional DO/MDO pump(s) switch(es) to “OFF” position.
Set the pre-selection switch local/remote to “local” position.
Close shut-off valves for the trace heating from and to the machine. (module trace
heating off).
Close trace heating steam/thermal oil valve 06-7-001
Switch on the main switches 1S0 / 2S0 on the control cabinet.
Fuel type
Push the MGO key at the control unit
Bring the 3/2-way flange valve 10-7-007 to “MGO” position.
Bring the 3/2-way flange valve 10-7-001 to “MDO/MGO” position. just for information
Check the position at control cabinet display. If no limit switch is activated a time
delayed alarm signal will occur. The VBU will operate in HFO-mode!

Automatic filter
Open valves to supply automatic back flushing filter (10-4-002) with compressed air!
Switch over the indicator filter 99-4-001/002/003/004 to one filter position. Pay attention
to the position of the arrow marked on the top of the filter.
Switch over from bypass filter to automatic back flushing filter 10-4-003. Pay attention to
the position of the arrow marked on the top of the filter.

Feeder part
Open shut-off valves on the suction and discharge side of the feed pumps.
Fill the pipes on the suction side with oil. Vent the piping system via pressure switch
cock 10-7-030, if necessary (located on delivery side of feed pumps)!
(Safety pre-caution: Be sure to avoid dry running of the feed pumps!!!)
Feeder pump start manually: Set switch 1S1 (control switch feed pump) to “ON”
position.
Filling the mixing and degassing tank. (Check of level switch)
Wait until the indication lamp LSL (10-9-012) tank at the control unit display continuously
lights.
Close vent valve 11-7-001, open compressed air shut-off valve 08-7-001 on top of the
mixing tank and wait until the indication lamp LSL Tank 10-9-012 on the control unit
display goes off. Solenoid valve 08-7-002 to be opened locally or at touch panel
Then close solenoid valve 08-7-002, open vent valve 11-7-001 again. Compressed air
conditions see set point list. The conditions for automatic degassing of the system are
now met.
Flushing of feeder part fuel supply pump
Switch over to standby pump for flushing this volume

Booster part
Close the feed and discharge shut-off valves 10-7-018/019/020/021 of the heavy fuel oil
preheaters (safety check)
Open the shut-off valve 10-7-022 of the bypass line of the preheaters.
Open shut-off valves on the suction and discharge side of the booster pumps and fill the
pipes with oil. Vent the piping system via pressure switch cock 10-7-031, if necessary
(on delivery side of circulation pump)!
(Safety pre-caution: Be sure to avoid dry running of the booster pump!!!)
Open shut-off valves of the fuel cooler 10-5-005
Pre-select the booster pump 1 to "automatic" position and push the booster pump 1 key
via the control unit, to switch on the booster pump 1. Pre-select the booster pump 2 to
"0” position.
(Safety check!!!) Pay attention, start of booster pump in “automatic mode” is only
possible when LSL level switch 10-9-012 of the mixing tank is activated!

MGO 7 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Open shut-off valve 10-7-029 mounted in the supply line to the compensation damping
pressure tank(s) 10-2-002

MGO 8 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Booster part fuel cooler 10-5-005 ACTIVATION


Open shut-off valves before and after the viscosity measuring device and close the
bypass line to activate the fuel cooler control (min. viscosity)
If fuel vsicosity is below MIN-setpoint the fuel cooler has to be activated
- Cooling water flow must be initiated after fuel has been switched over to
cooler completely
- a message on PLC will indicate the necessity to open cooling water
valves. STEPWISE
- Too quick valve action could lead to fuel-temperature shock at
engine

Open shut-off valves 10-7-011/012 of fuel oil consumption meter 10-9-011 and close
bypass 10-7-013
Open shut-off valves 10-7-026/027 of fuel oil consumption meter 10-9-024 and close
bypass 10-7-028
Open shut-off valves 12-7-004/005 of fuel oil consumption meter 12-9-001 and close
bypass 12-7-006

Switch all pumps and valves to "AUTO"-mode


The VBU is now working in MGO-mode.
All standby components and bypass-pipes have to be flushed with MGO. (feeder
pumps, booster pumps, pre-heaters, strainers, etc.)

MGO 9 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Start-up Instructions HFO Operating Mode


This chapter describes the VBU start up in HFO operation mode.
PROVIDED THAT THE VBU HAS BEEN FLUSHED / FILLED ACCORDING TO THE
FLUSHING CHAPTER. MAKE SURE THAT ALL STRAINERS/FILTERS ARE CLEAN
AND ALL PIPES ARE COMPLETELY FILLED UP/VENTED.
Make sure that the emergency DO-pump is ready for operation
Make sure that bypass filter of automatic back flushing filter 10-4-003 is clean.
Set control switches 1S1/ 2S1 (control switch feed pump) to “OFF” position.
Set control switches 1S3 / 2S3 (control switch booster pump) to “OFF” position.
Set the additional DO/MDO pump(s) switch(es) to “0” position.
Set the pre-selection switch local/remote to “local” position.
Close trace heating steam/thermal oil valve 06-7-001
Open shut-off valves for the trace heating from and to the engines
Switch on the main switches 1S0 / 2S0 on the control cabinet.
Fuel type
Push the HFO key at the control unit
Bring the 3/2-way flange valve 10-7-001 to “HFO” position. just for information
Check the position at control cabinet display. If no limit switch is activated a time
delayed alarm signal will occur. The VBU will operate in HFO-mode!

Automatic filter
Open valves to supply automatic back flushing filter (10-4-003) with compressed air!
Switch over the indicator filter 99-4-001/002/003/004 to one filter position. Pay attention
to the position of the arrow marked on the top of the filter.
Switch over from bypass filter to automatic back flushing filter (10-4-003). Pay attention
to the position of the arrow marked on the top of the filter.

Feeder part
Open shut-off valves on the suction and discharge side of the feed pumps.
Fill the pipes on the suction side with oil. Vent the piping system via pressure switch
cock 10-7-030, if necessary (located on delivery side of feed pumps)!
(Safety pre-caution: Be sure to avoid dry running of the feed pumps!!!)
Feeder pump start manually: Set switch 1S1 (control switch feed pump) to “ON”
position.

Filling the mixing and degassing tank. (Check of level switch)


Wait until the indication lamp LSL (10-9-012) tank at the control unit display continuously
lights.
Close vent valve 11-7-001, open compressed air shut-off valve 08-7-001 on top of the
mixing tank and wait until the indication lamp LSL Tank 10-9-012 on the control unit
display goes off. Solenoid valve 08-7-002 to be opened locally or at touch panel
Then close solenoid valve 08-7-002, open vent valve 11-7-001 again. Compressed air
conditions see set point list. The conditions for automatic degassing of the system are
now met.
Booster part
Close the shut-off valve 10-7-022 of the bypass line of the preheaters.
Open the fuel feed and discharge shut-off valves of one heavy fuel oil preheater
Open shut-off valves in heating medium pipe for one pre-heater (06-7-006+07-7-001 or
06-7-007+07-7-002)
Open shut-off valves on the suction and discharge side of the booster pumps and fill the
pipes with oil. Vent the piping system via pressure switch cock 10-7-031, if necessary
(on delivery side of circulation pump)!
(Safety pre-caution: Be sure to avoid dry running of the booster pump!!!)
Pre-select the booster pump 1 to "automatic" position and push the booster pump 1 key
via the control unit, to switch on the booster pump 1. Pre-select the booster pump 2 to
"0” position.
(Safety check!!!) Pay attention, start of booster pump in “automatic mode” is only
possible when LSL level switch 10-9-012 of the mixing tank is activated!
Open shut-off valve 10-7-029 mounted in the supply line to the compensation damping
pressure tank(s) 10-2-002

HFO 10 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Open shut-off valves before and after the viscosity measuring device and close the
bypass line to activate the fuel viscosity control
Open shut-off valves 06-7-002/004 at heating valve 06-7-003

HFO 11 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Heater ACTIVATION
The fuel viscosity will be controlled by heating valve 06-7-003 and sensor 10-9-021

Booster part fuel cooler 10-5-005 DE-ACTIVATION


- Cooling water flow must be stopped 16-7-001
- Open fuel 2-way valve 10-7-010 cooler bypass
- Close fuel 2-way valves at cooler 10-7-008/009

Open shut-off valves 10-7-011/012 of fuel oil consumption meter 10-9-011 and close
bypass 10-7-013
Open shut-off valves 10-7-026/027 of fuel oil consumption meter 10-9-024 and close
bypass 10-7-028
Open shut-off valves 12-7-004/005 of fuel oil consumption meter 12-9-001 and close
bypass 12-7-006

Switch all pumps and valves to "AUTO"-mode


The VBU is now working in HFO-mode.
Make sure that bypass filter of automatic back flushing filter 10-4-003 is clean.

Regularly check of the presented injection viscosity until stable characteristics have
adjusted.
Damping tank 10-2-002 must be drained and vented once a week.
All error messages must be acknowledged after checking its reason!

HFO 12 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Shutting Down the Complete Fuel Supply Modul (HFO => MDO)
This chapter describes the switch over to MDO and shut down of VBU in HFO operation
mode
Follow instructions for "HFO => MDO switch over"

Stop the engines.

Flushing the pipe leading to the day tank is possible by switching over the 2/2-way-valve
12-7-001 in return position to the day tank (manually-operated).
Attention: The booster pumps must be switched off. (Risk of pump damage!

Push the active pump keys at the control unit to switch off all pumps and switch over the
pump control switches to "OFF" position.
Switch off the main switch on the control cabinet.

Shut HFO=>MDO 13 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Shutting Down the Complete Fuel Supply Modul (HFO => MGO)
This chapter describes the switch over to MGO and shut down of VBU in HFO operation
mode
Follow instructions for "HFO => MGO switch over"

Stop the engines.

Flushing the pipe leading to the day tank is possible by switching over the 2/2-way-valve
12-7-001 in return position to the day tank (manually-operated).
Attention: The booster pumps must be switched off. (Risk of pump damage!

Push the active pump keys at the control unit to switch off all pumps and switch over the
pump control switches to "0" position.
Switch off the main switch on the control cabinet.

Shut HFO=>MGO 14 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Shutting Down the engines without Switching Over from HFO to MDO/MGO
This chapter describes the shut down of VBU in HFO operation mode
Trace heating sytem
Starting the trace heating system outside the fuel supply module.
Open shut-off valves of the thermal oil or steam inlet

Switch off the main engine or auxiliary engines.


Continuous circulation of the heavy fuel oil (HFO) through the fuel supply module. In
case of longer shut down periods of the engine we recommend to switch off the
whole Visco Booster Module. It is insured by the trace heating system that the
heavy fuel oil will be fluid able in case of re-start. => activate trace heating system
When the engine is started, close the shut-off valves off the trace module heating

Shut HFO 15 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

HFO => MDO switch over procedure


This chapter describes the switch over procedure from HFO to MDO
Trace heating sytem
Shutting down the trace heating system outside the fuel supply module.
Close shut-off valves of the thermal oil or steam inlet (trace heating)

Fuel type
Pre-select “MDO” at select “MDO”-switch at control panel
Push the MDO key at the control unit and check the position via control unit (Display).
Fuel injection temperature ramp
In parallel the heating valve 06-7-003 will be closed on a fuel temperature ramp.
(for a free adjustable time “delay timer Viscosity controller OFF” / Delay time 0 =>
steam/thermal oil valve complete closed and blocked ). As long as viscosity controller is
active the fuel viscosity will be kept on setpoint by reducing heat input.
If fuel temperature is controlled instead of fuel viscosity the fuel temperature will be
decreased on a setpoint ramp (parametric).
Carry out the flushing process until the viscosity reading in the controller display
corresponds to the viscosity of the diesel oil.
Flushing of feeder part fuel supply pump
Switch over to standby pump for flushing this volume
Booster part fuel cooler 10-5-005 ACTIVATION
The fuel cooler has to be activated if the fuel viscosity is below MIN-setpoint (“Value
MDO viscosity cooler ON”)
- Open fuel 2-way valve at cooler 10-7-008/009
- Close fuel 2-way valve 10-7-010 cooler bypass
- Cooling water flow must be initiated after fuel has been switched over to
cooler completely
- a message on PLC will indicate the necessity to open cooling water
valves. STEPWISE
- Too quick valve action could lead to fuel-temperature shock at
engine

Flushing
The HFO in standby components or bypass lines will cool down to ambient air
temperature due to switched off trace heating. To avoid any later blocking all HFO
content in VBU must be replaced by MDO.
Switch over to standby booster pump
Flushing process of the bypass-lines. (approx. 1 minute)
a) Switch over from automatic back flushing filter to bypass. Pay attention to the
position of the arrow marked on the top of the filter.
b) Fuel oil consumption meter, open shut-off valve of the bypass line and close shut-
off valves of the main line.
(at all fuel oil consumption meters)
c) Viscosity meter, open shut-off valve of the bypass line and close shut-off valves of
the main line.
d) Fuel oil preheaters, switch over to stand by preheater
d) Fuel oil preheaters, after standby preheater has been flushed open shut-off valve of
the bypass line 10-7-022 and close shut-off valves of the main line.
Flushing the pipe leading to the day tank is possible by switching over the 2/2-way-valve
in return position to the day tank (manually-operated).
Attention: The booster pumps must be switched off. (Risk of pump damage!
Carry out the flushing process for 4 hours! For other flushing times follow the
instructions in the instruction manual of the motor supplier.
The switch over procedure is completed. The time period for total replacement of HFO
by MDO is depending on total fuel volume in fuel system and fuel consumption.
The VBU is now working in MDO-mode.

HFO=>MDO 16 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

MDO => HFO switch over procedure


This chapter describes the switch over procedure from MDO to HFO
Fuel type
Bring the 3-way valve 10-7-001 to “HFO” position. Push the HFO key at the control unit
and check the position via control unit (Display). The actuator time can be adjusted by a just for information
timer setting.
Attention: Too quick switch over could lead to too fast temperature changing at
engine.
Booster part fuel cooler 10-5-005 DE-ACTIVATION
If fuel vsicosity is above “MDO viscosity controller OFF”-setpoint the fuel cooler has to
be de-activated
- Cooling water flow must be stopped before fuel has been switched over
to cooler bypass. STEPWISE (16-7-001)
- Open fuel 2-way valve 10-7-010 cooler bypass
- Close fuel 2-way valves at cooler 10-7-008/009

Heater ACTIVATION
If the fuel viscosity is above the second max. setpoint the heater will take control over
the viscosity control.
The fuel viscosity will be controlled by heating valve 06-7-003 and sensor 10-9-021

The switch over procedure is completed if fuel temperature and viscosity correspondent
to pure HFO The time period for total replacement of MDO by HFO is depending on total
fuel volume in fuel system and fuel consumption.

MDO=>HFO 17 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

HFO => MGO switch over procedure


This chapter describes the switch over procedure from HFO to MGO
In general we recommend to use MDO as intermediate fuel to avoid fuel
incompatibilities
Trace heating sytem
Shutting down the trace heating system outside the fuel supply module.
Close shut-off valves of the thermal oil or steam inlet (trace heating)
Fuel type
Pre-select “MGO” at select “MDO/MGO”-switch at control panel
Push the MGO key at the control unit and check the position via control unit (Display).
Fuel injection temperature ramp
In parallel the heating valve 06-7-003 will be closed on a fuel temperature ramp.
(for a free adjustable time “delay timer Viscosity controller OFF” / Delay time 0 =>
steam/thermal oil valve complete closed and blocked ). As long as viscosity controller is
active the fuel viscosity will be kept on setpoint by reducing heat input.
If fuel temperature is controlled instead of fuel viscosity the fuel temperature will be
decreased on a setpoint ramp (parametric).
Carry out the flushing process until the viscosity reading in the controller display
corresponds to the viscosity of the diesel oil.
Flushing of feeder part fuel supply pump
Switch over to standby pump for flushing this volume

Booster part fuel cooler 10-5-005 ACTIVATION


The fuel cooler has to be activated if the fuel viscosity is below MIN-setpoint (“Value
MGO viscosity cooler ON”)
- Cooling water flow must be initiated after fuel has been switched over to
cooler completely
- a message on PLC will indicate the necessity to open cooling water
valves. STEPWISE
- Too quick valve action could lead to fuel-temperature shock at
engine
Flushing
The HFO in standby components or bypass lines will cool down to ambient air
temperature due to switched off trace heating. To avoid any later blocking all HFO
content in VBU must be replaced by MGO.
Switch over to standby booster pump
Flushing process of the bypass-lines. (approx. 1 minute)
a) Switch over from automatic back flushing filter to bypass. Pay attention to the
position of the arrow marked on the top of the filter.
b) Fuel oil consumption meter, open shut-off valve of the bypass line and close shut-
off valves of the main line.
(at all fuel oil consumption meters)
c) Viscosity meter, open shut-off valve of the bypass line and close shut-off valves of
the main line.
d) Fuel oil preheaters, switch over to stand by preheater
d) Fuel oil preheaters, after standby preheater has been flushed open shut-off valve of
the bypass line 10-7-022 and close shut-off valves of the main line.

Carry out the flushing process for 4 hours! For other flushing times follow the
instructions in the instruction manual of the motor supplier.
The switch over procedure is completed. The time period for total replacement of HFO
by MGO is depending on total fuel volume in fuel system and fuel consumption.
The VBU is now working in MGO-mode.

HFO=>MGO 18 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

MGO => HFO switch over procedure


This chapter describes the switch over procedure from MGO to HFO
In general we recommend to use MDO as intermediate fuel to avoid fuel
incompatibilities
Fuel type
Bring the 3-way valve 10-7-001 to “HFO” position. Push the HFO key at the control unit
and check the position via control unit (Display). The actuator time can be adjusted by a
timer setting.
Attention: Too quick switch over could lead to too fast temperature changing at
engine.
Booster part fuel cooler 10-5-005 DE-ACTIVATION
If fuel vsicosity is above “MGO viscosity controller OFF”-setpoint the fuel cooler has to
be de-activated
- Cooling water flow must be stopped before fuel has been switched over
to cooler bypass. STEPWISE (16-7-001)
- Open fuel 2-way valve 10-7-010 cooler bypass
- Close fuel 2-way valves at cooler 10-7-008/009
Heater ACTIVATION
If the fuel viscosity is above the second max. setpoint the heater will take control over
the viscosity control.
The fuel viscosity will be controlled by heating valve 06-7-003 and sensor 10-9-021
The switch over procedure is completed if fuel temperature and viscosity correspondent
to pure HFO The time period for total replacement of MGO by HFO is depending on
total fuel volume in fuel system and fuel consumption.

MGO=>HFO 19 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

MDO => MGO switch over procedure

Pre-select “MGO” at select “MDO/MGO”-switch at control panel


Bring 3-way valve 10-7-007 to “MGO” position. PLC-controlled
Flushing of feeder part fuel supply pump
Switch over to standby pump for flushing this volume
Booster part fuel cooler 10-5-005 ACTIVATION
Remark: If the cooler has been set into operation during MDO-mode already this
procedure can be skipped.
The fuel cooler has to be activated if the fuel viscosity is below MIN-setpoint (“Value
MGO viscosity cooler ON”)
- Cooling water flow must be initiated after fuel has been switched over to
cooler completely
- a message on PLC will indicate the necessity to open cooling water
valves. STEPWISE
- Too quick valve action could lead to fuel-temperature shock at
engine

Carry out the flushing process until the viscosity reading in the controller display
corresponds to the viscosity of the gas oil.
The switch over procedure is completed. The time period for total replacement of MDO
by MGO is depending on total fuel volume in fuel system and fuel consumption.

MDO=>MGO 20 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, CRM: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

MGO => MDO switch over procedure

Pre-select “MDO” at select “MDO/MGO”-switch at control panel


Booster part fuel cooler 10-5-005 DE-ACTIVATION
If fuel vsicosity is above “MGO viscosity controller OFF”-setpoint the fuel cooler has to
be de-activated
- Cooling water flow must be stopped STEPWISE before fuel has been
switched over to cooler bypass
- Open fuel 2-way valve 10-7-010 cooler bypass
- Close fuel 2-way valves at cooler 10-7-008/009
Remark: It is depending on MDO properties and setpoint value if the cooler will be
deactivated or not.
The switch over procedure is completed. The time period for total replacement of MGO
by MDO is depending on total fuel volume in fuel system and fuel consumption.

MGO=>MDO 21 of 22 VBU Start-Stop_2015.xlsm


WS-order: 1451323175, PN: 30017649
Costumer: Jiangsu New Yangzi Shipbuilding Co., Ltd
Hull number: YZJ 2013-1091

Emergency Operation MDO/MGO-Pump


Emergency Operation MGO-Pump

This chapter describes how to start the emergency DO pump by manual


PROVIDED THAT THE EMERGENCY DO SYSTEM HAS BEEN FLUSHED / FILLED
ACCORDING TO THE FIRST CHAPTER. MAKE SURE THAT ALL
STRAINERS/FILTERS ARE CLEAN AND ALL PIPES ARE COMPLETELY FILLED
UP/VENTED.
Fuel type
Bring MDO/MGO valve 10-7-007 to required position
Set switches S1 (stand by feed pump) and S2 (stand by booster pump) to “2” position,
the control switches 1S1/ 2S1 (control switch feed pump) and 1S3 / 2S3 (control switch
booster pump) to “0” position.
Stop feeder and booster pump of VBU
Safety pre-caution: Be sure to avoid dry running of the DO pumps!!!
Open all shut-off valves in DO-section
Make sure that the DO pipe to engine is not blocked. RISK OF PUMP DAMAGE!
Fill the pipes on the suction side with oil. Vent the piping system via pressure switch
cock 20-7-030, if necessary (located on delivery side of feed pumps)!
Open vent screw at pump housings until fuel is visible
Start DO pump by switch "DO-pump"-switch to "ON" position.
In case of "black out" the air driven DO-pump will start automatically
Flush and deaerate the complete DO-section inclunding standby components for
approx. 15 min.
Fuel cooler activation 10-5-004
Switch over 3-way valve 20-7-005 to cooler direction
Open fuel valves 20-7-003/-004 to/from fuel cooler 10-5-005
Close fuel bypass valve 20-7-002
Make sure that fuel valves to booster part at fuel cooler are closed
Make sure that fuel cooler bypass on fuel side in booster part is open
Open cooling water valves 16-7-001/17-7-001
Switch over to second DO-Pump and flush pipe for a few minutes
Flush and deaerate the complete cooler-section for approx. 15 min.
Switch off DO-pump and clean all strainers
Close cooling water valves 16-7-001/17-7-001

Em-DO 22 of 22 VBU Start-Stop_2015.xlsm

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