fresh water generator

www.alfalaval.coml__--- - -~-

~ INSTRUCTION MANUALFOR

FRESH WATER GENERATORHULL NO. : 1648

SEC. NO. SHIP DESIGN OFFICE SHIP TYPE.

C3D6 SHIP OUTFITTING DESIGN DEP'T 2 9,200 TEU CLASS CONTAINER CARRIER

TEL NO. SHIP NO. SHIP NAME..

3709 1648 CMA CGM FIDELlO (MO 9299642

APPROVED Y. S. HAN NAME OF DRAWING

CHECKED Y. E. HONG FRESH WATER GENERATOR

DRAWN

DATE 2006.4.6 SCALE DRAWING NO. 6U-2846-185,I.. HYUNDAJ HEAVY INDUSTRIES ce.im CONSOUDATED NO. IM-22

ULSAN SHIPYARD. KOREA

" W~

--t..~'\d~t .

FINAL DRAWINGS WITHINSTRUCTION MANUAL

FORFRESH WATER GENERATOR

HULL NO. : 1648

CUSTOMER : HYUNDAI HEAVY INDUSTRIES CO., LTD.

ALFA LAVAL REF NO. : NK.()1742---'---------DATE : 060103

Alfa Laval

FINAL DRAWINGS LIS_T

CUSTOMER:

HULL NO :

HYUNDAI HEAVY INDUSTRIES CO.,LTD.

1648

Freshwater Type: DPU-36-C100

No Description Document No. Remark

1 Instruction manual

2 Order Specification

3 General description, freshwater generator

4 Technical data, freshwater generator

5 Technical data, pump and motor

6 Dimension drawing, freshwater generator

7 Flow chart, excl. I incl. options

8 Equipment specification

9 Vertical plant positioning

10 Assembly drawing, fresh water generator

11 Assembly scheme, plates

9.2.3.2-1

9.2.3.2-2

98516058

98517305

9.2.3.4-1

9.2.8-1

98519922

98513474....................................._ _ ; _..; ..

12 Outline drawing, motor for freshwater pump

13 Dimension drawing, Feed water treatment build-on

14 Dimension drawing, feed water treatment

15 Dimension drawing, Salinometer build-on

16 Technical datalelectric diagram. salinometer

17 List of loose supply items

18 Dimension drawing, thermometer

985 16704-01

98519815

9.2.9.~2

98517016

98517551

LOOSE

984 30365-01

19 Dimension drawing, V-type strainer (Size 10K-125A) BYS-1 0-1 00-000

20 Technical data, steel box for spare parts

21 Standard spares included in the delivery

9.2.9.2-3

9.3.1.1...................................................................; .- .

......... : .

Dept

Marine & Diesel

Date

060103

Drawn

SSKim

Checked

SSKim

Approved

SRJUNG

Instruction Manualfor Freshwater Generator

Type O-PU-36-C100

Book Number 036WE05.fm

A1fa Laval reserve the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvementof this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval company.

Published by: Alfa Laval Desalt NSMaskinvej 5DK-2860 Sl1Jborg(Copenhagen) Denmark

Copyright Alfa Laval Desalt.This document and it content must not be copied, reproduced, transmitted.or dis-dosed to any third party without consent of Alfa.Laval Desalt.

2 036WE05.fm

Table of Contents

Safety Instructions and Warnings

1.0.0 Safety Instructions and Wamings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 7

Storage/Long Term Standstill

1.0.0 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 91.1.0 Standstill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 91.1.1 Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 101.2.0 Long Term Standstill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 101.2.1 Preservation Procedure for Freshwater Generator ... . . . . . . . . . . . . . . .. page 101.2.2 Restart Freshwater Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 101.2.3 Preservation Procedure for Pumps . . . . . . . . . . . . . . . . . . . . .. page 111.2.4 Restarting of Pumps page 111.2.5 Preservation Procedure for Electric Motors . . . . . . .. . . . . . . . . . . . . . . . .. page 111.2.6 Restarting of Electric Motors ..... . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. page 121.2.7 Preservation Procedure for Electric Panel. . . . . . . . . . . . . . . . . . . . . . . . .. page 121.2.8 Restarting of Electric Panel . . . . . . . . . . . . . . . . . . . . . .. page 131.2.9 Solenoid Valves page 13

System Description

1.0.0 Working Principle. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. page 151.1.0 Freshwater Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 16

-. 1.2.0 Main Components page 17

Operating Instructions

1.0.0 Starting and Stopping Procedure " . . .. page 191.1.0 Starting ; page 191.1.1 Evaporation : : . . . . . . . .. page 191.1.2 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 201.2.0 Adjustment of Hot Water Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 201.3.0 Adjustment of Sea Cooling Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 211.4.0 Stopping the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 211.5.0 Long Term Standstill '.' page 22

036WE05TOC.fm 3

Table of Contents

Mallltellance

1.0.0 Why you need to perform reqular maintenance duties. . . . . . . . . . . . . . .. page 231.1.0 Overhaul Intervals. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. page 231.2.0 Maintenance of Separator Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 241.3.0 Maintenance of Evaporator Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 251.4.0 Maintenance of Condenser Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 261.5.0 Renewal of Plate Heat Exchanger Gaskets. . . . .. . . . . . . . . . . . . . . . . . .. page 271.5.1 Removal of Old Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 271.5.2 Cleaning page 281.5.3 Preparation of new Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 281.5.4 Fitting new Gaskets page 28

Pressure Test

1.0.0 Pressure Testing Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 31

Chemical Dosing of Scale Control Chemicals

1.0.0 Prevention of Scaling. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 331.1.0 Feed Water Ratio. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 331.2.0 Chemical Dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. page 331.2.1 Scale Inhibitor Dosage Equipment for Feed Water page 341.2.2 Safety Precautions with the use of Chemicals . . . . . . . . .. page 35

Trouble-Shooting

1.0.0 Test Sheet '. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 371.1.0 Trouble Shooting Table. . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 37

Maintenance of Freshwater Pump

1.0.0 Maintenance of Freshwater Pump Types PWF 1525-1532-2040 .... . .. page 411.1.0 Overhaul of the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 411.1.1 Clearance " '.' .., page 421.1.2 Dismantling Pump Shaft '. . .. : : . . . . . . . . . . . . . . . . . . .. page 42

Maintenance of Ejector Pump

1.0.0 Maintenance of Ejector Pump : . . . . . . . . . . . . . . . . . . . . . . . .. page 451.1.0 Overhaul of the Pump ; . . . .. page 451.1.1 Clearance : ". . . . . .. page 461.1.2 Dismantling Pump Shaft : . . . . . . . . . . . . . . . . . . . .. . . . . . . .. page 48

4 036WE05TOC.fm

Table of Contents

Salinometer

1.0.0 Salinometer Type OS-20 page 491.1.0 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 491.2.0 Installation (for OS-20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 491.3.0 Instructions for use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 501.3.1 Testing the Instrument page 501.3.2 Adjustment of Alarm Level page 501.3.3 Maintenance page 51

Spare Parts

1.0.0 Ordering Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 531.1.0 Alfa Laval Service ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 53

Index

036WE05TOC.fm 5


Should you need further clarification regarding this manual, do not hesitate to con-tact your local AJfa Laval representative - or call Alfa Laval Desalt directly.

Telephone

Telefax

+45 (for Denmark) 39 53 60 00

+45 (for Denmark) 39 53 65 66

1.0.0 Safety Instructions and Warnings

The following symbols in this manual point out safety precautions. It means your at-tention is needed and your safety is involved.

Lt WARNING'This symbol is used to indicate the presence of a hazard which can or willcause severe personal injury, if the waming is ignored .

.-::> CAUTIONCertain passages of the text will be marked with a caution mark. This markindicates the presence of hazard which will or can cause property damageif the instructions are not observed .

NOTE

This type of instruction indicates a situation which, if not avoided, could re-sult in damage to the equipment.

It is the owner's and operator's responsibility to see that any person involvedwith the use or operation of this equipment follow all safety instructions.

Read all safety instructions carefully and insist that they will be followed bythose working with you and for you. Not following the instructions may causesevere personal injury or damage the equipment beyond repair.

Do not allow this equipment to be used if it is faulty or the operator does notunderstand the proper use.

Samare04.fm 7


& WARNINGThe freshwater generator is not to be operated in polluted water or within20 miles from the coast

Freshwater must not be produced from polluted water, as the produced water canbe unsuitable for human consumption.

If manuals are translated to local language the unit comply with the EEC MachineryDirective and EN 292-1/2 standards. For EEC land installations manuals MUST beavailable in local language before installing and operating the unit.

The unit also comply with EN 50081-2 and EN 50082-2 "Industry" with regards to theEMC directive from EEC.

& WARNINGNoise hazards Use ear protection in noisy environments.

Crush hazards . Use correct lifting tools: .

Do not work under hanging load.

Burn hazard Wear gloves to avoid burns by hot surfaces.

Cut hazards Wear gloves to avoid cuts by sharp edges when handling machined

parts . Wear helmet to avoid cuts by sharp edges during maintenance of the

equipment.

NOTE

8

Max. ambient temperature for the equipment is 50C (122F).Min. ambient temperature for the equipment is OC (32F).

Samare04.fm


1.0.0 Storage

Unless otherwise agreed, Alfa Laval delivers the equipment ready to be put in ser-vice upon arrival and after installation. .

However, should it be necessary to store equipment for a longer period (1 month ormore), certain precautions should be made in order to protect and prevent unneces-sary wear of the equipment. .

The best solution is often to leave the equipment in the packing until it's time for in-stallation. In this case A1fa Laval should be informed. in order that proper preparationcan be done prior to packing.

Preferably, the equipment should be stored inside in a vibration free area at a tem-perature around 15 to 20 deg.C (59 to 68 deg.F) and humidity around 70%.

.

NOTE

There should ABSOLUTELY NOT be any OZONEPRODUCING equip-mentin the room,like operating electric motors or arc-welding, since ozone

. destroys many rubber materials. . .

Do not store organic solvents or acids in the room.

Avoid heat and ultraviolet radiation.

If the equipment must be stored outdoor, the precautions mentioned above shouldbe taken as far as practical. The need for protection against the climate ect. is ofcourse even more important in this case.

1.1.0 Standstill

If the freshwater generator is out of operation for a period of 14 to 30 days.

Close all valves in connection with the unit and it's pumps.

Open drain valve on the freshwater generator.

Storage.fm

Open front cover and clean the unit inside with fresh water.

Check that the anodes are functioning. If the anodes are not functioning orworn out replace them.

9


Let the unit dry out completely before closing and tighten the cover.

Turn the pump/motor shafts once a week to avoid damaging the mechanicalshaft seal and motor bearings.

NOTE

To preserve the natural protection of the inside of the vessel DO NOTscrape or scratch the inside surface.

1.1.1 Restart

Close drain valve on the freshwater generator and visually check outside for defects.

Before restart turn the pump/motor shaft by hand to check for any obstructions. afterstarting the pump watch the operation of the pump and electric motor for approx. 10minutes.

1.2.0 Long Term Standstill

1.2.1 Preservation Procedure for Freshwater Generator

If the freshwater generator is taken out ofoperation for a period longer than 30 days. Close all valves in connection with the unit and it's pumps.

Open drain valve on the freshwater generator.

Open front cover and clean the unit inside with fresh water.

Check that the anodes are functioning. If the anodes are not functioning orworn out replace them.

Drain the unit and let it dry out completely before closing and tighten the cover.

1.2.2 Restart Freshwater Generator

Close drain valve on the freshwater generator and check visually outside for defects.

For other equipment in connection with the freshwater generator follow proceduresas described below.

10 Storaqe.tm


Remove the salinometer sensor in the freshwater pipe after the freshwater pump,clean the sensor and store it in the electric panel or in a dry place.

1.2.8 Restarting of Electric Panel

Before taking the panel into service, ensure that anti-condensation heater (if fitted)have been disconnected and removed.

Check that no foreign matter is present in the panel.

Remove all surface dust and dirt.

Test the insulation resistance between phases and earth.

If an insulation resistance lower than one megaohm at 20 deg.C (68 deg.F) is mea-sured, the panel must be dried out until a minimum of one megaohm is obtained.

Clean and mount the salinometer sensor in the freshwater pipe.

1.2.9 Solenoid Valves

Solenoid valves are removed, flushed with warm fresh water and stored in a cleandry ozone free area. . ...

Before replacing, the valves are flushed again with warm fresh water and the functionofthe valve is checked by energizing the col I.

Slorage.fm 13


1~2.3 Preservation Procedure for Pumps

Drain the pump through the bottom drain.

Flush the pump with hot fresh water (maximum 60 deg.C, 140 deg.F), flushingcan take place through the manometer connections.

Let the pump dryout.

Flush the pump with 'Mobil Arama 25' or similar quality.

Mount drain plug and manometer connections.

Turn the pump shaft once a week to avoid damaging the mechanical shaft seal.

1.2.4 Restarting of Pumps

Fill the pump with hot fresh water through themanometer connections.

Mount the manometer connections.

Turn the pump shaft by hand to check forany obstructions.

Open valves and check that the mechanical shaft seal is not leaking (if leakingstart the pump and let it run for 1to 2 minutes, if still leaking the mechanical sealmust be replaced).

Start the pump and watch the operation of the pump and electric motor for ap-prox. 10 minutes. .

1.2.5 Preservation Procedure for Electric Motors

Factory fitted bearings use a lithium based grease with a recommended shelf life oftwo years. If stored for a longer period, grease may need to be replaced.

Shielded bearings have a storage lifeof five years and a further two years operationallife following the installation.

To avoid static indentation during long term standstill, the area should be vibrationfree.

Where exposure to some vibration is unavoidable, the shaft should be looked. Rollerbearings may be fitted with a shaft locking device which should be kept in place dur-ing long term standstill. .

Shaft should be rotated by hand, one quarter of revolution weekly.

Storage.fm 11


& WARNINGWhere anti-condensation heaters have been fltted, it is strongly recom-mended that they are energized.

In such case, prominent warnings of live terminals inside the terminal boxmust be posted inside and outside the motor terminal box.

Where anti-condensation heaters is not fitted, the use of desiccant is recommended.

1.2.6 Restarting of Electric Motors

Before taking a motor into service, ensure that anti-condensation heaters (if fitled)have been disconnected and isolate before starting the motor.

Check that no foreign matter is present.

Remove all surface dust and dirt.

Test the stator insulation resistance between phases and also to earth.

. lfan insulation resistance lower than one megaohm at 20 deg.C (68 deg.F) is mea-sured, the windings must be dried out until a minimum of one megaohm is obtained.:

Start the motor.

Watch the operation of the electric motor for approx. 10 minutes.

1.~.7 Preservation Procedure for Electric Panel

The electric panel normally includes motor starters with thermal relays, transformer,contactors and salinometer.

The panel have to be disconnected from the main supply and kept clean and dry dur-ing the long term standstill period.

The panel is kept dry inside either by an anti-condensation heating element (25 W)or by use of a desiccant.

& WARNINGIf anti-condensation heater is used, prominent warnings of live terminals in-side the panel must be posted inside and outside the panel.

12 Storage.fm

System Description

Condenser

Jacket water

InletJacket water OutletFeed waterInlet

Air suctian

Demister

: I. J I/. /'

-' '--"" -,-,-'----_......

Brine

Brine Outlet

Working ptincipte:

The feed water is introduced into the evaporator section and the produced fresh-water is extracted from the condenser and led to the freshwater storage tank .

1.0.0 Working Principle

The combined brine/air ejector driven by the ejector pump creates a vacuum in thesystem in order to lower the evaporation temperature of the feedwater.

The feedwater is introduced into the evaporator section through an orifice, and is dis-tributed into every second plate channel (evaporation channels).

The hot water is distributed into the remaining channels, thus transferring its heat tothe feedwater in the evaporation channels.

Having reached boiling temperature - which is lower than at atmospheric pressure-the feed water undergoes a partial evaporation, and the mixture of generated vapourand brine enters the separator vessel, where the brine is separated from the vapour

Sy1dpeOO.fm 15

System Description

and extracted by the combined brine/air ejector.

Having passed a demister the vapour enters every second plate channel in the con-denser section.

The sea water supplied by the combined cooling/ejector water pump distributes itselfinto the remaining channels, thus absorbing the heat being transferred from the con-densing vapour.

The produced freshwater is extracted by the freshwater pump and led to the fresh-water tank.

Sea coolinwater. Inlet

Air suction

Jacket waterInletFeed waterFresh waterOutlet

Sea coolinwaterOutlet

o

oo

o o

o o

o

o

.o

o

Jacket waterOutlet

1.1.0 Freshwater Quality

To continuously check the quality of the produced freshwater, a salinometer is pro-vided together with an electrode unit fitted on the freshwater pump delivery side.

If the salinity of the produced freshwater exceeds the chosen maximum value. thedump valve and alarm are activated to automatically dump the produced freshwaterto the bilge.

If there are no special requirements from the authorities, the produced freshwatercan be used directly as drinking water.

16 Sy1dpeOO.fm

System Description

1.2.0 Main Components

The freshwater generator consists of the following components:

1. Evaporator sectionThe evaporator section consists of a plate heat exchanger and is enclosed inthe separator vessel.

2. Separator vesselThe separator separates the brine from the vapour.

3. Condenser sectionJust like the evaporator section the condenser section consists of a plate heatexchanger enclosed in the separator vessel.

4. Combined brine/air ejectorThe ejector extracts brine and incondensable gases from the separator vessel.

S: .Ejector pumpNormally, the ejector pump is delivered by Alfa Laval, and the ejector pump isa single-stage centrifugal pump. This pump supplies the condenser with seawater and the brine/air ejector with jet water as well as feed water for evapora-tion.

6. . Freshwater pumpThe freshwater pump is a single-stage centrifugal pump. The freshwater pumpextracts the produced freshwater from the condenser, and pumps the water tothe freshwater tank. .

7. SalinometerThe salinometer continuously checks the salinity of the produced water. Thealarm. set point is adjustable.

8. Control panelNormally, the control panel is delivered by Alfa Laval.It contains motor starters, running lights, salinometer, contacts for remote alarmand is prepared for start/stop. .

Sy1dpeOO.fm 17


& WARNINGDO NOT operate the plant in polluted water.

Freshwater must not be produced from polluted water, as the produced water will beunsuitable for human consumption.

1.0.0 Starting and Stopping Procedure

-=:> CAUTIONBefore starting up please observe instructions for feedwater treatment, see"Chemical dosing of scale control chemicals".

Please refer to PI-diagram (see "FWG Order Specification").

1.1.0 Starting

1. Open valves on the suction and discharge side of the ejector pumpPU-SC-01.

2. Open overboard valve for combined brine/air ejector.

3. Close air screw VA-E1-o1 on the separator.

4. Start ejector pump PU-SC-01 to create a vacuum of min. 90%.

Pressure at combined brine/air ejector in/et minimum 300 kPa (3.0 kp/cm').Back pressure at combined brine/air ejector outlet maximum 60 kPa (0.6 kp/cm'). .

1.1.1 Evaporation

When there is a minimum of 90% vacuum (after maximum 10 minutes).

5. Open valve for feedwater treatment, if any.

OpjweOO.fm 19


6. Open hot water inlet and outlet valves.

7. Start hot water supply to distiller by adjusting bypass valve or hot water pumpif any, step-wise 1O'C, until the desired jacket water temperature is reached.

The boiling temperature now rises, while the obtained vacuum drops to approx.85%.

This indicates that evaporation has started.

1.1.2 Condensation

After approx. 3 minutes the boiling temperature will drop again, and normal vacuumis reestablished.

8. Open valve to freshwater tank.

9. Switch on salinometer.

10. Start freshwater pump PUFR.QlIPU-FR.Q2.

NOTE

The freshwater pump discharge pressurewill tie between 120 and 160 kPa(1.2 - 1.6 kp/cm").

After starting the freshwater pump the flow sight glass in the air suction pipe must~em~. .

-=:> CAUTIONIf water remains in the flow sight glass in the air suction pipe, please referto "Trouble shooting".

1.2.0 Adjustment of Hot Water Flow

Please refer to "FWG Order Specification" for specified hot water flow.

Inorder to obtain the specified flow of hot water, it is necessary to adjust the bypassvalve until desired flow is achieved.

20 OpjweOO.fm


The flow can be calculated as follows:

MJW= KJW x cap.m3/24h =m3/h

~tJW

Where:

MJW Flow of hot water in one hour.

KJW = Constant =25.6for 1-stage freshwater generator. .KJW = Constant =15.52 for 2-stage freshwater generator.

~tJW = Difference in temperature of hot water in and out.

Cap.m3/24h = Freshwater production in 24 hours, Le. production in 5min. times 288.

Example: cap. m3/24h

TswdtJW

= 15m3= 32C=18.4C

MJw= 25.6 x 15 = 20.9 rnvn18.4

1.3.0 Adjustment of Sea Cooling Water

The sea cooling water flow is correct, when the pressure at the inlet side of the com-bined air/brine ejector is between 300 and 400 kPa (3.0 - 4.0 kp/cm2)

1.4.0 Stopping the Plant

1. Stop hot water supply to distiller.

2. Close valve for feedwater treatment, if any.

3. Stop freshwater pump PU-FR-01/PU-FR-o2.

4. Switch off salinometer.

5. Stop ejector pump PU-SC-01.

6. Open air screw VA-E1-o1.

OpjweOO.fm 21


7. Close valves on the suction and discharge side of the ejector pump.

8. Close overboard valve for combined brine/air ejector.

9. Close the valve to freshwater tank.

~ CAUTION.

All valves must be shut, while the distiller is out of operation. Except airscrew.

1.5.0 Long Term Standstill

If the distiller is out of operation for a period longer than 14 days.

Open front covers and clean unit inside with freshwater.

Let the unit dry out completely, before closing covers.

Please observe "Maintenance of separator vessel" .

22 OpjweOO.lrn

Maintenance

1.0.0 Why you need to perform regular maintenance duties

Regular maintenance of the plant will improve performance and availability.

The maintenance schedule on the following pages will tell you how often serviceshould be performed on the main components.

As the actual operating conditions of the plant are of major influence on the life time,the overhaul dates are not obligatory but only recommended intervals.

When the plant has been in operation for a longer period of time and experience hasbeen established as to the actual performance, it will be possible to adapt the main-tenance schedule.

For service on minor components please refer to component instructions.

1.1.0 Overhaul Intervals

Component Operating ActionHours

Evaporator section As required Clean in inhibited acid bath

Condenser section As required Clean with pure freshwater andbrush

Combined ejector/cooling 8000 h Measure seal ring and impeller..water pumpwith motor Examine mechanical shaft seal,

cooling water pipe passage.Megger-test electric motor.Clean pump thoroughly beforereassembly.

Freshwater extraction 8000 h See abovepump with motor

Combined air/brine ejector 8000 h Measure nozzles and diffuserand compare to measurementsin technical specification.

MV-valves 4000 h Disassembly and inspect for. damage.Demister 8000 h Clean in inhibited acid bath

Madpue01.fm 23

Maintenance

Component Operating ActionHours

Manometers 8000 h Adjust with control manometer

Salinometer See separate in- See separate instructionsstructions

1.2.0 Maintenance of Separator Vessel

The separator vessels and the pressure plates for the heat exchanger sections(evaporator and condenser) are made of stainless steel with a special chemicaltreatment. This treatment will reestablish normal surface oxidation after work- up atthe factory. The preparation is a natural protection of the stainless steel.

-=:> CAUTIONTo preserve this natural protection DO NOT scrape or scratch the insidesurface of the separator vessels.

Further, there are isolating layers on the separator inside walls, where the heat ex- .changer sections are mounted.

Whenever the sections are dismantled, these isolating layers must be checked fordefects. Repair any defects according to the maintenance guide for glass flake coat-ing.

Whenever the separator vessel is opened,

check that the anodes are functioningIf the anodes are not functioning and/or wom, replace them.NOTE

If the unit is stopped for a longer period than 14 days.

24

Open separator covers and clean unit inside with freshwater.

Let the unit dry out completely,-before closing covers .

.Madpue01.fm

Maintenance

1.3.0 Maintenance of Evaporator Section

Clean evaporator as follows:

1. Remove bolts in front cover, and open.

2. Loosen the 6 nuts in plate stack gradually, so that no nut is carrying the entireload alone

3. Remove plate stack.

NOTE

If some of the gaskets come loose on removing plate stack, please seesection 1.5.2

.4. Submergeplates completely in a hot, inhibited acid bath at maximum 50C. Forfurther instructions see "Chemical dosing of scale control chemicals".

& WARNINGAlways follow carefully the suppliers instructions when using inhibited ac-ids. '., .

Remember to neutralize according to suppliers instructions.

5. Examine plates and gaskets for possible damage, and remove damaged platesand/or replace damaged gaskets.

6. If a defective plate is found, remove the plate together with one of the adjacentplates.

NOTE

The assembly measurements must be reduced with 5.4 mm per plate, ifplates are removed from plate stack.

Madpue01.fm 25

Maintenance

-=:> CAUTIONThe ES and EEplate cannot be removed but must always be replaced, witha corresponding plate.

Reassemble evaporator section in accordance with assembly scheme.

Tighten plate stack to measurements stated in technical specification.

7.

8.

9. Pressure test evaporator section before closing front cover.

The evaporator section is pressure tested by letting hot water circulate throughthe section with bypass valve for hot water in normal running position.

'10. When the evaporator section is found to be tight, close front cover and tightenbolts.

11. Retighten, when vacuum has been reestablished.

1.4.0 Maintenance of Condenser Section

Clean condenser as follows:

1. Remove bolts in front cover, and open.

2. Loosen the 6 nuts in plate stack gradually, so that no nut is carrying the entire

load alone.

3. Remove plate stack.

NOTE

If some of the gaskets come loose on removing plate stack, please seesection 1.5.2

4. Scrub plates with a soft brush and plain hot water at maximum 50C.

5. Examine plates and gaskets for possible damage, and remove damagedplates and/or replace damaged gaskets.

6. If a defective plate is found, remove the plate and one of the adjacent plates.

26 Madpue01.fm

Maintenance

.

NOTE

The assembly measurements must be reduced with 5.4 mm per plate, ifplates are removed from plate stack.

o CAUTIONThe ES and EE plate cannot be removed, but must always be replaced,with a corresponding plate.

7. Reassemble condenser section in accordance with assembly scheme.

8. Tighten plate stack to measurements stated in technical specification.

9. Pressure test condenser section before closing front cover.

The condenser section is pressure tested by letting sea water from the com-bined cooling water/ejector pump circulate through the section.

o CAUTION. Before starting the combined ejectorlcooling water pump, the feed water

must be sealed off.

10. When the condenser section is found to be light, dose front cover and tightenbolts.:

11. Relighten, when vacuum has been reestablished.

1.5.0 Renewal of Plate Heat Exchanger Gaskets

1.5.1 Removal of Old Gaskets

Pull the old gaskets out of groove.

If the gasket cannot come off directly, heat the back ofthe gasket groove with ahot-air blower or butane gas bumer. .

Madpue01.lm 27

Maintenance

Pay attention not to overheat the plates.

You will obtain a suitable temperature, if the flame is held 10 to 15 cm behind theplate.

WARNING

DO NOT use acetylene gas

1.5.2 Cleaning

Charred or loose glue and rubber remains must be removed, e.g. using a rotatingstainless steel brush. The width should be adapted (040-50 mm, width 8-10 mm).Thin layers of glue which are difficult to remove, may remain.

Clean the gasket groove with a clean cloth, dipped in a solvent (acetone, methyl eth-yl ketone, trichlorethylene etc.).

& WARNINGBe careful when handling these solvents, as they may be hazardous toyour health. Observe suppliers' instructions.

Gaskets, that have loosened, can be glued on. Clean gasket groove carefully with asharp tool. Then clean the loose part of the gasket with emery cloth or sandpaper.Finally clean groove and gasket with a solvent, and glue .

1.5.3 Preparation of new Gaskets

Dry new gaskets with a clean cloth that has been slightlymoistened with a solvent.

1.5.4 Fitting new Gaskets

1. Apply a thin layer of glue to both gasket and groove.

2. Let the glue dry for 10-15 minutes.

3. Fit new gasket into groove.

Gaskets may sometimes be slightly short or long.

28 Madpue01.fm

Madpue01.fm

Maintenance

Short gaskets should be stretched before being fitted into the groove.

Long gaskets should be fitted into the grooves at the plate ends first and thengradually be pushed into the groove towards the middle.

If necessary, tape gasket into groove.

29

Pressure Test

1.0.0 Pressure Testing Separator

If there are leaks in the system, it will be necessary to carry out a pressure test inorder to identify the leak:

1. Close valve on discharge side of combined cooling water/ejector pump.

2. Close discharge valve on overboard line from combined brine/air ejector.

3. Close valve on discharge line to freshwater tanks.

4. Open separator vessel in order to vent the vessel, when supplying water forpressure test.

5. Supply water (sea or freshwater) at the socket for the connection offeed watertreatment. .

-=:> CAUTIONMaximum pressure on the separator vessel is 150 kPa (1.5 kp/cm") (21PSI).

PrdpueOO.fm 31


1.0.0 Prevention of Scaling

During the evaporation of sea water there is always a risk of scaling on the heatingsurfaces. This will lead to a reduction of the K-values of the heating surface and de-creasing freshwater production and reduction of plant efficiency.

In order to effectively prevent scaling the operators must be aware of the factors in-fluencing the scale formation.

1.1.0 Feed Water Ratio

The feedwater ratio is an extremely important factor. It is defined by the relationshipbetween the feedwater amount fed into the plant and the produced amount of fresh-water.

If the feedwater ratio is reduced, the concentration will rise in the plant subsequentlyresulting in scale formations.

Two things may shift the feedwater ratio: first of all direct adjustment of the feedwatersystem, and secondly exceeding the maximum freshwater production laid out for theplant. The operators must observe the following rules at all times.

-=:> CAUTIONDO NOT adjust feedwater system. Feedwater pressure min. 3.0 max. 4.0bar g.

1.2.0 Chemical Dosage

In order to control scale formations on the heating surfaces and continuously ensurelong operation periods without acid cleaning the plant, it is absolutely necessary todose scale control additives to the feedwater. The operators must follow the instruc-tions for chemical dosing given by the chemical supplier carefully.

CdgnpeOO.fm 33


-=:> CAUTIONIf the distiller is operated at boiling temperatures above 4S'C without chem-icals, frequent cleaning of the evaporator will be necessary.

We recommend that you do not operate the freshwater distiller without rec-ommended chemical dosage at boiling temperatures above 4SC. Even at .lower temperatures it can be recommended.

1.2.1 Scale Inhibitor Dosage Equipment for Feed Water

Please refer to drawing, see "FWG Order Specification".

When adding chemicals mix thoroughly to ensure a homogenous blend ofchemicals and water.

Use a fully soluble scale inhibitor, e.g. on polymer basis. The following products canbe recommended:

NALFLEET Evaporator treatment 9-913

AMEROYALEVAPORATORTREATMENT

HEXAMETHAPHOSPHATE

1. Mix the required quantity for 24 hours operation in the tank according to mak-er's instructions.

2. Adjust flowmeter to cover the maximum freshwater output from the distiller.

3. Flush the dosage system regularly.

34 CdgnpeOO./m


1.2.2 Safety Precautions with the use of Chemicals

& WARNING1 USE eye protection and gloves. Avoid direct skin contact, eye contact

or contact with clothes.

2 CLEAN empty containers before disposal.

3 If chemicals are spilled on clothes, rinse with water and dispose offclothes.

4 ltchernlcals are spilled on the floor, rinse with water and suck remain-ing chemicals off with sand. Clean the spot immediately afterwards.

5 .. Scale inhibitor is hazardous, if consumed in a concentrated solution.If consumed by mistake.IMMEDIATELY SEEK MEDICAL ATTENTION.

6 If eyes get in contact with the chemicals, rinse for at least 20 minutes.IMMEDIATELY SEEK MEDICAL ATTENTION.

CdgnpeOO.fm 35

Trouble-Shooting

1.0.0 Test Sheet

Before taking any action, please fill in a test sheet to find possible causes of malfunc-tions.

Test sheets can be found in the back of this binder.

1.1.0 Trouble Shooting Table

Problem Cause Action

Drop in production. Partially blocked feed water DismanUe evaporator section,orifice and/or sludge deposits and clean evaporator and ori-on hot water side. . fice.

Sludge on the heat exchanger DismanUe condenser section,plates on the sea water side. and clean.

Inlet channel in evaporator/ DismanUe evaporator/ con-condenser plate stack denser section, and dean.blocked, e.q, with rust scales,gasket fragments etc.

Too low ejector pump pres- See instructions for "Low Seasure. Cooling water/Ejector pump

flow / pressure", below.

.Leakages' Carry out a pressure test atmax. 150 kPa (1.5 kp/cm')(21.8 PSI).a

Foreign bodies in ejector noz- Inspect nozzles, and clean.zles. Replace nozzles, if damaged.

Too high back pressure on Check overboard pipe andejector outlet side. Max 60 . valves for blocking / function-kPa (0.6 kp/cm') (8.7 PSI). ability.

Non-retum valve in air extrac- Replace non-retum valve.tion pipe defect.

Hot water temperature too Reduce to specified tempera-high. ture.

Defective water' clock. Examine water clock. Let theproduced water flow throughwater clock into a 10 I pail, andcheck production with a stopwatch.

Trw26e03.fm 37

Trouble-Shooting


Low Sea Cooling water/Ejector Too low ejector pump pres- Clean, or replace pressurepump flow / pressure. sure. gauge.Minimum pressure 300 kPa(3.0 kp/cm') (43.5 PSI). Suction strainer blocked. Clean suction strainer.At inlet side of ejector.

Valves on suction or pressure Examine and overhaul defec-pipe defect. tive valves.

Leakage from suction pipe to Repair.pump.

Impeller / seal ring defective. Checkpump maximum clear-ancesee "Maintenance ofEjector Pump"

Clocked up condenser plate Dismantle condenser platestack. stack and clean.

Pump rotating in wrong direc- Interchange phases.tion.

Sight glass overflow. Normal Suction pipe leakage. Check suction pipe especiallyback pressure for freshwater unions and connections. Re-pump is 120 -160 kPa (1.2- pair.1.6 kp/cm') (17.4 - 23.2 PSI).Except for JWP-16-C40 gener- Mechanical seal in freshwater Replace mechanical seal.ator type, where the max. back pump defect.pressure is 80 kPa (0.8 kp/cm')(11.6 PSI). Impeller / seal ring in freshwa- Check pump maximum clear-

ter extraction pipe defect. .' . ance see "Maintenance ofFreshwater Pump"

Pump rotating in wrong direc- Interchange phases.non.

Valves to freshwater tank Check all valves.closed.

Inlet filter for water clock Clean filter.blocked .

Salinity too high (more than 2.0 Demister not fitted correctly. Check that demister is fittedppm). against baffle and front cover.

Front cover gasket defect or Replace front cover gasket.not fitted correctly.

Insufficient brine extraction. Seeseparate instructions forlnsuffident brine extraction,below .

Electrode unit defective or Examine electrode unit fordirty. cracks. Check that it is fitted

correctiy. Clean, if necessary.

38 Trw26e03.fm

Trouble-Shooting


Leakage in condenser sec- Open distiller and pressure testtion. condenser. Max. 600 kPa (6.0

kp/cm') (87 PSI). If there is adefective plate, remove togeth-er with adjacent plate assem-ble plate stack according tonew plate number with re-duced assembly measure-ments. Check plate gasketsand replace, if necessary.

Insufficient brine extraction - Ejector pump pressure too See s~al instructions forbrine level in sight glass higher low. "Low ea Cooling waterlEjec-than 20 mm. tor pump flow I pressure",

above. '

Foreign bodies in ejector noz- Check nozzles, and clean. Re-zles . place damaged nozzles.

Too high back pressure down- Examine overboard pipe andstream of ejector. valves.

wr~ dimension of feedwa-' Examine orifice dimension -ter on ce. check technical specification.

Non-retum valve in brine sue- Examine valve and repair, ortion pipe of ejector defect. replace.

Frequent refill of freshwater Leakage in evaporator sec- Open distiller and pressure testexpansion tank due to loss of ' tion, ' condenser. Max. 600 kPa (6.0hot water. kp/cm') (87 PSI).

If there is a defective plate, re-move together with adjacentplates assemble plate stackaccording to new plate numberwith reduced assembly mea-surements. Check plate gas-kets and replace, if necessary.

Abnormal amperage con- Ejector nozzles defective. Replace nozzles.sumption of ejector pump mo-tor. Wrong dimension of feedwa- Check dimensions on spare

ter inlet orifice. parts list, see List of spare partdrawings", and replace if nec-essary.

Bearings in motor defective. Examine with stetoscoree, andreplace bearings, if de ective.

Contactor defective. Examine and replace contactorset, if defective.

Breaking of phases. Max. 5% difference in amper-age between phases.

Trw26e03.fm 39


1.0.0 Maintenance of Freshwater Pump Types PWF 1525-1532-2040

The following instructions must be carefully observed whenever it becomes neces-sary to overhaul or repair the freshwater pump.

Please refer to drawing for item references in the text.

10

6

111419

17

23 . 18

1.1.0 Overhaul ofthe Pump

1.

2.3.4.

5.

6.

7.

8.

Remove the nuts 14 on the pump casing 1.

Lift motor with pump cover 4 and impeller 2 clear of pump casing 1.

Unscrew countersunk screw 20 (right hand thread).

Remove impeller. Normally, it can be removed without using dismantling tools.

Remove key 19.

Remove the mechanical shaft seal 22.

Inspect the ceramic ring, the carbon ring and the spring.

Replace mechanical shaft seal, if necessary. It is recommended to grease theshaft and seat for the ceramic ring with glycerine in order to make it easier toassemble the mechanical shaft seal. Please also observe separate instruc-tions for mechanical shaft seal delivered together with the seal.

MapvfeOO.fm 41


9. Fit carbon ring. spring and spring holder on pump shaft.

10. InspecUmpeller and the drilled sealing water channel for clogging. and clean.

11. Remember to replace gasket 3.

12. Reassemble in reverse order.

1.1.1 Clearance

In connection with the inspection be sure to measure the impeller and wear ring 17in order to secure that the clearance is no more than 0.5 mm on the diameter.

o CAUTIONThe pump shaft 11 must only be dismantled. ifpump shaft or electric mo-tor bearing has to be replaced. .. .. .. . .

In this case carefully observe "Dismantling pump shaft".

1.1.2 Dismantling Pump Shaft

If thepump shaftdoesnot come loose, use the special dismantling tools shown..... beloiN.

42

1.

2.

3.

Dismantle the pump as described above.

Unscrew pointed screws 11.

Carefully insert two screw drivers behind the pump shaft, and loosen it.

The tool is not Alfa Laval Desalt supply.

MapvfeOO.fm


B

A

6

The tool consists of a pipe (A), a disc (B) with hole for the screw (C) and a nut(D), washer (E).

Please note that the length L must be longer than the length I.

Place pipe around the shaft. Fasten the screw with nut and washer into thethreaded hole (M12) on the shaft end.

Loosen shaft by tightening the nut while holding on to the screw.

I-==> CAUnONDO NOT grind the motor shaft.

4. Mount the new pump shaft on the motor shaft.

5. Make sure that the pump shaft fits the motor shaft without any obstructions, be-fore final shaft fitting as follows: .

Tap onto the end of the pump shaft slightly with a RUBBER hammer.

6. Tighten pointed screws 11 as follows:

MapvteOO.fm 43


NOTE

The torque should be 5 Nm (0.5 kpm) and the maximum wobble 60 u.rn.

7. Check the wobble of the pump shaft with a dial indicator.

8. Assemble the pump as described above.

44 MapvfeOO.fm


1.0.0 Maintenance of Ejector Pump

(If supplied from Alfa Laval)

The following instructions must be carefully observed 'whenever it becomes neces-sary to overhaul or repair the above mentioned pump. Please refer to drawing foritem references in the text.

1.1.0 Overhaul ofthe Pump

1. Remove the set screws 19 in pump cover 2.

Motor with motor bracket 6, pump cover 2, and impel/er 5 can now be liftedclear of the pump casing 1.

2. Unscrew the screw 22 (right-hand thread).

3. Remove impeller.

MacnleOO.fm 45


NOTE

Normally, the impeller can be removed without using dismanUing tools.

If not, you can fit dismanUing screws into the two threaded holes in the im-peller.

4. Remove the key 26 and the mechanical seal 8 (including spring holder, springand carbon ring).

5. Inspect the ceramic ring, the carbon ring and the spring. Replace, if necessary

If mechanical seal has to be replaced, proceed as follows:

Unscrew set screw 20 to remove pump cover 2 from motor bracket 6in order to gain access to ceramic ring..

In order to make it easier to assemble the mechanical seal, the shaft and ringseat may be greased with glycerine. Please also refer to separate instructionsfor mechanical seal delivered together with the seal.

After fitting the ceramic ring, fit pump cover 2 to motoi'bracket6.

Fit carbon ring, spring and spring holder.

6. Ciean drilled cooling water channel in pump cover 2.

7. Inspect impeller and threaded holes for clogging.

8. Remember to change the O-ring 7.

9. Reassemble in reverse order.

1.1.1 Clearance

In connection with the inspection, the impeller 5 and wear rings 10 are measuredin order to secure that the clearance is not larger than stated in the diagram below:

46 MacnleOO.fm


;l~ ---- --

Wear ring 121 Clearance maximum Clearance minimum

100 mm 0.5mm 0.15 mm

150 mm 0.6mm 0.2 mm

200 mm 0.7 mm 0.25 mm

250 mm 0.8 mm . 0.28 mm

300 mm 0.85 mm 0.3 mm

350 mm 0.9 mm 0.3 mm

If the clearance is too big, replace wear rings as follows:

1. Unscrew countersunk screws 25.

2. Pull out wear (seal) rings.

3. Fit new wear rings and tighten countersunk screws.

-=:> CAUTIONThe pump shaft may only be dismantled,if pump shaft or bearings, in theelectric motor have to be replaced.

Carefully observe instructions for "Dismantling pump shaft".

MacnleOO.fm 47


1.1.2 Dismantling Pump Shaft

If the shaft 4 has to be dismantled due to a defect or if electric motor bearing has tobe replaced, proceed as follows:

1. Unscrew pointed screws 16.

2. Remove shaft 4. Normally this can be done without using dismantling tools.

Ir::> CAUTIONDO NOT grind the motor shaft.

3. Fit shaft 4.

4. In order to make sure that the coupling is fitted correctly, tap slightly atthe shaftend with a RUBBER hammer.

5. Tighten pointed screws 16 with a torque of 35 Nm(3.5 kpm) .

48 MacnleOO.fm

Salinometer

1.0.0 Salinometer Type 05-20

1.1.0 Technical Specification

Function Measuring (Dot Bar) and supervising salinity offreshwater produced by seawater desalination.

Supply voltage 90-120 V or 200240 VAC.

Frequency SO/50 Hz

Power consumption Salinometer 10 VA.Relay contacts Max.load 100 VA.Salinity display 0,5 - 20 ppm (Dot Bar).

Temperature correction Automatic in the range 5 - 85C.

Alarm level Can be set to any value between 0,5 - 20 ppm.

Test Can be checked by test switch, 10 ppm.

Output 4-20 mA Current Loop.

Max. ambient tempera- 55C.ture

Protection degree IP 54.

1.2.0 Installation (for 05-20)1. Open front cover.

2. Select correct voltageselect according to the main supply voltage 115 Vor 230VAC.

3. Screw salinometer on to bulkhead with six nuts.

4. Connect necessary cables to the terminals.

5. Close front cover.

6. Test salinometer function (see instructions for use).

SaliseOO.fm 49

Salinometer

1.3.0 Instructions for use

1. Switch on mains.

2. Switch on sec. alarm.

Green pilot LED should light up. Dot. Bar displays the measured salinity.

1.3.1 Testing the Instrument

& WARNINGThe salinometer must be tested at least once a month. and the electrodeunit must be cleaned.

Push TEST switch on.

The Dot Bar should read 10 ppm.

If the alarm level is less than 10 ppm, the salinometer will give an alarm.

1.3.2 Adjustment of Alarm Level

1. Switch "MAINS" on.

2. Push sec. alarm off.

3. . Adjust Alarm Set to desired alarm level by using the switches .

4. Switch "Sec.Alarm" on.

The salinometer is now ready for use.

If the salinity exceeds the alarm level,

The two red alarm LEDS flash.

Solenoid valve is activated.

Buzzer (if fitted) and external alarm system is activated.

Cancel buzzer and external alarm system by switching "Sec. Alarm" off. Solenoidvalve is not affected.

Switch "Sec. Alarm" on as soon as the salinity is normal again; i.e. when the two red

50 SaliseOO.fm

Salinometer

LEDS are off.

1.3.3 Maintenance

-=:> CAUTIONRemove electrode unit and inspect/clean after every 1000 hours of opera-tion. Use a clean and dry rag. Avoid touching the electrodes with the fin-gers.

SaliseOO.fm 51

Spare Parts

1.0.0 Ordering Spare Parts

When ordering spare parts please always state:

1. Serial number.

2. Capacity..

3. Designation.

4. Spare parts drawing number.

5. Position number.

. 6. Article number.

In order to identify article numbers, please refer to FWG Order Specification and oth-er drawings.

When ordering parts for pumps proceed as follows:

1. Find article number in the list of drawings.

2. Check spare part drawing and item list with corresponding article number toidentify the item to be ordered.

1.1.0 Alfa Laval Service

The Alfa Laval group is represented in all major ports of the world .

DO NOT hesitate to contact your Alfa Laval representative if you have any ques-tions, problems or require spare parts.

Spmare01.fm 53

Index

A

Adjustment of alarm level page 50Adjustment of hot water flow page 20Adjustment of sea cooling water page 21Alfa Laval service " . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 53

C

Chemical dosage page 33Cleaning page 28Clearance page 46Condensation page 20

0

Dismantling pump shaft page 48

E

Ejector PumpEvaporation

page 45page 19

F

Feed water ratio page 33Fitting new gaskets .............. ,............................... page 28Freshwater Pump Types PWF 1525-1532-2040 page 41Freshwater quality page 16

Installation (for OS-20) page 49 Instructions for use page 50

L

Long Term StandstillLong term standstill

page 10page 22

M

Main components page 17Maintenance page 51Maintenance of condenser section . . . . . . . . .. page 26Maintenance of ejector pump page 45Maintenance of evaporator section page 25Maintenance of Freshwater pump page 41Maintenance of freshwater pump types PWF 1525-1532-2040 page 41Maintenance of separator vessel page 24

036WE051X.fm 55

Index

oOperating Hours page 23Ordering spare parts page 53Overhaul intervals page 23Overhaul of the pump page 45

p

Perform regular maintenance duties . . . . . . . . . . . . . . .. page 23Preparation of new gaskets page 28Preservation Procedure for Electric Motors page 11Preservation Procedure for Electric Panel page 12Preservation Procedure for Freshwater Generator. . . . . . . . . . . . . . . . . . . . . .. page 10Preservation Procedure for Pumps . . . . . . . . . . . . . . .. page 11Pressure testing separator page 31Prevention of scaling page 33

RRemoval of old gaskets page 27Renewal of plate heat exchanger gaskets ;.. page 27Restart page 10Restart Freshwater Generator page 10Restarting of Electric Motors ,...... page 12Restarting of Electric Panel ;.... page 13Restarting of Pumps page 11

S

Safety instructions and warnings page 7Safety precautionswith the use of chemicals ".:..... page 35Salinometer type DS-20 page 49Scale inhibitor dosage equipment for feed water page 34Solenoid Valves page 13Spare Parts page 53Standstill page 9 .:Starting page 19Starting and stopping procedure : :..... page 19Stopping Procedure page 19Stopping the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 21Storage page 9System description .............................................. page 15

T

Technical specification page 49Telefax page 7Telephone page 7Test sheet page 37Testing the instrument page 50Trouble shooting table page 37

56 036WE051X.fm

Index

W

Warning page 7Why you need to perform regular maintenance duties page 23Working principle ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. page 15

036WE051X.frn 57

Freshwater generator type: OPU-36-C100

Order Specification1 Set! Ship

Icustomer:

Technical data

HYUNOAI HEAVY INO. CO., LTD.

Freshwater generator size Capac:ily (m3124h]: 40.0 NElNK: 48/48

Jacket water temperature Inlet rC]: 78.0 Outla. rC]: 66.7

Jacket water flow/pressure drop Flow (m3Ih]: 91.5 Pressure drop [bar): 0.3

Heat ccnsurretrcn from jacket water [Mcallh] : - or (kW): 1192Seawater temperature Inlet rei: 32.0 Outlet rC]: 42.4

Seawater fIowfpres5ure drop Flow[m3Ih]: 90 Pressure drop (bar): 0.3

Basic data (Xl (Xl (X) Other (Not standard)Main power 3x380V/SO Hz 3x440/60 Hz X 3x480V/60 Hz Control voltage l00V 110-115 V 22(1.230 V XFlange connection DIN AN$J JIS -xPainting colour Blue C303-B Munsell 7.5 BG 7/2 Munsell2.5 G 7/2

Classification society VVorkshop certificate

Scope of supplyBasic equipment:

. Structure"incl. freshwater pump. standard spares. standard packing and plates: CQAdditional equipment necessary for operation:

Electric motor for freshwater pump: CQFeed water treatment: CQOptional equipment I design:

Salinometer in a box .. CQSpecial painting: RAL6019 CQWater dOck by-pass: CQReturn pipe to brine: CQSteel box for spare part kit: GJOther Not standard:

Item 13 Thermometer 'Nith thermo\WUas loose suppty I CQItem IThe root valves for pressure gauges to be provided I CQItem IThe name plates for all instruments to be fitted I CQItem IFeed water treatment induding FWfilling line with vatve build-on unit. I CQItem IS~linometer mounted on left side as seen from cover side I CQComments:

-, Sea water strainer to be supplied. (Size JIS 10K-125A). Swimming pool connection C37. .. Temperature Transmitter on evaporator body.

Order Specification filled in b

Name: DKS

Date: 2003.12.19

Order Specification review at Oesalt

RevieVll8d by:

Date:

"-".". -- -..... . - .._ . -'--'" ""0"'" ,....._ ....'........~.

I I i i. . ......,Cl"

--~--' ..:~.- - - - - - - - - - - - - - - -- ... ---_..1.

,'... I

ICl"

I IJ .-

The capacities shown in FIQ. 1 are IS

capacities at a cooling Water tempera-ture of 32C. to

IS

Capacity range

The DPU-36-C series covers a capacityiange from-10 to-55--m:1124h,de'pencfll19-on the healing medium and cooling

water temperatures.

The freshwater generator can bedimensioned to suit any jacket water

temperature from 55-90C at anycooling water temperature required.

.......-"toIS

'"

'"IS

ID .. '" . .. " .. .. . .. toThe quantity of fresh water produced

can be altered simply by varying the :', Fig,.l Gapacity range for DPU-36-e generators size 100 and 125.number of plates in the internal plateheat exchanger.

Working principle

See Fig. 2

The feed water to be distilled is takenfrom the sea cooling water outlet of thecondenser (1). tt enters the evaporator(101 where it evaporates at about40-60C as it passes between theplates heated by the heating medium.

The evaporating temperature corre-sooncs to a vacwm at 85-95 %.maintained by the brine/air ejector (not

shown on fig. 2). The vapours gener-

ated pass through a demister whereany drops of seawater entrained areremoved and tall due to gravity to thebrine sump at the bottom of the gener-ator chamber. The clean freshwatervapours continue to the condenser (9)..where they condense into fresh wateras they pass between the cold platescooled by the sea cooling water.

Installation.The DPU-36-C freshwater generator isdesigned ter automatic operation inperiodiCally unmanned engine roomsand other automated operations.

The heating medium iseither engine jacket cooling water or adosed circuit heated by steam.

. The.ejeCtor pump is separately installed.and has separate suction from tne sea.This pump supplies coolant in the:form .of seawater to the condenser, feed-water for evaporation and jet -warer forthe combined brine/air ejector.

The fresh water produced is pumped tothe tank by the built -oo freshwaterpump.

'i

~1

, ~~~'=or.~

11

The separately installed control caner,with motor starters and salinometer.supplies stectrical power to the ejectorand freshwater pumps as'well ascontrol voltage to the salinometerand dump valve.

1. Seawater feed2. Heating medium in3. Heatir.g medium cot4. Seawater COOling in5. Seawatercoolingout

6. Fresh water out7. Evaporated steam8. Demister9. Condenser

10. Evacorator11. Brine CUi

Fig. 2. Crcss-secuon through Atta Lava!

Desalt freshwater generator cnarncer.

Alfa Laval Marine & Power9.2 Product informationEdition: 98-019.2.3.2-1 Technical data. D-PU-36-C100

Power consumptionFreshwater pump:

60 Hz0.75 kW

Pressure

9.2.3 Freshwater generatorDPU-36-ClOO

.... Jacket Watertemperature: 55-95C

Max. jacket water pressure:Max. back pressure to freshwater tank:Max. seawater pressure to inlet condenser:Min. seawater pressure to ejector:Max. back pressure at ejector outlet:

TemperatureSeawater temperature: 0-32 C

Flow

bar(g)4.01.64.03.00.6

Ibslin'582358438.7

Seawaterflow: 90 m3/h

MaterialsSeparator:Front cover:Bed frame:Pipe for brine discharge:Evaporator/condenser plates:Demister:Pipe for seawater:Pipe for fresh water:Combined brine/air ejector housing:Combined brine/air ejector nozzle:

..Flange for evaporator/condenser:

Shipping data

Jacket water flow: 40-110 m3/h

Stainless steelStainless steelSteel (hot dip galvanized)SG-iron (hot dip galvanized)TitaniumStainless steelCuNi 90/10CuNi 90/10Red brassStainless steelSG-iron (hot dip galvanized)

Freshwater generator, complete with ejector pump, electrical panel, dosing unit and standard spares.Weight: net: 1480 kg, gross: 1950 kgDimensions: (I x w x h) 1900 x 2400 x 2090 mmVolume: 9.5 m'

Illustrations, indications of material, dimensions andweights etc. herein, do not constitute any commitment on ourpart.Wereserve the right to change such specifications when necessary.

Alfa Laval Marine & Power9,2 Production Information

Edition 99-01

9.2.3 Freshwater GeneratorO-PU-36-C100

".' ,)_.'

9.2.3.2-2 Technical data, Pump and Motor for D-PU-36-C100

No. of elates NElNK: . 3413448J48Pumn function Freshwater -.Pump Type PVVF-2040Motor type 71 BNom. flow x pressure m'Jh xmwc 2.1 x26

.-~. '"

lmpeller size 60Hz: mm" 0128

Rotatinn speed 60Hz: RPM 3360

'.

3 y 440 \, fjO Hz;:::

, 510

Owg.na. 985 17586 R:OO

Tank for sdulion ofscale inhibitNot to be placed lowerthan d'lStBler foundation.

11

5

Recommendation

Use fully soluble scale inhibitor for instance on poljrnere basis.Mix quantity required for 24 hours operation in tank according tomaker's instruction and adjust dosage to cover max. freshwateroutput from distiller.Flush regularly.

1 Flowmeter inc!. reg. valve2 Nipple 3/8" x 1/8"3 Non return valve 3/8"4 Hose connection 3/8" x 105 Hose clip6 Hose 3/8" (4000 mm)

7 Connection 3/8" x 1/4"8 Connection 1/8" x 109 Connection 1/2" x 10

10 Ball Valve 1/2"11 PE tonk (130 I)

"'011w ~

."' JIU ...........~ ....-.~

........................ 4..a.l.........~ ....~'K

u........~.....-.......... 1(,....,... ...... ~.IfQ

m

1llIe

Feed water treotment & ~~~g - 130 liter:ll llate a.... ....... ~ """ ..:l! 01.04.97 SSK JSC YHM

'=no

150

..

o

6 7

/,

..

1 IlmIntad~ ,.....1+1 _ Jl102 IlQJ IIF !IFN

SAUNOMmR ON:5 lIFT SIDE or FRAMEJ,. D-PU-J6-C~ I V.1ll1l:3 ..r:..rv'" CAD ..

I

Bill Of Material

Parent item no.: Description: Date:

98519816-80 R: 00 SALINOMETER MOUNTED 20031111 Page 1 of 1

Drawing no.: ON RIGHT SIDE OF FRAME Ini

98519816D-PU-36-C

BBU-

BUBL QTY U/M DESCRIPTION DRAWING NO. ARTICLE NO. MATERIAL REMARKS

1 1.000000 EA SALINOMETER0520 IN BOX 985 17B94ROQ 9B4 22520-00

2 2000.000000 MM CABLE 2X " 5MM LSM-HF 98561350-40

3 3.000000 EA SCREW M6 X 16 DIN 912 HFC 1790 984 40906-19 ISO 683/13/86 : TYPE 20A

4 300.000000 MM CABLE TRAY 20-70 MM 9856"32002

5 2.000000 EA SCREW M6 X 50 DIN 84 985 30470-50 . 150 6B3/13/86 : TYPE 20A

6 800.000000 MM CABLE TRAY 20-70 MM 985 61320-02

7 4.000000 EA SCREW M6 X 50 DIN 84 985 30470-50 ISO 683/13/86 : TYPE 20A

Alfa laval Copenhagen A/S

Maskinvej 5OK2860 Soborg. DenmarkCVR No. 10134285VAT. No. 14646647

TelephoneTelefaxBank

+ 45 39 53 60 00+ 45 39 53 65 68DANSKE BANK Holmens Knnal BranchAce. No. DKK 31003117108007Ace. No, EUR 3100-3'40-854301Ace. No. USD 3100-3016-576794

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~ain supply (220V ,60 HZC============~ ~ -- --- --- --- - ~ ~-l2- '"' 0

Alarm hol ( 220V C:::::===========f ';:. i N ~ INormolly closed Solenoid Valve------------,- '" '" I

Normollyopen Solenoid vo'~e~===========I : IExternal Alarm NC Contoct '-- = SALINOMETER OS20 IExternol A10rm NO Contoct t i5 I" '00 "' ~~f:Jl::~ ~ ,

ec rem ~: ===t==1 ~ I_______ ~~JJJ[ .....

Salinometer signal 4-20 mA. I I I I I '" I-------''Ti-'-r m I~-t ::::ill

The shild must be connected 10 the: i~ -...J - es ~I I..... "0 I

computer shild. ~~ : JOrw.no. 985 17551 R:01

,

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AIr,l'wit!I'''9 "985 17551 fPage 2 01 2.....

RtlIision

6

Salinometer in 0 boxtwe DS20-M2

ISO S

Equipment specificationFreshwater generator DPU-36-C100

List of loose supply items

No. Description Drawing No. Article No. Setlsl/Unlt Remark

1

2

Thermometer W/pocket L=l OOmm

Thermometer W/pocket L=160mm

Y type, Strainer

98430365-01

BYS-1o-1QO.OOO

98500037-24

985 00053-69

2

1

J.W Inlet/Outlet

SW Inlet

10K-125A

.. ~ " ~' _ _ 0 _ .. " _ ..

...............................................................................-............................ .. .. ..

DEPT

Marine & Diesel

DATE

030609

DRAWN

DKS

CHECKED

DKS

APPROVED

YHM

DOCUMENT NO.

LOOSEXLS

I I J I 4 I I I 5 I I I 7 I I1 2.liS

35F- 35

"" I I I I A...,! I-e-CO

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t i o- lOO' C32 - 212' F f-- ~ItI

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sw 27 r 1 1

11 I 11 GIlt I 11 GIltDD

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iI J ~I - . Datt I- I-I"",,,'''~ J ~ Er I Wilt Thermometer, Straight &bWID~~II Pocket, Brass Nfo LoYal KenoJ ~ g Dimensional Drawing - -.1 Loose Supply for J.WIn i jDoll 981207 I"SsK I., J"'1il I....'rLoose Supply for S.W In lOut ~-

"'lIt ~ 984 30365-01 F r E rv1 ....., CAD~1184"1tL ,...1 I.... " ...

I I J I4 I I I 5 I I I 7 I I1 2

NO.

REVISIONa

_0______________________L _

.Jt:.t'h _ 1. __

-_._----------_.__ ._-._--------_.- _._--- -,,- '-_._-_.-- -"._--------------

91 09 o~

d H S

,IIIYS-10-IOO-O,

Young Valve

Y-'IYI'E STRAINER--'-' M,s'y----

, 00" DC ISEI--- - COl.'! lOt A$1ll:$lm IJ Se..." (l.Iulo) StlSJ04-----2 CO.... 8C

Oody BCNO. DSUW'ilOtf lOAn Q'rr

Genoral !}?eclflcollonlll1. ApplJcolJle lIuid :

S,W2. Mall. Working Temp.

According 10 "JIS 0 2201-B04J .. ltAox. Wo,ldng Press. :

According 10 JIS 0 2101-84

A 1> 12~ I' 4-19 1>. 8J ., 8.'-- -"------ --- -- ---- -- --J1A J2 .0 'I> "- "-IS 1>' " ,. '.8 J1A J' .00 m " 4-19 l";~ " 5' 8.'---- -- -- -------- -- --,,- --- --- -- -- .- -----'0' 95 110 11 ",: 15 t72 IUJ 54 '-' 'UA '0 IU, 140 16 4-19 '80 'DJ ,. 9.0---- _._- -- ----- --- ~._..- --- -- ---- --- ---- ---- ---- ----50A 50 '05 tJo 14 .. -I!) '" 115 '8 11.9 SOA SO 1'20 I5S " .. -19 2DO 115 ve 14.7--- ----------- - --.'" 65 'JO I ~J5 14 4~15 252 .6/ 1.10 '. 'SA .5 140 .115 '8 4-19 160 '61 1.10 20.9--- --- --- --- -- ..- ---- --- --- -- -- ----- -- "--- -- ----.OA 8tt ,,5 '80 " 4-19 2.' '.. 'So 17 80" 80 'SO '85 '8 8-19 1.0 198 'SO 18--- ----- -- -- -- -~.- -- -- --- - --l00fl~ '00 165 100 '8 0-19 J16 lJO '80 J' 100" 'DO ,IS 110 '8 8-19 J80 2JO '8D J2.5--- --- ---- --- --- --12~ 11:;' '00 'J> " 8-19 1:11 .\07 220 .. i-~I~:~ '1> 110 1>0 20 8-2J 4>0 JO' 220 .,--- ._- -- -,-- ----- ---.- --- -_ .. ---- -- -_. -- -- ---- -- --- ---l~O'" 1~1) 7JU '}r.~ I. n.. \9 4~1 .,~n 7~O 51.5 .I~tl" , ~IO 1 40 1nn ]I n7J Hi5 .150 ,,. ..

Alfa Laval Marine & Power9.2 Production Infonnation

Edition 99-01

9.2.9.2-3 Steel box for spare part kits

General

9.2.9 Design/Optional/Ancillary equipment

Spare part box storing spare parts and tools of machinery on ships. Made of steel and hinged jn one side. Providedwith a chain with hook and a lock with two keys. Made in accordance with Japanese standard JIS F 0902-1978.

Dimensions

T400

Dwg.no. 985 17526 R:OO

Materials

Box: Steel (painted).

Painting:Munsell 7.5 BG 7/2

9,2.9.2-3 Steel box for spare part kitsIllustrations, indications of material, dimensions and weights etc. herein, do not constitute any commitment on our part.We reserve the right to change such specifications when necessary.

Page 1

Mar ine &Diesel Product Catalogue - Copyright 2003 Alfa LavaI

Edition: 01-01

9.3.1.1 Included in delivery

DescriptionContent:

a) 1 Rubber joint for front cover

b) For each of the pumps:

1 Mechanical seal

c) For each electric motor:

1 Ball bearing (D-end)

Document published on Extranet

Created by PavelM Minarik on 2001-02-01

9. Fresh water generators (Desaltl - 3 Standard spare parts - 1 Freshwater Generator

Mope

Modified by PavelM Minarikon 2001-02-01

Marine & Diesel Producl CatalogueIllustrations, indications ofmaterial, dimensions and weights etc. herein, do notconstitute anycommitment onour part.Wereserve therightto change such specifICations when necessary.

Page: 1

o

B

,

c

QCEnsure correctto\ol gluing

B

ToIeronces: ISO 3302 end DIN 7715 Port 3

Ci\ I

"-v II

II

BE 1"\ I1...-/ I

I

I AII

I1

I1284

Moteriol: Gosket material '17 AL 113 3034-71

A-AJ 'n.- M. ,""..

GASKET FOR~1JJmwlmIlCS SEPARATORI .NI. lavlII Curlenhagen AJSr-

~ D-PU-36-C ....- - ...:+; 10.... mj Dot. Rep!. r1I 'n. - ~"""'g851~5J12en ll3ic 0"~in9 R~. byno. t...

5

r' I , I I I 5 I 6 I 7 I 81 I 2 J~8~

fresh water generator

Documents

restarting of pumps

freshwater type

motor6 dimension drawing

scale drawing

outline drawing

alfa laval ref

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preservation procedure