FramoMounting InstructionMain contents12345689IntroductionLocation on boardEquipment handling - Storage at yardInstallation of submerged cargo pumpsInstallation/Storage of portable equipmentInstallation of submerged ballast pumpsInstallation of hydraulic power unit, closed loopsystemInstallation of electrical equipment1401-0001-4011401-0002-4011401-0003-4011401-0004-4011401-0005-4011401-0006-4011401-0034-41401-0009-4011401-0010-4011401-0012-4011401-0026-41401-0017-4011401-0018-4011401-0019-4011401-0020-40110 Yard equipment12 Installation of deck mounted cargo heat exchangers14 Installation of submerged tank cleaning pumps17 Hydraulic piping18 Cargo piping19 Hydraulic oils - Oil filling - Flushing20 Framo commissioning - TestingJune 2003FramoMounting InstructionNo. 1401-0001-4Feb-2000IntroductionCONTENTS1 Framo documentation2 Ordering new parts - Return of parts3 AddressesFramo Mounting InstructionINTRODUCTIONNo.1401-0001-4 Feb-2000 Page 2 of 41 FRAMO DOCUMENTATIONThe Framo documentation consists of instructions and drawings for installation, operation andservice. This documentation is our property. It is not to be traced, copied or published without ourwritten consent, nor to be misused in any way.Framo Mounting Instruction is the general requirements to the yards for handling and installationof a Framo cargo pumping system, and it contains general instructions for handling, storage andinstallation of Framo equipment, in addition to design and installation of the hydraulic pipingsystem.It is based upon practical experience from installation of high pressure hydraulic systems in co-operation with yards and owners all over the world. Kindly follow the instructions carefully to ensurea successful installation and a well functioning cargo pumping system. Please make specialattention to the following:Think safety during design: - Appropriate location of equipment. - Sufficient service space. - Appropriate lifting equipment for maintenance and repair of installed equipment. - Appropriate marking of noisy areas.Think safety during installation: - Use of correct and approved lifting equipment. - Be aware of foreign voltage from interfaced equipment and switch off the main switch before any work on electrical equipment. - Hydraulic oil (on mineral oil base) has a flash point between 180-230C, and any leakage must not come in contact with heated surfaces. - Hydraulic pipe connections, flanges, valves etc. must not be located above or close to heated surfaces.Think cleanliness during installation: - Maintain a high standard of cleanliness at all times. - Keep pipes and components clean and protected during the whole production- and installation period.Others: - Do not paint mechanical parts of switches (valve shutdown switches, or equal), manometers, level gauges or similar equipment, or flexible rubber elements (flexible hoses, dampers etc.) - Never weld on Framo equipment without special agreement.The instructions are also based upon the authorities' requirements. These are however revisedfrom time to time, and it is therefore necessary to keep oneself informed about the alterations anddiscrepancies between the different national authorities and classification societies.If drawings are sent to Framo for information or comments, yard must call attention to eventualdeviation from Framo Mounting Instruction by giving remarks on the drawings.Framo Mounting InstructionINTRODUCTIONNo.1401-0001-4 Feb-2000 Page 3 of 4Documentation for yards design and installation is supplied to the yard shortly after receivingthe order, and contains the following:FRAMO MOUNTING INSTRUCTIONFRAMO DRAWINGSPUMPING SYSTEMFRAMO DRAWINGS PIPING SYSTEMGeneralrecommendationsand requirementsfor design, handlingand installation ofthe Framo cargopumping system.General ArrangementFramo specificationEquipment drawingsTechnical dataSystem drawingsPiping specificationsLayout drawingsComponent drawingsSupplied only if hydraulicpiping system is includedin Framo supplyFramo Service Manual includes information for initial start-up, operation and maintenance of thesystem. The manuals are supplied to the yard before commissioning.FRAMO SERVICE MANUAL PUMPING SYSTEMFRAMO SERVICE MANUAL PIPING SYSTEMTechnical dataInitial start upOperationMaintenanceDrawings - Part listsPiping specificationLayout drawingsSupplied only if hydraulicpiping system is included in Framo supply2 ORDERING NEW PARTS - RETURN OF PARTSWhen ordering new parts due to repair, guarantee claim or simply because parts are missing,please give the following information: Yard / Hull no. / Name of vessel. Yard claim no. Framo sales order number (see cover for Framo Documentation). Item no., identification no., part name (from Framo Specification or Packing List) and quantity required.- Required delivery date at yard/vessel, marking etc.When parts are returned in connection with guarantee claim or repair, the following must be given:----Yard / Hull number / Name of vessel.Framo sales order number (see cover for Framo Documentation).Reason for return.Name and number of part, vessel's claim no. if applicable.----The parts must be protected against rust and be properly packed.Return of parts to:Frank Mohn Services AS.Attention: Guarantee claim co-ordinatorHardangerveien 150N-5226 NESTTUNFramo Mounting InstructionINTRODUCTIONNo.1401-0001-4 Feb-2000 Page 4 of 43 ADDRESSESSales DepartmentFRANK MOHN A/SP.O. Box 98 SltthaugN-5851 BERGEN, NorwayTelephone:Telefax:E-Mail:Internet:(47) 55 99 90 00(47) 55 99 93 80marine@framo.nowww.framo.comProject ManagementThe Project Department is totally responsible for every order on Framo Cargo PumpingSystem. To handle each individual order, a Project manager in the Project Department will beappointed. The Project manager is the main contact during the project- and installation period.If the order contains hydraulic- or cargo piping, this part of the order will be handled by thePiping Department which will handle the engineering, documentation and supply of piping.A Project engineer in the Piping Department will be appointed accordingly.Checking of the installation during commissioning and follow-up during the guaratee period ishandled by the Service Department. A Project engineer at the Service Department will beappointed, and will be the main contact during the commissioning and guarantee period.Contact addresses:Project DepartmentFRANK MOHN FUSA ASP.O. Box 10N-5641 FUSA, NorwayTelephone:Telefax:E-Mail:(47) 55 99 96 00(47) 55 99 97 84project.marine@framo.noPiping DepartmentFRANK MOHN FLATY A/SFlatyN-5918 FREKHAUG, NorwayTelephone:Telefax:E-Mail:(47) 55 99 94 00(47) 55 99 95 84piping.marine@framo.noService DepartmentFRANK MOHN SERVICES ASP.O. Box 44 SltthaugN-5851 BERGEN, NorwayTelephone:After 1600 hrs.:Telefax:E-Mail:(47) 55 99 92 00(47) 90 99 00 06(47) 55 99 93 82service@framo.noFramoMounting InstructionNo. 1401-0002-4Rev. B Dec-2001Equipment - Location on boardCONTENTS1 Framo cargo pumping system2 Location in general3 Submerged cargo pumps4 Submerged ballast pumps5 Location of other equipment6 Framo control system7 Hydraulic power units8 Hydraulic transmission equipment9 Hydraulic oil storage / Clean oil drain tankFramo Mounting InstructionEQUIPMENT - LOCATION ON BOARDNo.1401-0002-4Rev.B Dec-2001 Page 2 of 81 FRAMO CARGO PUMPING SYSTEMThe Framo hydraulic system is designed as a central hydraulic ring line system. The hydraulicpower unit delivers oil to the main pressure line, and from this line it is possible to run a numberof hydraulic motors as long as the oil delivery is sufficient. In order to control the speed of themotor and to prevent over-speed, a control valve is fitted for each motor.For most of the systems delivered today, the hydraulic power packs, system tank, oil cooler andmain filter are assembled, tested and supplied from our factory as complete compact power units.Fig. 1 Framo cargo pumping system2 LOCATION IN GENERALThe following factors must be considered when selecting suitable locations for the equipment:-------Most efficient suction and stripping possibilityCargo piping layoutHydraulic piping layoutCable layoutNoiseVentilation of power pack roomSufficient service spaceFramo Mounting InstructionEQUIPMENT - LOCATION ON BOARDNo.1401-0002-4Rev.B Dec-2001 Page 3 of 83 SUBMERGED CARGO PUMPSNote! Submerged cargo pumps should be installed at the aft end or in the lowest part of each tank, located either to port or starboard (to allow optimal tank emptying).Arrangement on deckAn obstruction-free zone must be preparedabove the pump, making it possible to lift thecomplete pump out of the tank if necessary.For operation the following valves andconnections must have free access: - Local control valve - Stripping valve - Cargo valve (if not remotely operated) - Cofferdam purging connection - Cargo pipe purging connection - Exhaust trap drain valve - Hydraulic pressure service valveFlexible clampCargo pipeCargo valveStripping pipeStripping valveExhaust trapService valvesLocal control valveHigh pressure pipeLow pressure pipeDrop lineValve fordrop lineC pipestackLBu elkhadPipestack parallelto bulkheadLocation of bracketfor intermediate supportPumps with intermediate supportPipe stack centerline (through thecenter of cargo pipe and hydraulicpipes) to be parallel to the bulkheadwhere the bracket for theintermediate support is welded.Location of bracketsfor lower support ringPosition of suction wellClearance betweensuction bellmouth and wellSuction wellCargo tanks should be designed with suction wells for optimal :- Cargo pumping- Stripping- Service accessFor further information see section 4.Fig. 2Framo Mounting InstructionEQUIPMENT - LOCATION ON BOARDNo.1401-0002-4Rev.B Dec-2001 Page 4 of 84 SUBMERGED BALLAST PUMPSSubmerged ballast pumps should be installed as low as possible and in the aft part of the ship.Suction lines to be designed with ample size to reduce pipe losses and cavitaiton.Arrangement on deckAn obstruction-free zone must beprepared above the pump, making itpossible to lift the pipe stack and thepump head out of the tank ifnecessary.For easy operation the followingvalves and connections must havefree access:- Local control valve- Evacuating control unit- Hydraulic pressure service valveThe header tank must have freeaccess for inspection and filling.For further information see section 6.Fig. 3 Arrangement of ballast pump in tankFramo Mounting InstructionEQUIPMENT - LOCATION ON BOARDNo.1401-0002-4Rev.B Dec-2001 Page 5 of 85 LOCATION OF OTHER EQUIPMENT----Hydraulic driven pumps on deck, see section 7.Hydraulic driven thruster motor, see section 11.Deck mounted cargo heat exchangers, see section 12.Submerged cargo heat exchangers, see section 13.6 FRAMO CONTROL SYSTEMThe Framo cargo pumping system is normally operated/monitored from the Framo control panel,consisting of hydraulic system control panel and cargo pump control panel.The control panel should be installed in the cargo control room or other indoor location where livingquarter conditions can be kept. It should also be sufficiently illuminated and arranged for goodcontact/communication to the cargo manifold area to ensure a proper and safe cargo handling.The panels are sometimes designed for installation in yards console, but the above recommenda-tions still apply.The control system may also be interfaced with, and operated from vessels integrated control system.Local panels / motor starters should be installed in the vicinity of the controlled equipment.Emergency stop arrangementFramo supplies three emergency stop buttons as standard. One to be located close to the powerpack room, and two for location on deck, normally installed close to manifold.7 HYDRAULIC POWER UNIT (HPU)Location of the hydraulic power unit (HPU) must be considered in an early stage of the shipsplanning, and one has to take into consideration:----Minimum noise level in accommodation areaMinimum noise emitted from the shipOptimum pipe routingEasy access for maintenanceGenerally, HPU room location is recommended as shown below.For further information, see section 8.Fig. 4 Location of hydraulic power unitFramo Mounting InstructionEQUIPMENT - LOCATION ON BOARDNo.1401-0002-4Rev.B Dec-2001 Page 6 of 88 HYDRAULIC TRANSMISSION EQUIPMENTLocation of electrical equipment shall comply with degree of protection by enclosure (IP).Electrically operated hydraulic control valves supplied by Framo must be installed in safe area:- Electrical/hydraulical remote control assembly for the hydraulically driven pumps, controlling the pump speed, (normally installed on main deck level).- Thruster pilot control valve assembly, must be installed as close to the thruster motor as possible. For more details, see section 11.Separately supplied pilot filter for these valves must be located as close to the valves as possible.Fig. 5 Location of hydraulic transmission equipmentFramo Mounting InstructionEQUIPMENT - LOCATION ON BOARDNo.1401-0002-4Rev.B Dec-2001 Page 7 of 89 HYDRAULIC OIL STORAGE / CLEAN OIL DRAIN TANKThe hydraulic oil storage / clean oil drain tank incl. necessary equipment is yard supply.Design requirements are described in section 10.Framo recommend to install the storage/clean oil drain tank below the HPU, either as two sepa-rated tanks, or as a combination tank for storage- and clean oil drain. With this location, eventualoverflow from the system tank and drainage from the HPU will gravitate down to the clean oildrain tank.The storage tank/clean oil drain tank must be installed in-door, and the ship bulkhead or shellplating must not be part of the tank. This to avoid condensation and water in the hydraulic oil dueto temperature differences. Neither must heated surfaces with temperature above 60C be part ofthe tank, (fuel tanks etc.).The transfer unit must be located close to the storage/clean oil drain tank to minimise the suctionside pressure drop.Fig. 6 Separate storage- and clean oil drain tankFramo Mounting InstructionEQUIPMENT - LOCATION ON BOARDNo.1401-0002-4Rev.B Dec-2001 Page 8 of 8Fig. 7 Combined storage- and clean oil drain tankFramoMounting InstructionNo. 1401-0003-4Feb-2000Equipment handling - Storage at yardCONTENTS1 Goods receival2 Preservation, packing and marking3 Handling of Framo equipment3.13.23.33.4Handling of power unitsHandling of submerged cargo- and ballast pumpsHandling of heat exchangerHandling of portable equipment4 Storage at yard4.1 Storage in dry and clean conditions4.2 Warehouse storage4.3 Outdoor storageFramo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDNo.1401-0003-4 Feb-2000 Page 2 of 91 GOODS RECEIVALImmediately after receipt of equipment, please check that the supply corresponds to the packinglist. Any missing items must be reported to Frank Mohn Fusa AS without delay.The equipment should be carefully inspected for transportation damage. Damages should berecorded, photographed, witnessed and reported to carriers and to Frank Mohn Fusa AS.2 PRESERVATION, PACKING AND MARKINGPreservationStainless steel components are pickled, cleaned and ready for installation.Mild steel components are protected against corrosion by means of priming or painting outside andprotecting oil inside. The preserving oil is mixable with the hydraulic oil, and will give sufficientprotection for about 1 year provided that the blank flanges are kept on.Un-primed mild steel seal faces are normally protected by a removable corrosion preventivecoating (Tectyl).Packing and markingGenerally most of the Framo components are packed in plastic-covered wooden boxes.Electrical equipmentlike electrical cabinets, starters and control panels have also silica gel inside for protection againstmoisture. Ventilation openings and cable entrances on electrical motors are in addition covered byfire resistant tarpaulin.Power unitsare normally covered by plastics and shipped in containers. If they are shipped on open flat racks,they are covered by light tarpaulin (reinforced plastic) in addition to the plastics.Submerged cargo- and ballast pumpsare supported by special wooden racks. If the length is more than 14 meters they are split in twosections to simplify handling and transport.Smaller pump units, deck trunks etc.are fastened on pallets and covered by plastics.The deck trunks seal faces are protected by plywood.Prefabricated pipesare packed on transport racks with wooden frames and covered by plastics.Framo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDDispatch documents are - Packing list: - Packing specification: - Container specification:No.1401-0003-4 Feb-2000 Page 3 of 9Address and dispatch information in addition to the listed itemsCase- and pallet numberContainer-, case- and pallet number if shipped in containersThese documents are packed with the components.For further information see below:Packing listContentsFM order no.CustomerDispatch informationItemItem detailsSee Framo specification *Package no., Identification no.,quantity, description etc.* Every component is marked with an item number according to the packing list.Packing specificationContentsFM order no.Packages no.Packages detailsEvery case or pallet is markedwith packages no.Dimension and weight Container specificationIf the equipment is shipped in containers, the content in each container is given in this specification.ContentsFM order no.Packages no.Packages detailsDimension and weightFramo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDNo.1401-0003-4 Feb-2000 Page 4 of 93 HANDLING OF FRAMO EQUIPMENTEven if the components used in Framo Cargo Pumping Systems are of rigid construction, theyshould always be handled with care. Never step or climb on the equipment.Be careful not to destroy or remove the transport protection before final installation onboard.Lifting, lowering and handling in general should be done slowly and carefully to avoid damage tomotor bearings caused by vibration and shocks.Note! Handling information given on the package must be strictly followed.Stainless steel components must not be in direct contact with mild steel.3.1 Handling of power unitsGeneral infoThe power units are equipped with 4 lifting lugs. All of them must be used when lifting. Normally, alifting device with 4 slings of equal length can be used to lift the power unit. Avoid contact betweenexposed parts of the power unit and the lifting slings.If special lifting tools are required, these are supplied by Framo together with the power unit.Note! Forklift must never be used to lift the power unit.Transportation in containerNormally the power units are shipped in closed containers and should be taken out of the containeras shown for the cargo pumps on page 6.If the power units are shipped in containers with open top, please note that these containers have anarrow passage at the top. Therefore, the power units must be lifted free for easy guiding andtaken out broadwise. Special care must be taken not to collide with the side walls of the container.Fig. 1Transportation on flat rackIf the power unit is wider than the container width, it is transported on a flat rack with a special cagefor protection. This cage must be removed before the power unit can be lifted off the flat rack.Framo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDNo.1401-0003-4 Feb-2000 Page 5 of 93.2 Handling of submerged cargo- and ballast pumpsThe pumps are designed to withstand flexing and bending of the vessels structural members(bulkheads etc.). For this reason the pump bend easily, but as long as this bending is well within theelastic limits, it will do no harm to the pump. Incorrect and careless handling might, however, putundue strain on the pumps, causing permanent damage.The only acceptable way to lift pumps out of the wooden racks is to lift each pump/pump sectionseparately.Fig. 2The pumps shall under no circumstances be lifted like this:Fig. 3Note! Damage to pump due to incorrect lifting and handling will not be covered by Framos guarantee.Framo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDNo.1401-0003-4 Feb-2000 Page 6 of 9If the pumps have been shipped in a closed container, they have to be pulled out as shown below.The following equipment is necessary for unpacking and lifting (Framo supply):- Two softslings. Minimum working Load Limit (WLL): 5 000kg. Length: 18 meters- Four softslings. Minimum working Load Limit (WLL): 1 000kg. Length: 2 meters1. Four pallets in a good condition (yard supply) to be placed as shown in fig. 4 - 6.Fig. 42. The two softslings (L = 18m) must be fastened on the horizontal beam of the transportation frame and to a forklift. To pull the transportation frame out of the container the forklift must have a constant tension on the softslings. Pull load is approximately 60% of transportation frame and pumps weight.Fig. 53. The other two pallets must be placed as shown in fig. 6. They must not interfere with the lifting points.Fig. 6Framo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDNo.1401-0003-4 Feb-2000 Page 7 of 9SoftslingsMinimum WLL= 5000 kgMinimum lenght = 18 mMax. 30oWarning !Avoid contactFor securing and roping only !Do not hook any lifing arrangementto this frame construction.LiftingpointSoftslingsLength = 2mFig. 7 Lifting of pumps on a transportation frame.3.3 Handling of heat exchangerHandle the equipment unpacked in the packages supplied from Framo.If they are delivered in wooden rack like the cargo pumps (fig. 3) use instructions from chapter 3.2for handling.3.4 Handling of portable equipmentHandle the equipment unpacked in the packages supplied from Framo.Framo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDNo.1401-0003-4 Feb-2000 Page 8 of 94 STORAGE AT YARDGenerally it is preferred that all Framo equipment should be stored in-door.The equipment must be stored away from corrosive or chemically damaging fumes.Storage even for a short period in an area where work activities such as welding, grinding, sand-blasting, painting, etc. is going on is prohibited.For protection and easy identification, keep the equipment in the packages supplied from Framountil installation onboard. If only some items in a box are needed for installation, keep the others inthe box until installation.Blank flanges must not be removed before final installation.The protection on electric motors must be kept on until start up, and will then be removed by theFramo commissioning engineer.Control panels must be covered after installation onboard.As informed in chapter 2, Framo equipment is preserved for 1 year storage. This includes alsocargo- and ballast pumps due to the internal mild steel hydraulic motor and high pressure pipe.Note! For long time storage (1 year or more), contact Framo for special instruction.The minimum storage conditions for Framo equipment are given below.4.1 Storage in dry and clean conditionsAll electrical components must be stored in a dry, clean room where temperature is kept steadyabove dew point. Typical components are:----Electrical control panelsMain electric boxesStartersElectrically driven power units ** Electrically driven power units may be stored in warehouse without steady temperature provided that the electric motor heating elements are connected and switched on.Note! Connecting power voltage to termistors will damage the termistors and eventually the motor windings.Warnings should be placed on the motors when the heaters are connected.4.2 Warehouse storageThe following must be stored in a dry, clean warehouse:-------Diesel driven power units.Hydraulically driven components.All valves and fittings for the hydraulic system.Deck trunks in mild steel.Portable cargo pump.Flexible hoses.Mild steel pipes.Framo Mounting InstructionEQUIPMENT HANDLING - STORAGE AT YARDNo.1401-0003-4 Feb-2000 Page 9 of 94.3 Outdoor storageFollowing equipment may be stored outdoor, provided it is properly protected with tarpaulin to protectit from iron dust from grinding, welding spatter, sea water spray, sand and bird droppings.(Stainless steel may corrode if surface is polluted)-----Cargo coolers/heaters.Deck trunks in stainless steel, (flange protection must be kept on).Pump supports.Stainless steel pipes.Submerged cargo pumps and ballast pumps.Submerged cargo pumps and ballast pumpsmust be stored with their axis in a horizontal position, preferably in the same wooden rack as theywere received. If the pumps have to be removed from the rack, they should be supported in at leastthree points as shown below.Note! The pumps must not be in direct contact with mild steel.TarpaulinCargo pumpSupported in three pointsFig. 8Oil in drums.To prevent water from leaking into the hydraulic oil, the drums have to be stored horizontally andin such a way that the drum bungs are wet by the oil.The hydraulic oil is mixed with special additives, which improve the oil quality. If the oil is mixedwith water, the additives may lose effect, or in worst case, give negative effect. Corrosion willoccur and abnormal wear will lead to breakdown of the system.Fig. 9FramoMounting InstructionNo. 1401-0004-4Feb-2000Installation of submerged cargo pumpsCONTENTS1 General2 Orientation in tank2.1 Arrangement on top plate2.2 Nozzle loads2.3 Location of brackets for intermediate support(s)3 Installation of deck trunk and brackets for intermediate and bottom support3.13.23.33.43.5Framo dummyDeck trunkBracket for bottom supportBracket(s) for intermediate supportRecommendation for welding stainlesssteel to carbon steel4 Prefabrication of deck piping5 Assembling of pipe stacks6 Installation of pumps in tank6.1 Installation of SD100/125/150/200/2506.2 Installation of SD3000/3506.3 Additional information for pumps above 20 meter7 Pump with cofferdam header tankFramo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 2 of 221 GENERALFigures in this instruction are made for all cargo pumps. It is supposed that a dummy equipmentpackage intended for the pump type to be installed, is available. For further information,see drawings for the actual cargo pump, deck trunk, support, suction well and dummy.(Speed Torque Controller)STCThe Framo hydraulically drivensubmerged cargo pump consistsof three main parts:Top plateTop plate Resilienttop plate connectionDeck trunkThe cargo pump is supported bya deck trunk welded to the deck.A special gasket and a resilientbolt arrangement will preventnoise and cargo leakage.Pipe stackPipe stackIntermediatesupportCargo pipeCofferdam pipeHydraulic return pipeHydraulic pressure pipeCargo stripping pipeCofferdam check pipeThe pipe stack connects thepump head to the top plate.Dependent on pump length,the pipe stack is supported byintermediate support(s).Pump headThe pump head is welded orflanged to the pipe stack andsupported by the bottom support.Pump headBottom supportThe cargo tank should bedesigned with suction well foroptimal tank emptying. It shouldbe installed at the aft end of eachtank and preferably with tank topsloping towards the suction well.Prefabricated suction well can bequoted for on request.Suction wellFig. 1Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 3 of 222 ORIENTATION IN TANKNote! Submerged cargo pumps should be installed at the aft end or in the lowest part of each tank, located either to port or starboard (to allow optimal tank emptying).The overview below indicates how the orientation of the pumps affects location of the suction well,location of pipe stack support(s) (if any) and location of the cargo line and hydraulic line connections.Cargo stripping lineCargo discharge valveTwo first clampsresilient mountedPilot lineStripping valveAlternative orientation of STCCargo lineCofferdamconnectionService valvesSpools to beremoved for serviceDrop lineC pipestackLBu elkhadIntermediatesupportBracket forintermediatesupportCLCLCenterline (C ) to be parallel to bulkhead where Lthe bracket for intermediate support is weldedBottom supportSuction wellAlternative orientationof suction wellSpace for service.See dimensional drawingfor suction well.Fig. 2Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 4 of 222.1 Arrangement on top plateValves must be placed in areas which are easily accessed by pump operator. Air/inert gas supplyfor purging of cargo and cofferdam pipe1/2 closing valve with snap-on coupling(1 coupling included for each pump) Free area for service,installation/lifting of pumpAir/inert gas supplypressure 6-7 barFlex. hose with snap on couplings(normal length 2m)Min. 2000Cofferdamventing pipeND15,stainless steelPurging connection(purging of cofferdam pipe)Exhaust trap500500Drain valvePurging connection(purging of cargo pipe)Min. 500Min. 1500Fig. 32.2 Nozzle loadsTo ensure proper installation and avoid leakage between pump top plate and deck trunk themaximum allowable nozzle loads for the cargo pumps are given below:)25&(6020(17DSSUR[ [ $3, 6'6' ($&+ 12==/( )6' 6' 6' 6' 6' 81,7 N1N1N1N1PN1PN1P))000Too high nozzle loads will give leakage, andnoise will be generated by mechanical contactbetween top plate and deck trunk.Nozzle loads on cargo pumps have no influenceon rotating parts of the pumps.ZMZYFZMXMYXFYFXFig. 4Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 5 of 222.3 Location of brackets for intermediate support(s)Bracket is part of the ship design and supplied by yard. It is importantthat the yard is aware of the forces acting in the tank area (sloshing,structural deflection etc.).Brackets to be designed according to forces shown in table below:Centerline to beparallel to bulkhead3803 7N1@) >N1@F2F16'6'6'6'6'Fig. 5High stress concentrationHigh stress concentrationAcceptable solutionsFig. 6Not acceptable solutionsSupports for all cargo pumps except SD300 and SD350 may enter the cargo tank through standardman-hole openings. Due to the size the supports of SD300 and SD350 must be placed in tankbefore the deck is closed.All welding on suction well and deck trunk has to be finished before installation of the brackets.Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 6 of 22To find pump lenght (L) and location for the bracket(s) relative to the suction well, followingcalculation(s) has to be done:Pump length:L = TB + S - CLower edgeof top plate2QH LQWHUPHGLDWH VXSSRUW+HLJKW >PP@$ N [ /)DFWRU N N 7ZR LQWHUPHGLDWH VXSSRUWV+HLJKW >PP@$ N [ /!)DFWRUV N N!!" N N "$ N [ /"L =S =C =A1 =A2 =H =TB =Pump length [mm]Gasket, approx. 2 mm.Pump clearance, see page 12Intermediate support height [mm]Intermediate support height [mm]Deck trunk height [mm] *Height from bottom of suction well totop of deck trunk [mm]* Standard deck trunk height, 500 mm. (High deck trunks complicate cleaning work.)LIntermediate supportApprox.50-100 mmDeck trunkLower edge ofintermediate supportHFinal figures (A1, A2 and L) to be sent toFramo as soon as possible.CA1A2TBSuction wellbottomFig. 7SFramo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 7 of 223 INSTALLATION OF DECK TRUNK AND BRACKETS FOR INTERMEDIATE AND BOTTOM SUPPORTPrior to pump installation the deck trunk and brackets for intermediate and bottom support have tobe welded into the tank. Use of Framo dummy gives a correct installation of deck trunk, bottomsupport brackets and bracket(s) for intermediate support.The following installation procedure is based upon use of Framo dummy.3.1 Framo dummyThe dummy has brackets for all flanged pipe connections on the pumps top plate for adjustmentand prefabrication.It is neccessary to remove the flange protection for deck trunk (plywood) when usingthe top plate dummy. It is important to remount the plywood after use of dummy.The dummy equipment package and assembling of measuring pipe are shown on fig. 8a and 8b.For length of dummy (LD), see Framo specification.LaserTop plate dummyLabel ( length of dummy)Brackets for locationof flange connectionsAdjustment screwsfor deck trunk heightSupport dummyMeasuring pipe(one or several sets)Pipe no.2(Marked with twowhite tape rings)Tape ringsto be ofequal colorPipe no.1(Marked with onewhite tape ring)Support dummyDistance plateMeasuring tapeFig. 8a Framo dymmyFig. 8b Assembling of measuring pipeLDMake sure thatrubber elementis installed.Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSCalibration of laserThe laser is to be controlled before use to detect anyinaccuracy during transportation.Control and adjust the laser as follows:- Grease the laser flange to make turning of the laser easier.- Locate the laser on the top plate dummy installed on the deck trunk. See fig. 16.- Turn the laser on. Mark the spot where the centre of the beam hits the suction well.- Turn the laser 90 and mark where the centre of the laser beam now hits the target.- Repeat the turning in steps of 90 until a full circle is completed, and mark the spots for each step.- The collection of spots should be within a circle of =20 mm.- If not all spots are within this circle, adjust the laser by the two adjustment screws, using a screwdriver.- After the adjustment, re-check the laser as described above.- Continue the above procedure until the accuracy of the laser is as specified above.LaserOFFONNo.1401-0004-4 Feb-2000 Page 8 of 22Battery 1,5 volt(Size C)Adjustment screwsLaser flangeThe collection of spots to hitwithin a circle of =20 mm20 mmMark the spotsCAUTION! Avoid staring straight into the laser beam.Fig. 10Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 9 of 223.2 Deck trunkNote! It is important that the deck trunks are welded into the ship at the latest possible stage to ensure correct pump clearance C, according to page 12.1a) Mark pump centerb) Cut hole in deck for deck trunk.b) Position of cargo and hydraulic flange connections for the pump, see pumps dimensional drawing.Edges parallellto centre line C LYXPosition ofhydraulic valvePump center linePosition ofcargo flangeCentre line C Lthrough centre of cargo lineand hydraulic flange connectionsFig. 13Suction wellFig. 11YXc) If the pump has intermediate support(s):Edge parallel to bulkheadwhere the intermediatesupport bracket shallbe weldedAdjustmentscrewsPosition for laserHoles formeasuring pipe2When connecting the top plate dummyto the deck trunk, please note:a)Sealing surface hasto be protected in orderto avoid scratches.TrunkDeck trunkWelding seam must notbe orientated in ship'stransverse directionFig. 14Fig. 12Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 10 of 223Trunk alignmentLaser4Height adjustment8 mm distance platein the suction wellAdjustment nutsPosition ofmeasuring pipe:Highest pointin bottom of thesuction wellPUMPSD 100SD 125SD 150SD 200SD 300SD 350 230230230300350400Laser beam5Spot weldingSpot weld thedeck trunk to deckPump centerLaser beam20Approx. 0,5mmFig. 16Laser beam to hit within: =20 mmMeasuring pipenot to touchdistance plateFramo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 11 of 226 WeldingRemoveadjustmentscrews7 CheckingRulerLaserRThe trunk isto be weldedaccording toclassificationrequirements.After finishing the installationof the first trunk, measure thedistance TB in 0O, 90O, 180O, 270Oat a distance R from the center linewith the supplied calibratedmeasuring tape.Flat bar tobe locked tomeasuring tape.TBPUMPSD 100SD 125SD 150SD 200SD 300SD 350R1151151151501752000901800000Check for correct heightand straightness, by usingthe measuring pipe and laser.R2700Fig. 17Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 12 of 228Adjustment of procedure.After measuring the first trunk in accordance with 7 , proceed with the next trunk andadjust procedure according to the table below if necessary. The number listed in the tablebelow includes gasket and cargo pump tolerances. Proceed with welding of trunks untilrecommended height is reached.6'6'6'6'6'6'$FWLRQ,QFUHDVH GLVWDQFH SODWH WKLFNQHVV IRUWKH QH[W WUXQNV WR REWDLQ DFFHSWDEOHDYHUDJH FOHDUDQFH5HFRPPHQGHG FOHDUDQFH5HSHDW SURFHGXUH8VH D GLVWDQFH SODWH ZLWK UHGXFHGWKLFNQHVV LQ RUGHU WR REWDLQDFFDSWDEOH DYHUDJH FOHDUDQFH7R EH FKHFNHG DIWHU SXPSLQVWDOODWLRQ7%7%v// PLQ7%v/!!!!!&PLQ +- +- +- +- +-7% LV WKH PLQLPXP YDOXH RI 7%/ LV WKH VSHFLILHG OHQJWK RI WKH FDUJR SXPSRulerGasketApprox. 2 mmImportant:RInstall the deck trunk incorrect height relativeto the suction well.Too low clearance: - Service impossibleToo high clearance: - Unacceptable cargo residue.LTBFig. 18C(L)Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 13 of 223.3 Brackets for bottom supportAll welding on suction well and deck trunk has to be finished before installationof the bottom support brackets.12a SD125/150Support dummyBracketsLaser beam2b SD100/200/300/350Support dummyPump center3a SD125/150LaserbeamBlue tape3b SD100/200/300/350LaserbeamMirrorAdjust bracketsbefore welding0OBlue tape0OMirrorMarkBoltsMark90OBolts90OaFig. 19Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 14 of 223.4 Bracket(s) for intermediate support12Laser beam tohit dummy center0OBoltsLaser beamMeasuring pipe90OMirrorBlue tapeMark3CLCLPump centerCenterline C must be parallel to the bulkhead Lwhere the intermediate support shall be welded.Fig. 203.5 Recommendations for welding stainless steel to carbon steelSometimes it becomes necessary to weld stainless steel to carbon or low alloyed steel. A typicalexample is stainless steel wells welded into carbon steel tanks.The dilution of the weld metal by the base material must then be considered to avoid the formationof hard brittle structures.This is done by using a welding consumable with different composition to both base materials.Carbon steel filler metal will result in a high alloyed martensitic microstructure on the stainless steelside of the weld. Filler metal of the same composition as the stainless steel will result in the samemicrostructure on the carbon steel side. This microstructure will result in extensive cracking, oftenvery difficult to observe.The correct filler metal shall instead be overalloyed stainless steel or Ni-based alloys to secure aductile weld metal. These filler metals will tolerate a substantial dilution from the carbon steelwithout hardening.The composition should be specially balanced to ensure that the total alloy content is adequate toaccommodate dilution effects and which have a ferrite content sufficient to provide high resistanceto hot cracking.Preheating shall not be performed on austenitic stainless steel, since this will promote carbideprecipitation in the grain boundaries and the formation of sigma-phase (a hard and brittle phasethat dramatically increases the risk of cracking).Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 15 of 224 PREFABRICATION OF DECK PIPINGWhen the trunk is installed, the top plate dummy can be used for adjustment/prefabrication of thepiping.- Remove the laser from the top plate dummy.- Assemble the brackets for the current connections.- Bolt the top plate dummy to the trunk in correct position (see dimensional drawing for top plate).The dummy can now be used for adjustment of the piping by fixing the pipe flanges to the relevantpositions/brackets on the dummy.Hydraulic pipingCargo pipeConnections forother pipesFig. 21Be careful not to damage the sealing surface on the deck trunk andprotect the seal faces by the supplied plywood after this operation.5 ASSEMBLING OF PIPE STACKSThe pump is to be assembled in a horizontal position. Every pump part is to be supported in at leasttwo points.Note! The pumps must not be in contact with carbon steel.Pump no.Pump no.Fig. 22Check that pump no. on all the pump parts are identical. Pump no. is placed on top plate andflange for volute casing. Locate the pump parts in correct positions one after another.Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNote !All pipes must be checked forforeign bodies beforeconnection. Any parts left in thepipes (screws, nuts, plastic boltsrags, etc.) may cause seriousdamage to the pump.Clean all o-ring grooves and sealfaces with a dry rag.Check all seal elements, back-uprings, grooves and seal faces.Pay special attention to theteflon rings and be absolute sureof no deformation nor radialgrooves.Never install damaged sealelements.Assemble connection pipe andseals on the flange of lower part.Guide the two parts together. Becareful when the connection pipeenter the hydraulic pressurepipe.Assemble bolts and nuts.Tighten the bolts according tothe table below.No.1401-0004-4 Feb-2000 Page 16 of 22Bolt, washerand nutSeal ringsConnection pipeCirclipO-ringBack-up ringO-ringBack-up ringFig. 23Cargo stripping pipe-bolts-washers-nuts-seal ringBracketCofferdam check pipe-socket bolts-seal ringOptiontemp. sensor-bolts-washers-nuts-seal ringHydraulic pipes-bolts-washers-nuts-seal rings-connection pipe-circlipOptionvacuum drain-bolts-washers-nuts-seal ringCargo pipe-bolts-washers-nuts-seal ringFig. 24 Split flangesAll screws and nuts have to be assembled with specified torque.If no torque is specified, use the following torque:ACID RESISTANT BOLTS AND NUTS, QUALITY A4-80 M69.2 Nm M822.3 Nm M1044.2 Nm M1276.2 Nm M16190 Nm M20370 NmAcid resistant bolts are to be coated with Molybdenum disculphide (Molycote)or similar on threads and under bolt heads/nuts prior to assembling.Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 17 of 22Pumps shipped as one complete unit are pressure tested before leaving Framo works. Pumpsdelivered in two parts or more have to be pressure tested after assembling. Blank off cofferdamcheck pipe (see fig. 25). The blank flange is a part of the Framo supplied standard tool.Cofferdamcheck pipeBlank offcofferdam check pipeAir pressureor nitrogenRelief valveFig. 25 Pressure test of pumpUnscrew the complete relief valve and connect a manometer to the G1/4 connection (not Framodelivery). Connect air/nitrogen supply to the snap-on coupling on the purging connection (flex. hosewith snap on couplings is Framo delivery), and increase pressure to max. 3 bar. Stop theair/nitrogen supply and observe the pressurized volume for 15 minutes.Flush the split flanges with soapy water to be sure of no leakage.Reinstall the complete relief valve and assemble the blank flange on the outlet from cofferdamcheck pipe.Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 18 of 226 INSTALLATION OF PUMPS IN TANKThe Framo cargo pumps have two different resilient arrangements on top plate. Installation of eacharrangement is described separately.Preparations:Welding, sandblasting and grinding must be finished and tank must beproperly cleaned before installation of pump in tank.For carbon steel tanks, also coating must be finished before installation.PicklingPickling will be required prior to installation if the pump has been exposed to iron dust duringstorage or corroded surfaces/spots are detected. Framo recommend Avesta Pickling Paste orequal types for stainless steel.Follow the manufacturers procedure for pickling before starting the work.Blank flangesBlank flanges and seals on top plate shall be left until connection of the pump to the vessels pipingsystems. The blank flanges on the pumps suction opening and the protection around the pumpshaft shall be removed only by the Framo service engineer before water is filled into the tank.Transport securing (Only on pumps with vacuum stripping pipe)The steel wire on lower vacuum stripping pipe shall also be removed by the Framo service engineer.See tool list for descriptions.Special tools required for installations are supplied by Framo in the toolbox.Bottom support /Intermediate support(s)Install the support(s) on the bracket beforethe pump. Tighten upper nuts and lock nuts to174 Nm (Fig. 26).If coated surfaces on bracket for support:1) Assemble upper nut, use 174Nm torque.2) Retighten to specified torque.3) Assemble lock nut, use 174Nm torque.Support ring Framo supplyFasteners : Yard supplyMaterial : StainlessQuality: A4-80Flat washerSupport bracket Yard supplyCoating touch upFlat washerUpper nut (Torque 174 Nm)Lock nut (Torque 174 Nm)Deck trunkRemove the flange protection and inspect thesealing surface on the deck trunk flange.Required surface roughness is Ra 1,6 m. If thesealing surface has been damaged (scratches,grooves) during transport or installation, thedamages must be removed by careful grinding/polishing by abrasive paper.Note! If grinding/polishing is required, thismust be done according to figure below.Fig. 26 Bottom and intermediate supportNever grind acrossseal faceCorrect grindingdirectionFig. 27 Sealing surface - deck trunkFramo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 19 of 226.1 Installation of SD100/125/150/200/250Clean the gasket groove in the top plate. Stretch the gasketover the top plate, -take care not to damage the gasket.Install the gasket carefully in gasket groove while the pump isstill lying on the ground.Install two guide pins in top plate (180 apart).Install lifting tool on the top plate (supplied by Framo in thetoolbox)Two guide pinsFig. 28Lift the pump to a vertical position. Preferably two cranes should be used for this operation, one tokeep the pump clear of the ground and the other for lifting. The pump shall not be allowed to slidealong the ground during lifting.All pumps above 12 metres should be lifted by using a snatch block together with the crane on thelower part of the pump. Minimum length of the wire through the snatch block = 2 x length of thelower part of pump.SnatchblockLower partUpper partSplit pump above 20 meters.See chapter 10.3Fig. 29Lower the pump until the top plate rests on thedeck trunk. Be careful when the guiding pinsenter the deck trunk holes.Fig. 30Install rubber bushings and hexagon head bolts under thetrunk flange. Use Loctite on the bolts.Tighten bolts in a diagonal sequence to 44 Nm. Removethe two guide pins, and install the two remaining rubberbushings and bolts. Tighten bolts to 44 Nm.GasketRubberbushingWhen pump installation is completed:Check that the distance from pump suction opening to thesuction well bottom is according to the table on page 12.Remember: Dont remove any blank flanges.Fig. 31Hexagonhead boltFramo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 20 of 226.2 Installation of SD300/350Clean the gasket groove in the top plate. Stretch the gasket over the top plate, -take care not todamage the gasket. The gasket has to be greased with teflon grease before installation in the topplate. Gasket and grease are supplied by Framo. Install the gasket carefully in gasket groove whilethe pump is still lying on the ground.Install lifting tool on top plate (supplied by Framo in the toolbox).Lift the pump to a vertical position. Preferably two cranes should be used for this operation, one tokeep the pump clear of the ground and the other for lifting. The pump shall not be allowed to slidealong the ground during lifting.All pumps above 12 metres should be lifted by using a snatch block together with the crane on thelower part of the pump. Minimum length of the wire through the snatch block = 2 x length of thelower part of pump.SnatchblockLower partUpper partSplit pump above 20 meters.See chapter 10.3Fig. 32Two guide pinsLower the pump until the top plate rests on the decktrunk. Use 2 guiding pins to get the correct position.Fig. 33Remove the guiding pins. Assemble bolts, nuts, washersand bushings and tighten bolts in a diagonal sequenceto 44 Nm.When pump installation is completed:Check that the distance from pump suction opening tothe suction well bottom is according to table on page 12.Remember: Dont remove any blank flanges.Fig. 34Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 21 of 226.3 Additional information during installation of pumps above 20 meterNote !The pump has to be pressure testedafter assembling and installation in tank.That demand an arrangement in tankwhich give access to the split flanges.Lower the lower part of the pumpuntil the top is approx. 0.5 m fromdeck trunk.Fig. 35Place the installation tool on the decktrunk (see actual tool drawing).Continue lowering until the pumpslower part is resting on the tool.Remove the ring screw and liftingplate.Clean all o-ring grooves with a dry rag,and assemble parts shown in fig. 23 and 24Before lifting upper part of the pump,assemble guiding bolts on top plate (seefig. 27).Lift the upper part of the pumpin position above deck trunk, remove blindflanges and clean the flanges with a dry rag.Continue the lowering and guide it in correctposition. Be careful when the connection pipeenter the high pressure pipe.Before connecting lower and upper part of thepump the gasket between top plate and decktrunk must be placed upon the deck trunk.Use the procedure described on page 18 forpressure testing of the pump.Fig. 36Framo Mounting InstructionINSTALLATION OF SUBMERGED CARGO PUMPSNo.1401-0004-4 Feb-2000 Page 22 of 227 PUMP WITH COFFERDAM HEADER TANKPermanent liquid filled cofferdam is used when the submerged cargo pump is handling only onetype of cargo (oil production & storage vessels).Filling of cofferdam- Fill the cofferdam through the headertank until the liquid level stabilises just above low level mark on the sight glass.- Use a ISO VG10 hydraulic oil in the cofferdam. (DIN51524 (1) HL, for instance Shell Morlina Oil 10). Due to expansion and air in the system, the level will stabilize between 2 to 7 days after filling.- The cofferdam volume depends on pump size and pump length. The following formulas give approx. volume required to fill the cofferdam to header tank low level mark : (volume in litres)Header tankS D 100SD 125/150S D 200S D 250S D 300S D 350(L x 0,6) + 3(L x 0,6) + 12(L x 3,7) + 8(L x 3,7) + 14(L x 4,3) + 13(L x 5,1) + 19Fig. 37L=Pump length in metres. (See Framo Specification)FramoMounting InstructionNo. 1401-0005-4Rev. A Mar-2003Installation/storage of portable equipmentFramo Mounting InstructionINSTALLATION OF PORTABLE EQUIPMENTNo.1401-0005-4Rev. A Mar-2003 Page 2 of 31 STORING ON BOARDThe portable pumping equipment must be stored easy accessiblein a clean and dry area.The concentric hose can be stored on brackets on the bulkhead(see fig.1), or on a suitable hose reel, or lying in a shelf.The cargo hose and extension hoses can be stored on a suitablehose reel, or lying in a shelf.The pump and hoses must always be safely supported andfastened in order to avoid wear or damages due to shipmovements. It is especially important that the hoses are nothanging or laying over sharp edges, or that sharp objects areplaced upon them.The bending radius for the hoses during storage must beaccording to dimensioning drawings.For TK150 / TK6 control valve + snap-on couplings are delivered inan equipment box. For TK80 control valve is connected to pump,while snap-on couplings are delivered in an equipment box.Equipment boxes are delivered with bracket for installation in fixedlocation together with the portable pump.Fig. 1Fig. 2Portable winch:The portable winch must be safely supported and fastened in order toavoid wear or damages due to ship movements.Framo Mounting InstructionINSTALLATION OF PORTABLE EQUIPMENTNo.1401-0005-4Rev. A Mar-2003 Page 3 of 32 COUPLING STATIONS FOR PORTABLE EQUIPMENTThe portable pump includes hydraulic hoses with a control valve either connected to the end of thehose(concentric hose) or separately delivered. Standard length of this hoses are 10 and 18 m.Separate extension hoses must be connected between the control valve and the coupling stations(standard length of extension hoses is 10 and 18 m).The hydraulic ring line must be equiped with coupling stations (pressure and return) for connection/operation of the portable pump.Each coupling station consist of a ball valve with blind flange for pressure connection, and a non-return valve with blind flange for return connection. Snap-on couplings are delivered separately inan equipment box, and are only mounted by ship crew when pump is connected for use.The number and location of coupling stations must be selected so that the portable pump can beused in every tank.A coupling station should preferably also be located close to the pump storage, to simplify testing ofpump.Installation of coupling stations in hydraulic ring line must be according to figures below. This toavoid extra bending forces from the extension hoses on the coupling stations.h = sufficient height above ship deck to avoid exceeding the allowable bending radius of the extension hoses, and give easy access for connection of the extension hoses.Fig. 3FramoMounting InstructionNo. 1401-0006-4Rev.B Jan-2003Installation of submerged ballast pumpsCONTENTS1 General2 Arrangement and orientation in tank2.1 Pump casing2.2 Location of bracket for intermediate support(s)2.3 Arrangement on top plate2.4 Evacuation system3 Installation requirements4 Example of pump installation with Framo dummy4.14.24.34.4Framo dummyPump casingBracket(s) for intermediate support(s)Deck trunk5 Assembling of pipe stacks6 Installation of pumps in tank6.1 Additional information for pumps assembled during installation in tank6.2 Filling of liquid in cofferdamFramo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 2 of 231 GENERALFigures in this procedure are made general for all types of submerged ballast pumps. It is assumedthat a dummy equipment package intended for the pump type to be installed, is available. Forfurther information, see drawings for the actual ballast pump, deck trunk, intermediate support anddummy.The Framo hydraulically driven submerged ballast pump consists of:- Pump casing/ Air separator- Pump head- Pipe stack- Top plate- Evacuating systemPump casing/ Air SeparatorThe pump casing is bolted to afoundation.An ejector is connected at thesuction side.Pump headThe pump head is mounted insidethe pump casing.Pipe stackThe pipe stack consists of a hydraulicpipe stack and an arrangement withpipe and cable for the evacuatingsystem.The hydraulic pipe stack connectsthe pump head to the STC-valve.Supports on the pipe stack preventhorizontal movement and allow forvertical expansion.Top plate/ Control valvesThe pipe stack penetrates thetop plate.A sealing device (bellow) betweentop plate and pipe stack allows thepipe stack to expand.The evacuation control system isattached to the top plate.Fig. 1Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 3 of 232 ARRANGEMENT AND ORIENTATION IN TANKFig. 2The suction/discharge flange position has to be informed to Framo as soon as possible making itpossible to finalize the manufacturing drawings. See pump dimensional drawing.Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 4 of 232.1 Pump casingNozzle loadsTo ensure good installation and to avoid high tensile forces on pump casing, the maximumallowable nozzle loads to be as follows:MAX. ALLOWABLE FORCES/MOMENT (approx. 2 x API 610) EACHNOZZLEFx [kN]Fy [kN]Fz [kN]Mx [kNm]My [kNm]Mz [kNm]SB2008"DischargeSB30010"12"DischargeSB40014"16"DischargeSB60018"20"Discharge24"SuctionSuctionSuctionSuction5,04,03,23,61,82,66,85,44,55,02,53,88,06,75,46,13,04,69,07,25,86,43,24,810,28,56,77,43,75,411,69,87,68,34,26,112,911,18,59,34,86,815,613,810,211,15,98,2Fig. 3Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 5 of 232.2 Location of bracket for intermediate support(s)Bracket is part of the ship design and supplied by yard. It is important to be aware of the forcesacting in the tank area (sloshing, structural deflection etc.).Brackets to be designed according to forces shown in table below:PUMP TYPESB200SB300SB400SB600F1 [kN]771111F2 [kN]12121818Fig. 4Fig. 5Supports for all ballast pumps may enter the ballast tank through standard manhole openings.Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 6 of 23To find the pump length (L) and location of the bracket(s), following calculations have to be done:One intermediate supportA1 = 0,4 x L +/- 500Two intermediate supportsA1 = 0,3 x L +/- 500A2 = 0,6 x L +/- 500Tree intermediate supportsA1 = 0,25 x L +/- 500A2 = 0,5 x L +/- 500A3 = 0,7 x L +/- 500L= Pump length [mm]A1-A3 = Intermediate support height [mm]H= Deck trunk height [mm]Final figures (L, A1 and A2 ) to be sent toFramo as soon as possible.Fig. 6Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 7 of 232.3 Arrangement on top plateTrunk on deckFig. 7Trunk in void spaceFig. 8Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 8 of 232.4 Evacuation systemFig. 9The start and stop of the ejector is controlled by two electric level switches located in the pumpcasing. The signal goes to a solenoid valve(Exi) connected to the PLC. The solenoid valve controlsa pneumatic valve for start and stop of the ejector.Note! In order to protect the pneumatic valves it is necessary to place a filter/water trap in the air line.Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 9 of 233 INSTALLATION REQUIREMENTS(independent of installation method)To be confirmed before final installation of pump in tank.The center line of deck trunk and the center line of pump should be identical after installation.Maximum acceptable deviation is shown in fig. 10. This is to avoid excessive stress in the pipestack.The figures below also indicates how to use the laser from the dummy equipment package tocheck the tolerances.For height control see fig. 11.Fig. 10Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 10 of 23LD= Height from top of pump casing to top of deck trunkAD1- = Intermediate support height.AD3Height from top of pump casing to lower edge of intermediate support dummy.Fig. 11Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 11 of 234 EXAMPLE OF PUMP INSTALLATION WITH FRAMO DUMMYThe pump casing has to be placed in the section before it is closed. It is of importance that the pumpcasing is protective covered until the installation of pump in tank. Prior to pump installation, the decktrunk and brackets for pump supports have to be welded into the tank. Use of Framo dummy will helpyou to get a successful installation of deck trunk and bracket of intermediate supports.The following installation procedure is based upon use of Framo dummy.4.1 Framo dummyNote! It is necessary to remove the flange protection for deck trunk when using the top plate dummy. It is important to remount the protection after use of dummy.The dummy equipment package is shown on fig. 12.Fig. 12Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSCalibration of laserThe lasers is to be controlled each time before use todetect any inaccuracy during transportation. Controland adjust the lasers as follows:- Grease the laser flange to make turning of the laser easier.- Locate the laser on the top plate dummy installed on the deck trunk.- Turn the laser on. Mark the spot where the centre of the beam hits the target.- Turn the laser 90 and mark where the centre of the laser beam now hits the target.- Repeat the turning in steps of 90 until a full circle is completed, and mark the spots for each step.- The collection of spots should be within a circle of =20 mm.- If not all spots are within this circle, adjust the laser by the two adjustment screws, using a screwdriver.- After the adjustment, re-check the laser as described above.- Continue the above procedure until the accuracy of the laser is as specified above.CAUTION! Avoid staring straight into the laser beam.No.1401-0006-4Rev.B Jan-2003 Page 12 of 23Fig. 13Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 13 of 234.2 Pump casing1Pilot hole2 Pump casing- Place the pump casing in the center marked.- Fasten the laser to the pump casing dummy and place it on top of the pump casing.- Turn the pump casing dummy in steps of 90 until a full circle is completed as described on page 12. The collection of spots should be within a circle of = 20 mm.- If necessary tilt the pump casing until the laser beam hits the center of pilot hole.- Drill holes in foundation and fasten the pump casing with counter nuts.- Mark the center of the pump casing.- Measure the distances from this center to the bulkhead/frames (x,y).- Use these distances (x,y) to find the center of the deck trunk in the deck.- Cut a pilot hole 250 for the deck trunk.- Calibrate the laser according page 12.Fig. 14Fig. 15Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 14 of 234.3 Bracket(s) for intermediate support(s)3 Adjustment and weldingNote! Pump casing has to be protected against weld spatter, sand blasting and painting.- Connect the intermediate support dummy to the bracket.- Alignment (by use of mirror)- Height adustmentFig. 16Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 15 of 234.4 Deck trunk4 Final hole for deck trunk----Connect the top plate dummy with plexiglass to the deck trunk.Adjust trunk until the laser beam hits the center marked on plexiglass.Mark outside diameter of deck trunk.Cut final hole in deck for deck trunk.Position of deck trunkThe deck trunk must be connected to the top platedummy with connections for STC valve in correct position,see dimensional drawing of pump.Fig. 17Fig. 185 Adjustment- Move the laser to the top plate dummy and calibrate the laser (ref. page 12).- Trunk alignment- Height adjustment- Spot welding6 Welding and controlThe trunk is to be welded according toclassification requirements.Frequently check the position/alignmentduring welding.Fig. 19Fig. 20According to practical experience the distance between the top flange of deck trunk and the deckwill normally be reduced about 3-5 mm caused by the added heat when welding.If such a reduction is expected, this must be taken into consideration.Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 16 of 235 ASSEMBLING OF PIPE STACKPumps delivered in two parts have to be assembled in a horizontal position. Every pump section isto be supported in at least two points.Note! All ballast pumps type SB400 and SB600 delivered in two or three parts and SB200/SB300 pumps with total length above 20m have to be assembled during installation, see chapter 6.1.Fig. 21Note! The pumps must not be in contact with mild steel during assembling.Check that the pump no. on all the pump sections are identical. Pump no. is placed on top plate andpump head flange. Place the pump sections in correct positions one after another.Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNote !All pipes must be checked forforeign bodies before connection.Any parts left in the pipes (screws,nuts, plastic bolts, rags, etc.) maycause serious damage to thepump.Clean all o-ring grooves and sealfaces with a dry rag.Check all seal elements, back-uprings, grooves and seal faces.Never install damaged sealelements.Assemble connection pipe andseals on the flange of lower part.Guide the two parts together. Becareful when the connection pipeenter the hydraulic pressure pipe.Assemble bolts and nuts. Tightenthe bolts according to the tablebelow.No.1401-0006-4Rev.B Jan-2003 Page 17 of 23Fig. 22All screws and nuts have to be assembled with specified torque.If no torque is specified, use torque according to following:ACID RESISTANT BOLTS AND NUTS, QUALITY A4-80 M69.2 Nm M822.3 Nm M1044.2 Nm M1276.2 Nm M16190 Nm M20370 NmAcid resistant bolts are to be coated with Molybdenum disculphide (Molycote)or similar on threads and under bolt heads/nuts prior to assembling.Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSLevel switch cable:No.1401-0006-4Rev.B Jan-2003 Page 18 of 23Unscrew cap on evacuating control unit. Use a pulling rope as shown in fig. 23. Unwrap the cableand connect the end to the pulling rope.Fig. 23Pull the cable through the protection pipe and bracket for evacuating control unit.The cable end must be long enough to reach the terminals. Cut the cable in a suitable length withsufficient margin. Remount the cap.Fig. 24Pumps shipped as one complete unit are pressure tested before leaving Framo works. Pumpsdelivered in two parts or more have to be pressure tested after assembling.Connect air supply and manometer to connections shown on fig. 25 and carefully increase pressureto max. 3 bar. Stop the air supply and observe the pressurized volume for 15 minutes (pressuredrop indicates leakage).Flush the flange connections with soapy water to be sure of no static leakage.Reinstall the plugs.Fig. 25 Connections for pressure testing of cofferdamFramo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 19 of 236 INSTALLATION OF PUMPS IN TANKPreparations:Note! Welding, sandblasting grinding and coating must be finished and tank must be properly cleaned before installation of pump in tank.PicklingPickling is required prior to installation if the pump has been exposed to iron dust during storage orcorroded surfaces/spots are detected. Framo recommend Avesta Pickling Paste or equal types forstainless steel. Follow the manufacturers procedure for pickling before starting the work.Blank flangesBlank flanges and seals on top plate flanges shall be kept on until connection of the pump to thevessels piping systems.Special tools required for installation are supplied by Framo in the tool box.See tool list for descriptions.Intermediate support(s)Install the support(s) on the bracket(s) beforeinstallation of pump.1) Assemble upper nut, use 190 Nm torque.2) Tighten all bolts one more time, use 190 Nm torque.3) Assemble lower nut, use 190 Nm torque.Deck trunkRemove the flange protection and inspect thesealing surface on the deck trunk flange.Install two guide pins in top plate (180 apart).Locate the sealant joint on the deck trunk flange(ref. fig. 32b).Fig. 26Pump casingRemove protections from top flange, ejector pipeand level switch pocket. Inspect the sealingsurfaces. Install two guide pins (180 apart) and10 stud bolts. Put the gasket on the top flange.Regarding SB200:Remove the anodes in pump casing beforeinstalling the pump (fig. 27).Fig. 27Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 20 of 23Lifting of pumpsPumps shipped as one complete unitLift the pump to a vertical position. Preferably twocranes should be used for this operation, one to keepthe pump head clear of the ground and the other forlifting (ref. fig. 28).The pump head shall not be allowed to slide along theground during lifting.Fig. 28SB200/SB300 shipped in two sections (with total length < 20 m)(To be assembled prior to installation)The pumps have to be lifted by using a snatch block together with the crane on the lower part of thepump. Length of the wire through the snatch block = 2 x length of the lower part of pump.Fig. 29All SB400/SB600 (regardless of pump length)and SB200/SB300 with total length above 20mEach section has to lifted separately.See chapter 6.1 for installation in tank.Fig. 30Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPS- Lower the pump until the pump head approaches the pump casing.No.1401-0006-4Rev.B Jan-2003 Page 21 of 23- Remove the impeller protection. Apply grease to the o-ring in the house guide (see fig. 31a).- Lower the remaining distance, be careful when the pump head flange reaches the guiding pins. The pump seal ring will now enter into the pump casing sleeve, use lowest possible speed. Note! At the same time one have to watch the top plate guide pins entering into the deck trunk.- Remove guide pins, install the two remaining stud bolts, tighten the nuts in a diagonal sequence and lock with counter nuts (see fig. 31b).- Install the ejector pipe and fasten the lowest pipe clamp.- Put the level switch into the pocket, and tighten up the flange (4 bolts). (The SB400 is delivered with the level switch installed inside the pump head.)Fig. 31aFig. 31b- Remove transport bracket (belonging to toolbox)- If necessary use a plastic hammer on top plate in order to connect to deck trunk.- Install bushings and nuts under the trunk flange. Tighten bolts in a diagonal sequence.- Remove the two guide pins (belonging to toolbox), and install the two remaining bushings and nuts.Fig. 32aFig. 32bNote! Transport bracket and guide pins should be included in toolbox when installation is completed.Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPS- Remove the cap on evacuating control unit.- Connect cables according to el. diagram.- Remount the cap.No.1401-0006-4Rev.B Jan-2003 Page 22 of 23Note! When pump installation is completed. Do not remove any blank flanges before final connection to the piping system.Fig. 336.1 Additional information for pumps assembled during installation in tankNote !The pump has to be pressure tested after assembling andinstallation in tank. This requires an arrangement in tankwhich gives access to the flange connections in pipe stack.Lower the lower part of the pump until the top is approx.0.5 m from deck trunk.Fig. 34Install the installation tool on the deck trunk (see actual tooldrawing).Continue lowering until the pumps lower part is resting onthe tool. Secure the lower part before removing the liftingtool.Clean all o-ring grooves with a dry rag, and assemble partsshown in fig. 22.Before lifting upper part of the pump, assemble guidingbolts on top plate (see fig. 32a).Lift the upper part of the pump in position above decktrunk. Remove blank flanges and clean the flangeconnections with a dry rag. The gasket between top plateand deck trunk must be placed upon the deck trunk.Continue the lowering until the distance between theflanges is 50-100 mm. Install lifting bolts (toolbox) and liftthe lower part by using the lifting bolts. Be careful when theconnection pipe enters the high pressure pipe.For assembling of flanges, see page 17.Regarding the level switch cable, see chapter 5.Pressure test the pump.Fig. 36Fig. 35Framo Mounting InstructionINSTALLATION OF SUBMERGED BALLAST PUMPSNo.1401-0006-4Rev.B Jan-2003 Page 23 of 236.2 Filling of liquid in cofferdamAll the SB-pumps have liquid filled cofferdam.- Cofferdam liquid: Ethylene glycol or propylene glycol* : 50-60 % Use pure glycol without additives. Commercially available automotive anti-freeze should never be used. Some of the additives in anti-freeze tend to form deposits on seal parts and thereby causing failure on the seals.Corrosion inhibitor(Rocor NB Liquid or equal): 0.9% (initial dosing)Other types of corrosion inhibitors for coolingwater systems can also be used. The corrosioninhibitor must be compatible with glycol. The mixratio and the use of the corrosion inhibitor mustbe according to the suppliers data sheets, asthis can vary for the different types available.Demineralised water:Freezing pointFreezing point~ - 35C< - 40C40-50%v. 50% glycolv. 60% glycolVolumetricexpansion : 0 - 60C ~ 63.5 x 10-5 litre/litreCFilling:- Install the drain tool and unscrew the drain plug. Connect a hose to the drain tool. It is then possible to fill the cofferdam through the hose while venting at the header tank. Fill the cofferdam until liquid level stabilises at max. level mark on the sight glass.Fig. 37- Water/glycol to be filled after filling of hydraulic oil.The cofferdam volume depends on pump type and pump length. The following formulas giveapprox. volume (in litres) required to fill cofferdam to low level mark in header tank:Pump typeSB200SB300SB400SB600Pumphead 2,58095125 Pipe stackL x 0,5L x 3,5L x 3,5L x 3,5Header tank 2,5101010Total5 + (L x 0,5)90 + (L x 3,5)105 + (L x 3,5)135+ (L x 3,5)L = Pump length in metres. (See Framo Specification)* Other names for ethyleneglycol: monoethyleneglycol, 1.2 ethanediol, ethanediol. Other names for propyleneglycol: monopropyleneglycol, 1.2 propanediol, propanediol.FramoMounting InstructionInstallation of hydraulic power unitClosed loop systemNo. 1401-0034-4Rev.B Jan-2003CONTENTS123456789GeneralArrangementService space and lifting arrangementVentilation and heat dissipationFoundation and mountingCooling arrangementCable/starter cabinet for electric equipmentStarting system for diesel enginesFuel system10 ExhaustFramo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4Rev.B Jan-2003 Page 2 of 141 GENERALThe hydraulic power unit (HPU) delivers oil to the main pressure line and consists of the followingmain parts:- Electric driven hydraulic power packs- Diesel driven hydraulic power packs- Main hydraulic oil filter- Hydraulic oil cooler- Common foundation- Enclosure for separating high pressure hydraulic oil from hot surfaces.A hydraulic power pack consistsof a hydraulic pump with a builton pulsation damper, eitherdriven by an electric motor or adiesel engine. Each hydraulicpower pack is resilient mountedand exhaust, fuel and waterconnections are delivered withflexible connections.The auxiliary hydraulic unitconsists of a hydraulic systemtank and electric driven feedpower packs.Fig. 1 Hydraulic power unit (HPU) with 2 diesel driven and 2 electric driven hydraulic power packs.Normally the hydraulic power units are supplied as shown in fig. 1, but they may also bedelivered with the auxiliary unit as a separate item or with the auxiliary unit, power packs andfilter/cooler unit delivered separately.Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4 Rev.B Jan2003 Page 3 of 142 ARRANGEMENTNormally the HPU is located at the same deck as the auxiliary unit with the hydraulic pumps facingforward and with the motor shafts parallel to ship centre line. The shield must be extended to thenext deck. All hydraulic piping from HPU to consumers on deck will then be in the hydraulic roomand diesel engines/electric motors will be located in the engine room.Fig. 2 and 3 shows an arrangement which gives: Minimum noise level in accommodation area Minimum noise emitted from the ship Easy access for maintenance Optimum routing of hydraulic and exhaust pipes. Shielding of high pressure hydraulic oil from engines/hot surfaces and electric equipment (Shield to be extended as shown in fig. 12.)- Machinery room ventilation can be used for the electric motors/diesel engines.-----Fig. 2 Recommended HPU room arrangementNote! High pressure piping/flanges to be segregated from ignition sources (exhaust, electric starters, etc.)The auxiliary unit is normally a part of thepower unit. If it is delivered as a separateitem it may be oriented in any directions butshould if possible be located on the samedeck as the hydraulic power unit.If not possible it should be located on ahigher deck level but not more than8 meters above the hydraulicpower unit. This is limitedby the maximum allowabledrain oil pressure.Fig. 3 Auxiliary unit located above the hydraulic power unitFramo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4Rev.B Jan-2003 Page 4 of 143 SERVICE SPACE AND LIFTING ARRANGEMENTService spaceTo have access for service, a minimum free space isrequired around:----FilterHydraulic oil coolerHydraulic pumpsElectric motors/diesel enginesPlease note that the required dimensions for servicespace shown in the dimensional drawings areabsolutely minimum.Fig. 4 Service spaceThere must also be space for:-----Correct location of ventilation ductsCable traysLifting toolsElectric startersLocal control panelRef. fig. 6, 8, 9 and 10.Fig. 5 Service spaceFramo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPLifting arrangementNo.1401-0034-4 Rev.B Jan2003 Page 5 of 14Lifting arrangement is yard responsibility and must be installed above each power pack and thehydraulic oil cooler. Monorail is recommended above the diesel engines and electric motors.Approximately weights of the major components:Electric motor:Diesel engine:2000 kg2500 kgHydraulic pump (single): 400 kgHydraulic oil cooler:1400 kgFig. 6 Space for lifting4 VENTILATION AND HEAT DISSIPATIONIt is important that the power unit gets sufficient air supply according to motor size and number ofmotors. Yard is responsible for: - Sufficient ventilation capacity - Correct direction of air flow - Acceptable air temperature - Clean and water free airCapacityCalculation of necessary ventilation capacity is yard responsibility, but approximate air consumptionis given in fig. 7. For calculation of radiated heat see technical data.This curve is based on temp. increase T = 10C.Example:3 x Diesel engines 400 kW2 x Electric motors 400 kWTotal 1200 kWTotal 800 kW Total: 9 m3/s: 4 m3/s: 13 m3/sRequired air flow - Power Unit RoomInstalled power P (kW)350030002500200015001000500004Electric motorsDiesel engines with water cooled manifold.Cooling and combustion air5910152025Required air flow V (m3/s)Fig. 7Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPAir distributionNo.1401-0034-4Rev.B Jan-2003 Page 6 of 14The air should be distributed to all parts of the room to avoid pockets of stagnant hot air and any oilvapour from crankcase ventilation.Arrangement for separating the hydraulic side from motor side with ventilation ducts on both side isshown fig.8. When arranged like this, the ventilation capacity for the hydraulic room will be reduced.Fig. 8 Ventilation/Service arrangementAlternative location of venting duct for correct air flow:Fig. 9 Totally enclosed electric motorFig. 10 Open drip proof electric motorFramo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNoise reductionNo.1401-0034-4 Rev.B Jan2003 Page 7 of 14To avoid noise transmission to surrounding areas, some basic requirements to the power unit roommust be fulfilled if the HPU is installed in critical interface area. Key items are:- Hydraulic room (with entrance of double door type).- Noise trap on in- and outlet of ventilation in order to achieve effective absorption of high frequency noise.- Flexible and air tight penetrations for pipes and cables.- Critical interface areas such as bulkheads against accommodation areas should be covered completely by noise absorbing material. Ref. fig. 11.Fig. 11 - Noise reductionFramo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4Rev.B Jan-2003 Page 8 of 145 FOUNDATION AND MOUNTINGThe hydraulic power unit foundation to be welded (only outside) to a rigid deck structure and filledwith concrete to prescribed level.Gutter and drain possibility is recommended (Yard supply).Yard extension of shield is shown in fig. 12.Fig. 12Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPAuxiliary unit (if delivered separately)No.1401-0034-4 Rev.B Jan2003 Page 9 of 14To prevent vibrations transmitting to the steel structure, the auxiliary unit must be mounted on rigidfoundation filled with concrete (minimum 70 mm thickness).Auxiliary unit is resilient mounted as shown in the figure 13. Flat bars and rubber insulation aresupplied by Framo. For welding of flat bars to the foundation use the following procedure:- Place the auxiliary unit with flat bars and rubber insulation on the concrete filled foundation.- Spot weld the flat bars to the foundation (careful with the rubber insulation).- Remove the auxiliary unit and the rubber insulation before the flat bars are welded to the foundation with continuous fillet welding.- Assemble the auxiliary unit after cleaning and painting of welding zone.Fig. 13If the filter/cooler unit is delivered separately, same procedure as above (fig. 13) to be used.Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4Rev.B Jan-2003 Page 10 of 146 COOLING ARRANGEMENTThe hydraulic oil is cooled by sea water or fresh water automatically controlled by an electricallyoperated on-off valve. The valve is operated from the Framo PLC (Programmable Logic Control).The cooling water flow and max. pressure must be in accordance with the technical data given forthe system.Note!- Too low water flow through the cooler may cause corrosion/fouling problems.- Too high flow may cause erosion problems.The water flow is controlled by means of orifices at the water inlet and outlet side of the hydraulicoil cooler. This orifice is calculated and delivered by Framo. To verify that the flow is correct,differential pressure between the two test points must be measured. If differential pressure is out ofthe tolerances given in technical data, Framo must be contacted.Fig. 14 Cooling system arrangementWhen the power unit is installed above sea water level and sea water is used as cooling medium,piping at the outlet side must be routed above oil cooler and a vacuum breaker must be installed.Sea water piping should have sufficient zinc anodes.Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4 Rev.B Jan2003 Page 11 of 147 CABLE/STARTER CABINET FOR ELECTRIC EQUIPMENTRecommended cable routing:Fig. 15The hydraulic power packs are resilient mounted and therefore allowed to move relatively to thefoundation. Accordingly, cable trays and their supports must be connected to the foundation and notto the hydraulic power packs. Welding on electric motors are prohibited.The cables should be arranged to allow for removal of electric motors.The starter cabinet should be located outside the hydraulic room (ref. fig.8).Wiring between hydraulic power unit and local diesel engine control panelTo secure optimal performance and running conditions of the diesel engine, following details mustbe noted (ref. fig. 8): - Individual screened cables to be used for pick-up and actuator. - The screens to be terminated to dedicated terminals, not to ground. - Max. cable length and min. cross section to be respected.8 STARTING SYSTEM FOR DIESEL ENGINESAir startingThe piping from the reduction valves to thestarter shall be as short as possible in orderto limit pipe losses. Starter motor is suppliedwith a flexible hose.All connections should be made up withLoctite pipe sealant or equivalent.Teflon tape should not be used in starting airsystems.Design the piping to ensure that drain doesnot enter the starter motor. Install a drainvalve at lowest point (see fig.16).Fig. 16Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPElectric starter:No.1401-0034-4Rev.B Jan-2003 Page 12 of 14- Only starter type battery should be used in order to provide sufficient starting current with limited internal voltage drop. Refer to technical data for the project regarding recommended battery capacity.- Installation and charging of batteries must comply to class requirements with respect to location, ventilation etc.- Cables for starters must be dimensioned according to fig.17 to minimize voltage drop.- Make sure that good contact is obtained in all terminations in the starter circuit.1614Cable lenght (m)121086427090110130150170190Cable cross section (mm2, copper)Total lenght for bothplus and minus cablesFig. 17Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4 Rev.B Jan2003 Page 13 of 149 FUEL SYSTEMThe diesel engines are designed for fuel types DMA according to ISO 8217. Yard is responsible fora service tank with minimum volume 100 litre per engine located according to fig.18. Stainless steeltank material is recommended. Use pipe dimensions from HPU dimensional drawing.Fig. 18 Requirement for fuel system between diesel engines and the service tank.Yard is responsible for a system which serves the diesel engines with clean and water free fuel.A typical arrangement with a 10 micron pre-filter (Framo supply) and a float valve is shown in fig.19.Fig. 19Framo Mounting InstructionINSTALLATION OF POWER UNIT, CLOSED LOOPNo.1401-0034-4Rev.B Jan-2003 Page 14 of 1410 EXHAUSTTo achieve rated power, exhaust back pressure must be below maximum level, ref. technical data.Exhaust pipes from several engines shall have separate outlets. The exhaust piping should not be routedat the hydraulic side of the shield. It must be routed in order to prevent entrance of water (ref. fig. 20).Note! The exhaust system must be shielded .The diesel engines are provided with a compensator atthe outlet of the turbocharger to prevent excessivestress to engine.The compensator for exhaust pipe allows a maximumsimultaneous lateral movement of 10 mm and an axialmovement of 10 mm (ref. fig.21).A combined silencer/spark arrestor is provided for eachengine as a separate item.Keep the blank flange at the top of the exhaust Fig. 20compensator on until initial start-up to be sure there isno water ingress.Install the silencer as close as possible to the engine or near the outlet.The silencer can be installed in any position from horizontal to vertical, however flow directionindicated on the identification plate must be respected. When mounted horizontally note that thesoot collector must be at the lowest point enabling for periodically cleaning.Fig. 21Note! Installation, supporting and calculation data for the exhaust piping are given in separate instruction from the engine makers instructions.FramoMounting InstructionNo. 1401-0009-4Apr-2000Installation of electrical equipmentCONTENTS1 Framo control panel2 Motor starters2.1 Power pack starter2.2 Feed pump starter (closed loop system only)3 Electric motors4 STC remote control valve5 Interface to vessels integrated control system6 PreservationFramo Mounting InstructionINSTALLATION OF ELECTRICAL EQUIPMENTNo.1401-0009-4Apr-2000Page 2 of 61 FRAMO CONTROL PANELThe control panel should be installed in the cargo control room. It should also be sufficientlyilluminated and arranged for good contact/communication to the cargo manifold area to ensure aproper and safe cargo handling.Note that cargo operation require coordinated operation with other systems, such as cargo/ballastvalves, tank level and cargo pressure monitoring.- The panel must not be powered until wiring and termination has been checked by Framo commissioning engineer in co-operation with yard.- EEx equipment to be installed according to applicable rules. Note that intrinsically safe cables must be segregated.- All field cables to be marked with terminal number for simplified service.- Cable screens to be terminated close to inlet.- If applicable, bypass switch for tripping cargo pumps at low inert gas pressure, shall be installed on IG panel - not in Framo control panel.- Selfstanding cabinets to be bolted to yards foundation, refer to dimensional drawing:4(8) holes 12ACabinetYard foundationPlintYardfoundationAView A-ADeckAlternative type of control panel, ref. acknowledgement of order.Alt. 1Alt. 2Framo supply To be fixed to bulkhead by yardFramo supplyTo be fixed to bulkheadby yardBottom cable entry= Access for terminations and serviceBottom cable entryFramo Mounting InstructionINSTALLATION OF ELECTRICAL EQUIPMENTAlt. 3 HYDR. SYSTEMCONTROL PANELNo.1401-0009-4Apr-2000Page 3 of 6When operators panels are delivered for installation in yards common console,the following must be noted:- All internal/external components in addition to termination points must be accessible for service.- Precautions to be taken to avoid electric noise interference between the different systems and from external sources like walkie talkies etc:Refer to panel dimensional drawing for correct console cut out.Ensure good contact between all parts of the enclosure.Power- and signal cables/components to be separated.Separate the different sections with side walls. Any cut outs for cable transits to be minimized.2 MOTOR STARTERSFor starters delivered by yard, the following must be noted: - The individual stop contact from hydraulic system control panel to each starter must always trip the motors when open, regardless of command (local/remote). - Amperemeter to be provided for motors above 7,5 kW. - Facilities for local- and remote start / stop to be provided. Local opeartion only for transfer pump. - Overcurrent protection to be provided. Set point = rated current. - Selfstanding cabinets to be bolted to yards foundation. Refer to dimensional drawing.Yard to install circuit breakers withsufficient rating and breaking capacity forprotection of the motor circuit.Effort should be made to obtain optimalsetting of the short circuit protection.The setting shall be as low as possiblewithout interfering with the startingcurrent.Framo supplyTo be fixedto bulkheadby yard Bottomcable entry= Access for terminations and serviceBottom cable entryFramo Mounting InstructionINSTALLATION OF ELECTRICAL EQUIPMENTNo.1401-0009-4Apr-2000Page 4 of 62.1 Power pack starter- The thermistor amplifiers (one per power pack motor) must be installed in starters and connected to the thermistors in the motor. Thermistor amplif