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Start Visco T-Stop o Boos Instru Ster U Uctions Unit S: GE EA Mechan Nical Equip Pment
Start Visco T-Stop o Boos Instru Ster U Uctions Unit S: GE EA Mechan Nical Equip Pment
uctions
s
Viscoo Boosster Unit
U
Project: YZJ2013-1
1091
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
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
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.
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
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.
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
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
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!
Open shut-off valve 10-7-029 mounted in the supply line to the compensation damping
pressure tank(s) 10-2-002
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
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.
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
Heater ACTIVATION
The fuel viscosity will be controlled by heating valve 06-7-003 and sensor 10-9-021
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
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!
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"
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.
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"
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.
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
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.
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.
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.
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.