Cargo & Crew Safety

DUI 208E
Tanker Familarization
Pipe and pump systems of tankers
Enclosed spaces
 CRUDE OIL (Petroleum)

 Petroleum is a naturally occurring, smelly, yellow-to-black liquid

consisting of a complex mixture of hydrocarbons of various molecular
weights and other liquid organic compounds, that are found in geologic
formations beneath the Earth's surface which is commonly refined into
various types of fuels (Wikipedia, 2017).
 The name Petroleum covers both naturally occurring
unprocessed crude oils and petroleum products that are
made up of refined crude oil. A fossil fuel, it is formed
when large quantities of dead organisms, usually
zooplankton and algae, are buried underneath
sedimentary rock and undergo intense heat and
pressure.
 Petroleum has mostly been recovered by oil drilling (natural petroleum
springs are rare). Drilling is carried out after studies of structural geology
(at the reservoir scale), sedimentary basin analysis, and reservoir
characterization (mainly in terms of the porosity and permeability of
geologic reservoir structures) have been completed.
 It is refined and separated, most easily by distillation,
into a large number of consumer products,
from gasoline (petrol) and kerosene to asphalt and
chemical reagents used to
make plastics and pharmaceuticals. Petroleum is used in
manufacturing a wide variety of materials, and it is
estimated that the world consumes about 95
million barrels each day (Wikipedia, 2017).
 Petroleum includes only crude oil, but in common usage
it includes all liquid, gaseous and solid hydrocarbons.
Under surface pressure and temperature conditions,
lighter hydrocarbons methane, ethane,
 propane and butane occur as gases, while pentane and
heavier hydrocarbons are in the form of liquids or
solids.
 Composition by weight

Element Percent range

Carbon 83 to 85%
Hydrogen 10 to 14%
Nitrogen 0.1 to 2%
Oxygen 0.05 to 1.5%
Sulfur 0.05 to 6.0%
Metals < 0.1%
 Fraction Boiling range oC
Liquefied petroleum
−40
gas (LPG)
Butane −12 to −1
Gasoline −1 to 110
Jet fuel 150 to 205
Kerosene 205 to 260
Fuel oil 205 to 290
Diesel fuel 260 to 315
 OIL TANKER
 An oil tanker, also known as a petroleum tanker, is a
merchant ship designed for the bulk transport of oil.
There are two basic types of oil tankers: the crude
tanker and the product tanker. Crude tankers move
large quantities of unrefined crude oil from its point of
extraction to refineries. Product tankers, generally
much smaller, are designed to move petrochemicals
from refineries to points near consuming markets.
 Oil tankers are often classified by their size as well as
their occupation. The size classes range from inland or
coastal tankers of a few thousand metric tons
of deadweight (DWT) to the mammoth ultra large crude
carriers (ULCCs) of 550,000 DWT. Tankers move
approximately 2,000,000,000 metric tons (2.2×109 short
tons) of oil every year (Wikipedia, 2017).
 HISTORY
 The world's first successful oil tanker was Nobel's
Zoroaster. He designed this ship in Gothenburg, Sweden,
with Sven Almqvist. The contract to build it was signed
in January 1878, and it made its first run later that year
from Baku to Astrakhan.
 The Zoroaster, which carried its 242 long tons of
kerosene cargo in two iron tanks joined by pipes. One
tank was forward of the midships engine room and the
other was aft.
 Others point to the Glückauf, another design of Colonel
Swan, as being the first modern oil tanker. It adopted
the best practices from previous oil tanker designs to
create the prototype for all subsequent vessels of the
type. It was the first dedicated steam-driven ocean-
going tanker in the world and was the first ship in which
oil could be pumped directly into the vessel hull instead
of being loaded in barrels or drums.
The Falls of Clyde is the oldest surviving American tanker
and the world's only surviving sail-driven oil tanker
M/T SEAWISE GIANT-564.763 DWT
JAHRE VIKING-EX. HAPPY GIANT91-
EX.SEAWISE GIANT 89 1975/564.763
DWT/260.851 GRT/214.793 NRT.
 Smaller tankers, ranging from well under 10,000 DWT to
80,000 DWT Panamax vessels, generally carry refined
petroleum products, and are known as product
tankers. The smallest tankers, with capacities under
10,000 DWT generally work near-coastal and inland
waterways.
 "Supertankers" are the largest tankers, including very large
crude carriers (VLCC) and ULCCs with capacities over
250,000 DWT. These ships can transport 2,000,000 barrels
(320,000 m3) of oil/318,000 metric tons. By way of
comparison, the United Kingdom consumed about 1.6
million barrels (250,000 m3) of oil per day in 2009. ULCCs,
commissioned in the 1970s, were the largest vessels ever
built, but the longest ones have already been scrapped. By
2013 only a few ULCCs remain in service, none of which are
more than 400 meters long(Wikipedia, 2017).
 Stainless steel chemical
tankers
 Stainless steel chemical tankers represent the most
sophisticated tankers sailing on the high seas. These
ships are constructed with stainless steel cargo tanks,
feature a fully segregated cargo pumping arrangement
and are designed to carry the most aggressive, corrosive
or volatile liquids.
 Chemical and product oil
tankers
 Most of the world’s production of vegetable oils,
commodity chemicals and refined petroleum products
are transported on a large fleet of modern chemical and
product tankers. These vessels are typically designed
without a pump room and feature coated cargo tanks,
six to eight cargo segregations, submerged ballast
pumps, in-tank cargo pumps and deck mounted cargo
heaters.
Long-range tankers
 On long-range tankers, the use of one submerged
hydraulically driven cargo pump per tank or each Cargo
section (typically 3 or 4) Centrifugal pumps of large
capacity provides safe segregation between cargoes.
Stripping and tank cleaning is quicker for an efficient
switch between cargoes that substantially increases the
number of ton-miles.
OBO carriers
 Combination carriers alternating between wet and dry
cargoes have a specially designed one-pump-per-hold
system that is easy to clean and operate. The cargo
pumps are installed in protective enclosed corrugations
between the holds, with cargo piping and cargo heaters
located on deck.
 Ullage and Sounding

 Sounding is the measured height of the fluid from the

surface of the fluid to the bottom of the tank. Ullage is
the void space in the tank measured from the top of the
tank to the upper surface of the fluid. Ullage is
measured when the content of a tank is highly viscous
and if the tank is filled to the maximum.
 Sounding pipe is constructed in the tank. These pipes
protrude slightly above from the top of the tank so that
sounding can be taken safely and easily without opening
any manhole door. They even have protecting caps at
the top which can be opened at the time of sounding.
The sounding pipe is open from the bottom which allows
the liquid filling up the pipe and facilitating it to have
the same level as of the tank (Marineinsight, 2018).
 After measuring sounding or ullage, it is compared in
the sounding book to know the volumetric quantity of
the tank. Sounding frequency on a ship differs from
company to company and according to the working
policy and the nature of operations going on board. A
brief note as per the general procedure followed on ship
is given below:
 1) All Fuel oil tanks lube oil tanks and diesel oil tanks
must be sounded twice a day, once in morning and once
in evening, and recorded in the event of leak or any
other emergency related to oil content of tanks.
 2) All waste water tanks including bilge and sludge tank
must be sounded twice a day.
 3) Ballast water tank and fresh water tanks should be
sounded once a day.
 4) As bunkering operation is one of the most critical
operations, the frequency of operation drastically
increases at the initial and final stages of the operation
(every 15 minutes) to check the inflow of oil in correct
tank at initial stage and to avoid overflow of oil during
final stage of operation.
 5) When waste water of ship is internally transferred,
discharged overboard through 15 ppm equipment or
given to the shore facility, sounding is to be taken twice
or thrice every hour.
 6) When ballasting or de-ballasting of the tank is going
on, hourly sounding is to be taken or as decided by the
chief officer.
 7) Fresh water tank sounding to be taken daily. Feed
water tanks in the engine room are to be sounded at
every watch to keep a track of leakages (Marineinsight,
2018).
UTI (ULLAGE TEMPERATURE
INTERFACE DETECTOR)
 UTI detector is being used in measuring the ullage, the
oil-water interface and temperature of cargo in tanks.
It is consisted of a barrel which connects to the deck's
valve and the body which includes the mechanical
housing and the display unit. Inside the mechanical
housing is located the measuring tape, which length's
varies from 15m to 40m depending on the tank's depth.
The thermometer sensor, which is assembled to the
tape, measures temperatures with range from 10°C to
90°C.
 UTI
 ISGOTT
 UTI model: D-2401-2, Gas Tight

UTI model: D-2401-2

UTI model: HERMETIC UTIMETER MK3- UTI model: T2000-TFC-02
LBI-UNI GT
Pipe and pump systems of
tankers
 Pipes are silent ‘workers’, conveying fluids or allowing
air to enter or to leave a space and are the means
through which many control systems operate.
 Pipes penetrate almost every enclosed space, as well as
the shell above and below the waterline, and the
weather deck.
 Cargo piping
 The arrangement of loading and discharge lines is
collectively known as the Ship’s Cargo System.
 Cargo piping in oil tankers may be of stainless steel, but
is commonly of mild steel. The piping is protected from
rusting by external painting. Most large oil tankers have
a ring main system that allows increased operational
flexibility but with the penalty of reduced segregation.
Tankers fitted with deep-well pumps in cargo tanks have
dedicated piping. Each tank will have its own pump,
pipe and cargo manifold. Stainless steel piping is largely
used on chemical tankers, invariably on those with
stainless steel tanks for carrying corrosive chemicals.
 Cargo piping in LNG and LPG carriers conveys liquefied
gas at very low temperatures. These pipes are
constructed from special austenitic stainless steel able
to withstand very low temperatures (The Standart,
2012).
Piping Arrangement – Conventional Oil Tanker Basics
The pipes leading from the cargo tanks to the pumps are
termed as bottom lines, from the pump-room up to deck
are called risers. The lines on deck are termed as deck
lines. The lines which lead from the deck to the tanks are
called drop lines. Besides these, there are Crude Oil
washing lines on deck (COW lines).
The piping system has evolved over the years to cater to
varying cargo requirements. In a product tanker which is
designed to carry many grades
There are three basic types of pipeline systems:
 Direct Line system
 Ring main system
 Free flow system
Direct Line system
It consists of lines running longitudinally in the center tanks
and branching out to bellmouths in the center and wing
tanks. The system is uncomplicated and found on some
crude carriers.
The advantages are that:
 It is easy to operate and
less training of
personnel is required
 As there are fewer
valves, it takes less
time to set up the valve
system before
commencing a cargo
operation
 Contamination is
unlikely, as it is easy to
isolate each section.
The disadvantages are that:
 The layout is not as versatile
 A very rigid system which makes it difficult to plan.
Ring-main systems
 It is also called the circular system. This type of piping
system provides for the handling of several different
types of oil. A particular tank can be pumped out either
by a direct suction line or through another line by use of
a cross-over. The system is very versatile.
Free-flow system
In this system, the oil flows freely into the aft most tanks
when the interconnecting gate valves are opened. Main
suction bellmouths in a full free flow tanker will only be
provided in the aft tanks. This system has the distinct
advantage of having lesser and less complicated piping
system in the tanks and is suitable for large tankers which
usually do not carry many grades of oil.
Some ships are also designed as part free flow i.e. free
flow system only between certain tanks, which is a hybrid
or cross between a full free flow system and a ring main
system (Cultofsea).
Classification society rules require ships’ pipes to be inspected
during annual, intermediate and renewal surveys.
Annual surveys
Pipes are checked visually. A pressure test is done if there is
any doubt as to their integrity, and annually on a tanker’s
cargo system. Pipes passing through or connecting to the Shell
plating are subject to particular attention.
Intermediate surveys
The requirements are similar to those applying to annual
surveys.
Renewal surveys
Pipes are checked visually and hammer-tested, with some also
being pressure-tested (The Standart, 2012).
The Standart
Pump

In the simplest term, pump, used

for transferring the liquid from one
point to another. But pumps not
enough to carry liquid alone. By lines
we can transfer liquids from a tank to
another tank. We use different types
of pumps according to type of liquid.
 Pressu
Pump Electric
Motor and
re Side
Shaft

Pumps are generally driven by

electric. Usually depends on type
of liquid so different driven pumps
are on the market such as
hydraulics.
On the left, you can see
section of a basic type of pump
called centrifugal pump.

Impell Suction
er Side
Volute
Casing
(Body)
 Pump
PUMPS

Mainly divided in two, but POSITIVE

DYNAMIC
subsections also have different types. DEPLACEMENT

We usually use submersible pumps CENTRIFUGAL ROTARY RECIPROCATING

onboard chemical and oil tanker. By

now we will be treat both tanker types
AXIAL SINGLE MOTOR DIAPHRAM
separately.
MULTIPLE
PISTON
ROTOR
Chemical Tankers

Chemical tankers have a wide diversity as carried

cargo in the market. Very different types of liquids can be
carried onboard and they are listed in vessel’s P&A manual
or CoF. This liquids can be stored in same vessel but in
different segregated tanks. As we said in previously slide,
we will treat vessels separately, chemicals have a huge
benefit according to oil tankers as carrying parcel cargoes.
Cargoes up to 40-50 parcels can be carried onboard with
adequate segregation but also depends on the tank
amount.
 Chemical Tankers

The company called

Framo have a huge
market share in tanker
industry. Framo pumps
are commonly used in
chemical tankers and
have all essential
functions for sufficient
operation.
Framo

Framo is a submersible,
centrifugal pump. Hydraulic used as
prime mover. An Impeller in volute
casing sucks the liquid in the well
by turning. Turning creates a
centrifugal force, by this principle,
sucked liquid splashes in the walls
of volute casing. The created
suction force starts to transfer
liquid via lines to the manifold.
Framo

Hydraulic oil is essential for the

system. We will discuss importance of
oil later. Oil in the hydraulic tank
pressurized in Power Pack Units and sent
to the hydraulic motor inside the tank.
Framo

 As we mentioned before, this is a submersible pump and we need to

prevent contamination between cargo and system hydraulic.

 We have two main seals to prevent this.

Hydraulic Seal: Prevents leekage from Hyd to cargo.
Cargo Seal: Prevents leekage from cargo to hydraulic.

Both seals have a huge importance but especially cargo

seal’s leekage may have serious results for system.
Framo
Framo

Seals wear off by time until their next maintenance

schedule and starts to leak cargo or hydraulic.
Liquid passed through seals, get into the
cofferdam. Without purging we can’t be sure about
this.
Framo

Compressed air flown through the purging connection,

sweeps the all residue inside the cofferdam. This job looks
similar to cargo stripping but pin point in purging is
sweeping the cargo that shouldn’t be exist in void space of
submersible pump.

According the type of carried cargo, there are some

precautiouns should be taken into consideration foreseen
by framo.
Framo

Acid and Basic Cargoes: After discharge and purging finished, a flush of
fresh water will remove all residues.

Solidifying Cargoes: Fill cofferdam with fresh water.

Heated Cargoes: Fill cofferdam with Diesel oil or Light lubricant to keep
away any leekage into cofferdam.

Polymerising Cargoes: Fill cofferdam with Dioctyl Pthalate to prevent

leaking and blocking of cofferdam.
Framo
Framo

STC – Speed Torque Controller Valve is another main part of

the pump. This unit makes the pump turning at different
Rpm. Regulates the hydraulic oil flow to the pump. By this
unit we can run the pump at required speed.
Also STC is a protective feature to prevent pump from
overheating and overspeed. Mainly STC controlled by levers
in CCR. In other way can be controlled over the pump
locally.
Framo

Remote Control from CCR

Framo

Local control generally used

for stripping and cleaning
operations.
Framo

As we said, Hydraulic is essential for system and shouldn’t

be degraded due to environmental reasons.
1) Due to temperature differences, suction in the lines
makes oil moist.
2) Air in the system may cause vibration.
3) During repair or maintenance, particles may be
involved in system.
Framo

Feed pump protect the main pump from all this

considerations by working non stop. Positive pressure in the
system, prevents air, removes different temperatures.
Filters of feed pumps protects main pump from clogging.
Oil lines circulated at least 5 bar without stopping.
Oil Tankers

Oil tankers are not designed to carry

different types of cargoes. They carry
single type of cargo, crude oil.
Because of that, they don’t need a
separate line and pumping system for
each tank. 3 cargo pump can be
enough to operate a suezmax during
discharge. Pumps are not submersible
as in chemicals, so we can see the
casing in the right side.
Oil Tankers

A centrifugal pump turbine or C.O.P.T in short when used as

main cargo oil pump have two main parts; a turbine and a
centrifugal pump. The steam turbine consists of parts such
as boiler, feed pump, condenser and turbine working
together in a closed loop system. The high pressure steam
inters the turbine casing through a series of inlet nozzle.
Oil Tankers

These nozzles convert the high pressure steam into high

velocity jet directing them on turbine blades; to rotate
along with the shaft to generate rotational power. The
generated power is then transmitted to the centrifugal
pump through a connecting shaft; while exhaust steam goes
back to the boiler via condenser and feed pump.
Oil Tankers

On another hand a centrifugal pump works on the simple

law of centrifugal forces. The pump impeller throws the
fluid outwards away from the central axis. The process
transfers part of the kinetic energy of the impeller to the
fluid; which then pass through the volute casing to leave
under pressure.
The pressure difference created due to sudden change in
fluid volume creates a partial vacuum behind the impeller
eye; this creates the much needed suction pressure to
continue the process.
Oil Tankers

 Discharge of the cargo tanks is via three steam turbine driven centrifugal
cargo oil pumps, each of 2,800m3/h capacity situated in the cargo pump
room, discharging to the respective manifolds on deck. The cargo
stripping is performed by the cargo pumps with an automatic stripping
system, cargo stripping eductor and cargo stripping pump. Three cargo
oil pumps are fitted with an automatic stripping system consisting of two
vacuum pumps, one sealing water tank and three gas separators. Gas
and condensate from the automatic cargo stripping system are extracted
to the another slop tank by means of vacuum pumps.
Oil Tankers

Overview of a oil cargo pump can be

seen in the left side. Main driver in the
system is steam turbine. Turbines can
be controlled by cargo or engine room
to control speed. It is possible to
control locally and remotely. As
different than chemicals, engine
department have a huge role in the
discharge operations.
General overview of cargo piping of oil tanker
Oil Tanker

Capacities of the pumps reach up

to 2800m3/h.3 sets of pump can
handle 8400m3 of cargo hourly but
these are the maximum values.
Stripping pumps are automated by
cargo pumps and can reach to
240m3/h, with eductors 500m3 of
cargo can be pumped to the shore.
Enclosed Space for Tanker
An Enclosed Space is defined as a space that has the
following characteristics, where is an unsafe oxygen level
and/or toxic gas or other vapor, Limited openings for entry
and exit, Unfavorable natural ventilation. Not designated
for continuous worker occupancy.
 Enclosed space_The Standart
 Video 1
 Video 2