CLEAN FORCE
Symbols and Colour Scheme ............................................................................. 3
Electrical Symbol List ........................................................................................ 4
Abbreviation ....................................................................................................... 5
Part 1 : Engineering Data for Main Equipment
1.1 Main Turbine ..................................................................................... 1 - 1
1.1.1 Manufacturing Specification.................................................. 1 - 4
1.1.2 Main Turbine Operation Instructions..................................... 1 - 6
1.2 Main Boiler ........................................................................................ 1 - 9
1.2.1 Main Boilers Planning Data .................................................... 1 - 9
1.2.2 Instructions for Main Boiler Operation................................. 1 - 13
1.3 Generator Turbine ............................................................................ 1 - 17
1.4 Main Feed Water Pump Turbine ...................................................... 1 - 22
1.4.1 Operating Procedure ............................................................. 1 - 23
1.5 Diesel Generator Engine .................................................................. 1 - 24
1.6 Fresh Water Generator ..................................................................... 1 - 26
1.7 Bow Thruster ................................................................................... 1 - 28
1.7.1 Technical Specification ......................................................... 1 - 28
1.7.2 Remote Control System ........................................................ 1 - 28
Illustrations
1.1a Main Turbine General Arrangement ................................................ 1 - 3
1.2.1a Starting Up Curve (with Continuous Fire) .................................. 1 - 14
1.2.1b Characteristic Curves of Y-jet Type Steam Atomiser .................. 1 - 15
1.3.1a Governing System ..................................................................... 1 - 18
1.3.1b Control Oil Press. Adjusting Valve ........................................... 1 - 20
1.3.1c Time Schedule for Starting of Turbine Generator ..................... 1 - 21
1.6.1a Fresh Water Generator ................................................................ 1 - 25
1.7.1a Bow Thruster .............................................................................. 1 - 27
1.7.1b Bow Thruster .............................................................................. 1 - 27
Part 2 : Machinery System
Illustrations
2.1 Steam Systems ................................................................................... 2 - 2
2.1.1 Superheated Steam System ..................................................... 2 - 2
2.1.2 Desuperheated Steam & Steam Dump Systems ...................... 2 - 4
2.1.3 Bleeed System ........................................................................ 2 - 6
2.1.4 6 bar Steam System................................................................. 2 - 8
2.2 Condensate and Feed Water Systems............................................... 2 - 10
2.2.1 Main Condensate System...................................................... 2 - 10
2.2.2 Aux. Condensate Water System ............................................ 2 - 14
2.2.3 Boiler Feed Water System..................................................... 2 - 18
2.3 Sea Water Systems ........................................................................... 2 - 22
2.3.1 Main Sea Water Circulating Systems .................................... 2 - 22
2.3.2 Cooling Sea Water Service System ....................................... 2 - 24
2.3.3 Marine Growth Preventing System ...................................... 2 - 24
2.4 Centralised Fresh Water Cooling System ........................................ 2 - 26
Final Draft / 2007.12.28
Machinery Operating Manual
2.5 Boiler Water Sampling and Treatment Systems ............................... 2 - 28
2.6 Fuel Oil and Fuel Gas Service Systems ........................................... 2 - 32
2.6.1 Fuel Oil Bunkering and Transfer Systems ............................ 2 - 32
2.6.2 DO Purifying and G/E Fuel Oil System ................................ 2 - 36
2.6.3 Boiler Fuel Oil Service Systems ........................................... 2 - 38
2.6.4 Boiler Fuel Gas Service System............................................ 2 - 42
2.6.5 I.G.G and Incinerator Fuel Oil System .................................. 2 - 44
2.7 Lubricating Oil Systems .................................................................. 2 - 46
2.7.1 Main Turbine Lubricating Oil System .................................. 2 - 46
2.7.2 Stern Tube Lubricating Oil System ....................................... 2 - 50
2.7.3 Lubricating Oil Transfer & Purifying System ....................... 2 - 52
2.8 Engine Room Bilge System ............................................................. 2 - 56
2.9 Compressed Air Systems ................................................................. 2 - 60
2.9.1 Control Air System ............................................................... 2 - 60
2.9.2 Starting Air System ............................................................... 2 - 62
2.9.3 Working Air System .............................................................. 2 - 64
2.9.4 Emergecy Shut-off Air System ............................................. 2 - 66
2.10 Steering Gear ................................................................................. 2 - 68
2.11 Electrical Power Generators ........................................................... 2 - 70
2.11.1 Turbine Generator ............................................................... 2 - 70
2.11.2 Diesel Generator Engine ..................................................... 2 - 74
2.11.3 Emergency Diesel Generator............................................... 2 - 76
2.12 Electrical Power Distribution ......................................................... 2 - 78
2.12.1 Distribution and Loading .................................................... 2 - 78
2.12.2 Turbine Generators.............................................................. 2 - 83
2.12.3 Diesel Generator ................................................................. 2 - 84
2.12.4 Batteries & Battery Charger ................................................ 2 - 86
2.13 Accommodation Services............................................................... 2 - 88
2.13.1 Provision Refrigeration System .......................................... 2 - 88
2.13.2 Accommodation and Air Conditioning Plant ...................... 2 - 92
2.13.3 Package Air Conditioner ..................................................... 2 - 96
2.14 Fresh Water General Service Systems ........................................... 2 - 98
2.14.1 Fresh Water General Service System .................................. 2 - 98
2.14.2 Distilled Water Filling Service System ............................... 2 - 98
2.1.1a Superheated Steam System ........................................................... 2 - 1
2.1.2a Desuperheated Steam & Steam Dump System.............................. 2 - 3
2.1.3a Bleed System................................................................................. 2 - 5
2.1.4a 6bar Steam System ........................................................................ 2 - 7
2.2.1a Main Condensate System .............................................................. 2 - 9
2.2.2a Aux. Condensate Water System .................................................. 2 - 13
2.2.3a Boiler Feed Water System ........................................................... 2 - 17
2.3.1a Main Sea Water Circulating System............................................ 2 - 21
2.3.2a Cooling Sea Water Service System ............................................. 2 - 23
2.4a Centralised Fresh Water System..................................................... 2 - 25
2.5a Boiler Water Sampling and Treatment System............................... 2 - 27
2.6.1a Fuel Oil Bunkering and Transfer System .................................... 2 - 31
2.6.2a Diesel Oil Purifying and G/E Fuel Oil System ........................... 2 - 35
1 Index
2.6.3a Boiler Fuel Oil & Fuel Gas Service System ................................2 - 37
2.6.5a IGG and Incinerator Fuel Oil System ..........................................2 - 43
2.7.1a Main Turbine Lubrication Oil System .........................................2 - 45
2.7.2a Stern Tube Lubricating Oil System .............................................2 - 49
2.7.3a Lubricating Oil Transfer System .................................................2 - 51
2.7.3b Lubricating Oil Purifying System ...............................................2 - 53
2.8a Engine Room Bilge System ...........................................................2 - 55
2.8b Bilge Water Seprarator System ......................................................2 - 57
2.9.1a Control Air System ......................................................................2 - 59
2.9.2a Starting Air System .....................................................................2 - 61
2.9.3a Working Air System ....................................................................2 - 63
2.9.4a Emergemcy Shut-off Air System .................................................2 - 65
2.10a Steering Gear Hydraulic Diagram ................................................2 - 67
2.11.1a Turbine Generators Control Oil System ....................................2 - 69
2.11.1b Turbine Exhaust Steam System .................................................2 - 71
2.11.2a Diesel Generator Engine............................................................2 - 73
2.12.1a Distribution and Loading...........................................................2 - 77
2.12.2a Turbine Generators ....................................................................2 - 83
2.12.3a Diesel Generator ........................................................................2 - 84
2.12.6a Battery Charger Alarm Display Monitor ...................................2 - 85
2.13.1a Provision Refrigeration System .................................................2 - 87
2.13.2a Accommodation and Air Conditioning Plant.............................2 - 91
2.13.3a Package Air Conditioner ...........................................................2 - 95
2.14.1a Fresh Water General Service System ........................................2 - 97
Part 3 : Integrated Automation System (IAS)
3.1 General Principles of the IAS ............................................................3 - 3
3.1.1 General ....................................................................................3 - 3
3.1.2 IAS System Lay-out ................................................................3 - 3
3.1.3 Alarm and Monitoring .............................................................3 - 4
3.1.4 Log in and Access System.......................................................3 - 4
3.1.5 System Navigation ..................................................................3 - 5
3.1.6 OS Group/Command Group ..................................................3 - 5
3.2 Alarm Extension System ....................................................................3 - 6
3.2.1 Functional Description ............................................................3 - 6
3.2.2 Panel Operation .......................................................................3 - 7
Illustrations
3.1a IAS Overview ...................................................................................3 - 2
3.1.2a Engineer’s Alarm System Logic ....................................................3 - 4
3.1.5a Navigation Panel Lay-out ..............................................................3 - 5
3.2a Alarm Extension System ..................................................................3 - 6
3.2b Watech Cabin Unit ...........................................................................3 - 6
3.2c Extension Panel Alarm Indicators ....................................................3 - 6
CLEAN FORCE
Part 4 : Main Boiler Control System
4.1 Burner Sequences .............................................................................. 4 - 2
4.1.1 Fuel Oil Burning ..................................................................... 4 - 2
4.1.2 Gas Burning ............................................................................ 4 - 6
4.1.3 Burner Automatic Increase / Decrease .................................... 4 - 8
4.1.4 Fuel Mode Changeover ........................................................... 4 - 9
4.1.5 Fuel Oil Boost Up ................................................................. 4 - 11
4.1.6 Nitrogen Purge of Gas Supply Lines .................................... 4 - 12
Illustrations
4.1a Boiler FO & Gas Burning System ................................................... 4 - 1
4.1.1a Flowchart for Furnace Purging ..................................................... 4 - 2
4.1.1b Flowchart for Starting FO BNRs, the First FO BNR .................... 4 - 3
4.1.1c Flowchart for Starting FO BNRs, when Another FO BNR on .... 4 - 4
4.1.1d Flowchart for Stopping Fuel Oil BNRs ........................................ 4 - 5
4.1.2a Flowchart for Starting Fuel Gas BNRs ......................................... 4 - 6
4.1.2b Flowchart for Stopping Fuel Gas BNRs ....................................... 4 - 7
4.1.3a Flowchart for Burner Automatic Decrease.................................... 4 - 8
4.1.4a Flowchart for Changeover FOÎ Dual Mode ............................... 4 - 9
4.1.4b Flowchart for Changeover DualÎ GAS Mode .......................... 4 - 10
4.1.4c Flowchart for Changeover GasÎ Dual Mode ............................ 4 - 10
4.1.4d Flowchart for Changeover DualÎ FO Mode ............................. 4 - 11
4.1.5a Flowchart for Fuel Oil Boost Up ................................................ 4 - 11
4.1.6a Nitrogen Purge of Gas Supply Lines........................................... 4 - 12
4.1.6b Flowchart for N2 Purging of Main Line ..................................... 4 - 12
4.1.6c Flowchart for N2 Purging of Boiler Header................................ 4 - 13
4.1.6d Flowchart for N2 Purging of Boiler Burner ................................ 4 - 13
Part 5 : Main Turbine Remote Control System
5.1 Main Turbine Control System............................................................ 5 - 1
5.2 Function of the Remote Control System............................................ 5 - 4
5.2.1 W/H Manoeuvring .................................................................. 5 - 5
5.2.2 ECR Manoeuvring ................................................................ 5 - 10
5.2.3 Machine Side Manoeuvring .................................................. 5 - 10
5.2.4 Automatic Slow Down .......................................................... 5 - 10
5.2.5 Program Interlock ................................................................. 5 - 13
5.2.6 Control System Monitoring Function ................................... 5 - 13
5.2.7 Safety System ....................................................................... 5 - 14
5.2.8 Safety System Monitoring Function ..................................... 5 - 15
Illustrations
5.2a Block Diagram of Remote Control System ..................................... 5 - 3
5.2.1a Telegraph Lever Position .............................................................. 5 - 5
5.2.1b Time Program for Acceleration / Deceleration ............................. 5 - 5
5.2.1c Brake Steam Supplied Sequence ................................................... 5 - 6
Final Draft / 2007.12.28
Machinery Operating Manual
5.2.1d Example of Typical Control in Deceleration ................................. 5 - 6 Part 8 : General Information
5.2.1e Manoeuvring Valve Lift In Reversing Operation
(Ahead to Astern) ........................................................................... 5 - 6 8.1 Maker List ..........................................................................................8 - 1
5.2.1f Manoeuvring Valve Lift In Reversing Operation 8.2 Tank Capacity Plan and List...............................................................8 - 6
(Astern to Ahead) ........................................................................... 5 - 6 8.3 LO Chart ............................................................................................8 - 8
5.2.1g Auto Spinning Sequence ............................................................... 5 - 7
5.2.1h Block Diagram for Auto Spinning ................................................ 5 - 8 Illustration
5.2.1i Control Pattern of Overspeed Preventer Control ........................... 5 - 9
5.2.1j Block Diagram of Rough Sea Control ........................................... 5 - 9 8.2a Tank Location Plan ...........................................................................8 - 5
5.2.2a Conrol Pattern in Condition a), b), c), d), e), f), g)...................... 5 - 10
5.2.2b Control Pattern in Condition of Main Steam Drum Level High
or Low ........................................................................................ 5 - 11
5.2.8a Blcok Diagram for Safety System ...............................................5 - 15
Part 6 : Description of Critical Operation
6.1 Flooding in the Engine Room ............................................................ 6 - 1
6.2 Main Boiler Emergency Operation .................................................... 6 - 2
6.2.1 One-Boiler Operation.............................................................. 6 - 2
6.2.2 Operation of Stand by FDF ..................................................... 6 - 2
6.2.3 Emergency Operationl ............................................................ 6 - 3
6.3 H.P. and L.P. Turbine Solo Running Operation .................................. 6 - 6
6.4 Restore Engine Room Plant from Dead Ship Condition .................... 6 - 7
Illustrations
6.1a Floodable time, control position and method for valve operation .... 6 - 1
6.2.3a Boiler Emergency Operation Panel ............................................... 6 - 4
6.3a H.P. and L.P. Turbine Solo Running Operation ................................ 6 - 5
Part 7 : Steam Plant Heat Balance System
7.1 100% MCR FO Burning Condition ................................................... 7 - 1
7.2 100% MCR DUAL Burning Condition ............................................. 7 - 2
7.3 100% MCR BOIL OFF GAS Burning Condition .............................. 7 - 3
7.4 90% MCR FO Burning Condition (Guarantee Condition) ................ 7 - 4
7.5 90% MCR FO Burning Condition ..................................................... 7 - 5
7.6 90% MCR DUAL Burning Condition ............................................... 7 - 6
7.7 90% MCR BOIL OFF GAS Burning Condition ................................ 7 - 7
7.8 80% MCR FO Burning Condition ..................................................... 7 - 8
7.9 50% MCR FO Burning Condition ..................................................... 7 - 9
7.10 30% MCR FO Burning Condition ................................................. 7 - 10
7.11 Cargo Unloading Condition (FO) .................................................. 7 - 11
7.12 Cargo Loading Condition (FO) ...................................................... 7 - 12
7.13 Hotel Load Condition (FO) ............................................................ 7 - 13
2 Index
CLEAN FORCE Machinery Operating Manual

Symbols and Colour Scheme

Symbol Description Symbol Description Symbol

Symbol Description
Description Colour Description

Crossing Pipe, Not Connected Hose Globe Valve Float Type Air Vent Head Without Fire Screen
LNG Liquid
Crossing Pipe, Connected Hose Angle Valve Float Type Air Vent Head With Fire Screen
Flexible Hose Spray
Pressure Reducing Valve Filling Cap
Sliding Type Expansion Joint
Three Way Valve Sounding Head With Cap (Deck Stand Type) LNG Vapour
Sleeve Type Expansion Joint
Three Way Cock Sounding Head with Self Closing Valve
Gas
Expansion Bend
Three Way Control Valve Rose Box
Bellows type Expansion Joint Superheated Steam
Ball Valve Mud Box
Blank Flange
S De-superheated Steam
Soldnoid Valve Box Type Strainer
Spectacle Flange
A
Air Motor Operated Valve
Orifice ※ Cast Steel or Duct Cast Iron Nitrogen

M
Center Flange Electric Motor Operated Valve Y-type Strainer
Inert Gas

Reducer Pressure Control Valve Steam Trap

Lubricating Oil
Spool Piece Manual Operated Butterfly Valve Steam Trap With Strainer
Fuel Oil
Globe Angle Hydraulic Remote Operated Butterfly Valve Hand Pump

Angle Valve Pneumatic Remote Operated Butterfly Valve Ejector, Eductor Glycol Water

Screw Down Non-return Valve (Globe)

Hydraulic Cylinder Type Actuator Drain Hold With Plug Sea Water
Screw Down Non-return Valve (Angle)
Pneumatic Cylinder Type Actuator Oil Coaming
Lift Check Valve (Globe) Fresh Water
Intermediate Position Control Valve Actuator Suction Bellmouth
Lift Check Valve (Angle) A A Hydraulic Oil
Auto Control Valve Actuator Open Scupper
Swing Check Valve
Surface Valve Scupper for Indoor Part Diesel Oil
Flap Check Valve
Vapour Control Valve Electric Motor Driven Pump
Relief Valve (Globe) Condensate/Distilled Water

Hand Operated Pressure Gauge

Relief Valve (Angle)
Air
Hand Operated (Locked Open) Compound Gauge
Self Closing Valve (Globe)
Bilge
Self Closing Valve (Angle) Hand Operated (Locked Shut) Flow Meter

Gate Valve (Sluice) Deck Stand Sight Glass Fire Water

Goose Neck Air Vent Pipe Manual Hydraulic Operated Deck Stand

Final Draft / 2007.12.28 3 Symbols and Colour Scheme

CLEAN FORCE Machinery Operating Manual

Electrical Symbol List

STARTER (DIRECT ON LINE) TRANSFORMER OVERCURRENT RELAY BL BELL CP COMPOUND GAUGE

DPI DIFFERENTIAL PRESSURE INDICATOR
GSP DPS DIFFERENTIAL PRESSURE SWITCH
LOCAL GROUP I I/O CABINET (ALARM
LD LIQUID SENSOR O MONITORING SYSTEM)
Trip AUTOMATIC TRIP
DPT DIFFERENTIAL PRESSURE TRANSMITTER
STARTER PANEL
FD FLOW DETECTOR
FS FLOW SWITCH
C I CURRENT TO PRESS SIG
P CONTROL PANEL P
WHISTLE RELAY BOX RECTIFIER EQUIPMENT
CONVERTER RB FT FLOW TRANSMITTER
IL INDICATION LAMP
PD
P PRESS TO CURRENT GROUP JUNCTION BOX XX LAH LEVEL ALARM HIGH
440V DIST. BOARD I
GJB/XX MAKING CONTACT
CONVERTER (XX=LOCATION) LAL LEVEL ALARM LOW
AUXILIARY
RELAY LI LEVEL INDICATOR
LD CONTRACT
LIC LEVEL INDICATING CONTROLLER
220V POWER DIST. BOARD RPM RPM PICK-UP RESISTOR BREAKING
LS LEVEL SWITCH
LT LEVEL TRANSMITTER
LD
LIGHTING DIST. BOARD GAUGE VARIABLE RESISTOR MAKING CONTACT PAH PRESSURE ALARM HIGH
L WITH TIME PAL PRESSURE ALARM LOW
LIMIT IN
PI PRESSURE INDICATOR
CLOSING
INTRINSICALLY SAFE PIC PRESSURE INDICATING CONTROLLER
AIR CIRCUIT BREAKER IS CIRCUIT
DIMMER BREAKING
M PIAH PRESSURE INDICATOR ALARM HIGH
PIAL PRESSURE INDICATOR ALARM LOW
MCCB 1 PHASE POWER SUPPLY UNIT DIODE MAKING CONTACT PIAHL PRESSURE INDICATOR ALARM HIGH LOW
WITH TIME PS PRESSURE SWITCH
LIMIT IN
OPENING PT PRESSURE TRANSMITTER
MCCB 3 PHASE ZBK ZENER BARRIER BOX CAPACITOR BREAKING SAH SALINITY ALARM HIGH
SD SALINITY DETECTOR
SI SALINITY INDICATOR
BATTERY CHARGER LM LIMIT SWITCH FUSE MAKING CONTACT SV SOLENOID VALVE
10A
FLICKER TAH TEMPERATURE ALARM HIGH
RELAY
TAL TEMPERATURE ALARM LOW
BATTERY SOLENOID VALVE FUSE BREAKING
TI TEMPERATURE INDICATOR
TIC TEMPERATURE INDICATING CONTROLLER

SPACE HEATER VOLTAGE REFERENCE PUSHBUTTON SWITCH TIAH TEMPERATURE INDICATOR ALARM HIGH
(ELEMENT TYPE) VR SELECTOR
DISCONNECTION SWITCH
(ALTERNATIVE) TIAL TEMPERATURE INDICATOR ALARM LOW
TIAHL TEMPERATURE INDICATOR ALARM HIGH LOW

PUSHBUTTON SWITCH TS TEMPERATURE SWITCH

DG DIESEL GENERATOR RECEPTACLE SNAP SWITCH
(ALTERNATIVE) TT TEMPERATURE TRANSMITTER
VAH VISCOSITY ALARM HIGH
CHANGEOVER SWITCH VAL VISCOSITY ALARM LOW
EG EMERGENCY GENERATOR J NWT JOINT BOX PUSHBUTTON (START/STOP)
(CAM SWITCH)
VCA VACUUM ALARM
VCI VACUUM INDICATOR

M WT JOINT BOX INDICATOR LAMP PUSHBUTTON VCT VACUUM TRANSMITTER

AC INDUCTION MOTOR J J 2 GLANDS (4 GLANDS) WITH TRANSFORMER (START/STOP/RUNNING)
XS AUXILIARY UNSPECIFIED SWITCH
ZI POSITION INDICATOR
EMERGENCY STOP ZS LIMIT SWITCH
GM GOVERNOR MOTOR HS HUMIDISTAT RL INDICATOR LAMP
PUSHBUTTON BOX

EARTH WT WATER TRANSDUCER D-D RELAY COIL LOCALLY MOUNTED

XXX
INSTRUMENT

XXX REMOTELY MOUNTED

ALARM MONITORING
SHIELD WIRE AMS SYSTEM BZ BUZZER XXXX INSTRUMENT

Final Draft / 2007.12.28 4 Electric symbol List

CLEAN FORCE Machinery Operating Manual

Abbreviation BO/WU BOIL-OFF / WARM-UP DIFF DIFFERENTIAL FO FUEL OIL

A AIR BOG BOIL OFF GAS DIS DISCHARGE FORC FORCING
ABNOR ABNORMAL BOSUN ST BOSUN STORE DISCON DISCONNECT FPT FORWARD PEAK TANK
ABP AFTER BOTTOM PORT BRG BEARING DK DECK FREQ FREQUENCY
ABS ABSOLUTE BW BILGE WELL DO DIESEL OIL F-ST FOLLOW AUTO START
ABS AFTER BOTTOM STBD BWC BRIDGE WING CONSOLE DP DIFFERENTIAL PRESS FUNC FUNCTION
AC ALTERNATING CURRENT BZ BUZZER DRK W DRINKING WATER FUP FWD UPPER PORT
A/C AIR CONDITIONER C CARGO DRN DRAIN FW FRESH WATER
ACB AIR CIRCUIT BREAKER CAB CABINET DRV DRIVE, DRIVING FWC FRESH WATER CONTROL
ACC AUTOMATIC COMBUSTION CONTROL CAN CONTROLLER AREA NETWORK DRY DRYER FWD FORWARD
ACCOM ACCOMMODATION CCC CARGO CONTROL ROOM CONSOLE DSHTR DESUPERHEATED STEAM HEATER FWE FINISHED WITH ENGINE
ACCU ACCUMULATOR CCR CARGO CONTROL ROOM DW DISTILLED WATER GACP GENERATOR AUTO CONTROL PANEL
ACK ACKNOWLEDGE CCW COUNTER-CLOCK WISE EBU EMULSION BREAKING UNIT GEN GENERATOR
ACM AFTER CENTRAL MIDDLE CENT CENTRAL / CENTRIFUGAL ECC ENGINE CONTROL ROOM CONSOLE GMS GAS MANAGEMENT SYSTEM
ACT ACTIVATE CER CARGO EQUIPMENT ROOM ECONM EXHAUST GAS ECONOMIZER GMS GRAPHIC MODELING SYSTEM
ADJ ADJUSTING CFW COOLING FRESH WATER ECR ENGINE CONTROL ROOM GRAV GRAVITY
ADV ADVANCE CIRC CIRCULATING EDR ELECTRIC DISTRIBUTING PANEL ROOM GRP GROUP
AE AUXILIARY ENGINE CL CLOSE EDSHTR EXTERNAL DESUPERHEATED STEAM GS GENERAL SERVICE
AFT AFT CLK CLOCK . HEATER GUI GRAPHICAL USER INTERFACE
AHD AHEAD CLR COOLER EDUCT EDUCTOR GVNOR GOVERNOR
AHU AIR HANDLING UNIT CMR CARGO MOTOR ROOM EER ELECTRIC EQUIPMENT ROOM GW GLYCOL WATER
AIM ADVANCED INTEGRATED MULTIFUNCION CN COMMUNICATION NETWORK EHQ EMERGENCY HEADQUARTER H HIGH
SYSTEM CNR CORNER ELEC ELECTRIC HAND HANDLE/HANDLING
ALM ALARM C-O CHANGE-OVER ELEV ELEVATOR HD HIGH DUTY
ALS AFTER LOWER STBD CO2 CARBON DIOXIDE EMCY EMERGENCY HDR HEADER
AMP AMPERE COFF COFFERDAM EMR ELECTRIC MOTOR ROOM HFO HEAVY FUEL OIL
APT AFT PEAK TANK COMP COMPRESSOR ENG ENGINE HH HIGH-HIGH
AST ASTERN COMP RM CARGO COMPRESSOR ROOM EQP EQUIPMENT HP HIGH PRESSURE
ATM ATMOSPHERE COND CONDENSATE / CONDENSER ER ENGINE ROOM HPT HIGH PRESSURE TURBINE
ATOM ATOMISING CONDUCT CONDUCTIVITY ESBD EMERGENCY SWITCHBOARD HS HISTORY STATION
AUS AFTER UPPER STBD CONT CONTROL ESD EMERGENCY SHUT DOWN HSC HIGH SEA CHEST
AUTO AUTOMATIC COOL COOL, COOLING ESDS EMERGENCY SHUT DOWN SYSTEM HTML HYPER TEXT MARKUUP LANGUAGE
AUX AUXILIARY COUNT COUNT, COUNTER EXH EXHAUST HTR HEATER
AVAIL AVAILABLE CPP CONTROLLABLE PITCH PROPELLER EXP EXPANSION HYD HYDRAULIC
B BASE CSBD CARGO SWITCHBOARD EXT EXTENSION IAS INTEGRATED AUTOMATION SYSTEM
B/ATOM BURNER AUTOMIZING CSL CONSOLE EXTR EXTRACTOR IG INERT GAS
B/L BALLAST / LADEN CSW COOLING SEA WATER F FRESH IGG INERT GAS GENERATOR
B/THR BOW THRUSTER CTS CUSTODY TRANSFER SYSTEM F/VPR FORCING VAPORIZER IGV INLET GUIDE VANE
BALL BALLAST CUR CURRENT FCL FWD CENTRAL LOWER IN INLET
BATT BATTERY CW COOLING WATER FOSCLE FORECASTLE INCIN INCINERATOR
BC BOTTOM CENTRAL FCU FWD CENTRAL UPPER INCOM INCOMING
CW CLOCK WISE
BGB BOILER GAUGE BOARD CYL CYLINDER FCV FLOW CONTROL VALVE IND INDICATION
BH TK BILGE HOLDING TANK FDB FOREWARD DEEP BALLAST INH INHIBIT
D DUMP
BHD BULKHEAD FDF FORCED DRAFT FAN INJECT INJECTION
DAMP DAMPER
BLK BLOCK DB DOUBLE BOTTOM FDWC FEED WATER CONTROL INSPT INSPECTION
BLR BOILER FE FLAME EYE INSUL INSULATION
D/B DISTRIBUTION BOARD
BLWR BLOWER FG FUEL GAS INTERM INTERMEDIATE
DEARTR DEAERATOR
BMS BURNER MANAGEMENT SYSTEM DEL DELIVERY FILL FILL INTLK INTERLOCK
BNR BURNER FLP FWD LOWER PORT IR INFRA-RED
DET DETECTOR / DETECTION
BO BOIL-OFF FM FROM ISO ISOLATING
DG DIESEL GENERATOR

Final Draft / 2007.12.28 5 Abbreviation

CLEAN FORCE Machinery Operating Manual

L LOW OVLD OVERLOAD S/S SHIP SIDE TPS TANK PROTECTION SYSTEM
LAN LOCAL AREA NETWORK OVRD OVERRIDE S/T STERN TUBE TRANS TRANSMITTER/TRANSFER
L/VPR LNG VAPORIZER OW SEP OILY WATER SEPARATOR SAH STEAM AIR HEATER TRBL TROUBLE
LCD LIQUID CRYSTAL DISPLAY PORT PORT SAL SALINITY TURN GEAR TURNING GEAR
LCV LEVEL CONTROL VALVE P/WAY PASSAGE WAY SB SOOT BLOWER UMS UNMANNED MACHINERY SPACE
LD LOW DUTY PB PUSH BUTTON SBC Single Board Computer UPP UPPER
LDO LIGHT DIESEL OIL PC PERSONAL COMPUTER SC SEA CHEST UPS UNINTERRUPTED POWER SUPPLY
LED LIGHT EMITTING DIODE PCU PROCESS CONTROL UNIT SCRUB SCRUBBER URL UNIFORM RESOURCE LOCATOR
LIQ LIQUID PCV PRESSURE CONTROL VALVE SDC STEAM DUMP CONTROL UTC UNIVERSAL TIME CODRDINATE
LL LOW-LOW PD PIPE DUCT SEC SECONDARY V VOLTAGE
LNG LIQUEFIED NATURAL GAS PDU POVER DISTRIBUTION UNIT SEL SELECT V/F VOLTAGE/FREQUENCY
LO LUBRICATION OIL PID PROPORTIONAL INTEGRAL DERIVATIVE SEP SEPARATOR VAC VACUUM
LP LOW PRESSURE PIST PISTON SEQ SEQUENCE VAP VAPOR
LPT LOW PRESS TURBINE PKG PACKAGE SERV SERVICE VIB VIBRATION
LSC LOW SEA CHEST PLU PROCESS MAP LOGICAL UNIT SETTL SETTLING VISC VISCOSITY
LTG LIGHTING PMS POWER MANAGEMENT SYSTEM SG STEERING GEAR VL VERY LOW
LVL LEVEL PNEUM PNEUMATIC SHTR SUPERHEATED STEAM HEATER VPR VAPORIZER
LWR LOWER PNL PANEL SIN PH SINGLE PHASE VRC VALVE REMOTE CONTROL
M MACHINERY POS POSITION SOL SOLENOID VV VALVE
M/COND MAIN CONDENSER PP PUMP SP SPACE WBU WATCH BRIDGE UNIT (Bridge Watch Call panel)
M/LOADER MANUAL LOADER PPTW PUMP TOWER SPM SIMRAD POSITION MOORING WCU WATCH CABIN UNIT (Cabin Watch Call panel)
M/WHEEL MAIN WHEEL PRES PRESSURE SPR SPRAY WTR WATER
MAN MANUAL PRI PRIMARY/PRIMING SPV SINGLE POINT VIEW WH WHEELHOUSE
MANI MANIFOLD PROCESS PROCESS SS SUB-SYSTEM (RCA SYSTEM) WHC WHEELHOUSE CONSOLE
MANO MANOUVERING PROTECT PROTECT SSS SIMRAD SAFETY SYSTEM WIND WINDING
MB MAIN BOILER PROV PROVISION ST START WO WASTE OIL
MD MAIN DIESEL GENERATOR PRP PROVISION REFRIGERATION PLANT ST STERN TUBE WS WORKSHOP
MDO MARINE DIESEL OIL PS PROCESS STATION STBY STAND BY WU WARM UP
MFWPT MAIN FEED WATER PUMP TURBINE PSU POWER SUPPLY UNIT STC STEAM TEMPERATURE CONTROL X CROSS
MG MASTER GAS PU PROCESS UNIT (RCA SYSTEM) STM STEAM
MGPS MARINE GROWTH PREVENTING SYSTEM PURGE PURGE STOR STORAGE
MID MIDDLE PURIF PURIFIER STR STARTER
MSBD MAIN SWITCHBOARD PWR POWER STRIP STRIPPING
MSBR MAIN SWITCHBOARD ROOM RCA REDUNDANCY AND CRITICALITY SUC SUCTION
MT MAIN TURBINE ASSESSMENT SUPP SUPPLY
MTR MOTOR RECIRC RECIRCULATING SV SOLENOID VALVE
NDU NETWORK DISTRIBUTION NETWORK UNIT REDUC REDUCTION SVC SIMRAD VESSEL CONTROL
MV MANOEUVERED VALUE REF REFRIGERATION TYPE SVB SOLENOID VALVE BOX
N2 NITROGEN REG REGENERATION TYPE SW SEA WATER
NAV NAVIGATION REGUL REGULATOR SWBD SWITCHBOARD
NOR NORMAL RESV RESERVOIR SYNC SYNCHRONIZE
NZL NOZZLE REV REVERSE SYS SYSTEM
O/C OPEN/CLOSE RIO REMOTE IO TC TURBOCHARGER, THERMOCOUPLE
O2 OXYGEN RM ROOM TCV TEMPERATURE CONTROL VALVE
OMD OIL MIST DETECTOR RPB REMOTE PUSH BUTTON TEMP TEMPERATURE
OP OPEN RPM REVOLUTIONS PER MINUTE TG TURBO GENERATOR
OS OPERATOR STATION RTN RETURN THR THRUSTER
OUT OUTLET RVI ROTOR VIBRATION INDICATION TK TANK
OVBD OVERBOARD S STARBOARD TOPP UP TOPPING UP
OVFL OVERFLOW S/D SCHEMATIC DIAGRAM TRIP TRIP

Final Draft / 2007.12.28 6 Abbreviation

CLEAN FORCE Machinery Operating Manual

Part 1 : Engineering Data for Main Equipment

1.1 Main Turbine ..................................................................................... 1 - 1
1.1.1 Manufacturing Specification................................................... 1 - 4
1.1.2 Main Turbine Operation Instructions ...................................... 1 - 6
1.2 Main Boiler ........................................................................................ 1 - 9
1.2.1 Main Boilers Planning Data .................................................... 1 - 9
1.2.2 Instructions for Main Boiler Operation................................. 1 - 13
1.3 Generator Turbine ............................................................................ 1 - 17
1.4 Main Feed Water Pump Turbine ...................................................... 1 - 22
1.4.1 Operating Procedure ............................................................. 1 - 23
1.5 Diesel Generator Engine .................................................................. 1 - 24
1.6 Fresh Water Generator ..................................................................... 1 - 26
1.7 Bow Thruster ................................................................................... 1 - 28
1.7.1 Technical Specification ......................................................... 1 - 28
1.7.2 Remote Control System ........................................................ 1 - 28

Illustrations
1.1a Main Turbine General Arrangement ................................................ 1 - 3
1.2.1a Starting Up Curve (with Continuous Fire) .................................. 1 - 14
1.2.1b Characteristic Curves of Y-jet Type Steam Atomiser .................. 1 - 15
1.3.1a Governing System ..................................................................... 1 - 18
1.3.1b Control Oil Press. Adjusting Valve ............................................ 1 - 20
1.3.1c Time Schedule for Starting of Turbine Generator ..................... 1 - 21
1.6.1a Fresh Water Generator ................................................................ 1 - 25
1.7.1a Bow Thruster .............................................................................. 1 - 27
1.7.1b Bow Thruster .............................................................................. 1 - 27

Part 1
Engineering Data for Main Equipment
Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

Part 1 : Engineering Data for Main Equipment 3. Manoeuvring Valve : One (1) Unit

1.1 Main Turbine Type Single Lid Diffuser Type

Dia. throttle/pilot mm 190 / 80
1. Main Particulars : Valve
Lift ahead/astern mm 71 / 45
Piston dia. mm 600
Oil Cylinder Stroke ahead/astern mm 160 / 100
Type : KAWASAKI UA-400 Cross compound, impulse, double reduction geared marine turbine Oil Pressure bar Abt. 2.9

Item MCR NCR 4. Reduction Gear : One (1) Unit

Output PS 39,000 35,100
Type : Tandem articulated, double reduction, double helical type
HP Turbine rpm 4,962 4,791
Revolution LP Turbine rpm 3,275 3,162 Item P.C.D. mm No. of Teeth
Propeller rpm 88 85 HP 36
291.0
Steam Pressure 1st red. pinion
58.8bar LP 396.1 49
at manoeuvring. valve inlet
Steam Temperature HP 2,626.9 325
510°C 1st red. gear
at manoeuvring. valve inlet
LP 2,360.2 292
Condenser vacuum
at maximum output with 27°C sea water 720mmHgV at Cond. Top 722mmHgV at Cond. Top HP 658.2 57
inlet temperature 2nd red. pinion
LP 658.2 57
Astern max. torque
80% of the MCR ahead torque
at 50% of the MCR ahead rpm Main gear 4,110.7 356
70% of the MCR ahead rpm
Astern allowable max. continuous rpm Effective face width 1st red HP 510mm / LP 510mm
not exceed more than two(2) hours
(at P.C.D.) 2nd red 1,168
Ahead rotating direction Clockwise looking from aft
Main shaft speed at torsional vibration 27.94rpm & 48.74rpm

Critical speed of turbine rotor HP Turbine abt. 68rpm

5. Main Condenser : One (1) Unit
(converting into main shaft) LP Turbine abt. 121.5rpm
Type Reheating, surface type
Vacuum mmHgV 722
2. Turbine : One (1) Unit
Cooling surface m2 3,360

Item HP Turbine LP Turbine Quantity of condensed steam kg/h 81,410

8 (Ahead) Cooling water inlet temperature °C 27

No. of stages 10
2 (Astern) 3
Quantity of cooling water m /h 17,900
Main steam inlet nominal dia. 175mm x 2 175mm (Astern)
Velocity of cooling water m/s Abt. 1.82
Cross-under pipe nominal dia. 420mm
Distance between tube sheets mm 5,000
HP 125mm at HP turbine 5th stage
Dia. / Thickness mm 19.0 / 0.7
Bleeding pipe nominal dia. IP 200mm at cross over pipe
Cooling tubes Length mm 5,079
LP 300mm at LP turbine 3rd stage
Number - 11,260

Final draft / 2007. 12. 28 1- 1 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

6. Vacuum Pump : Two (2) Unit 10. Alarming and Tripping Point

Type Water Sealed, Rotary Type Item Unit Normal Alarm Trip

Capacity m3/h 12.7 Main condenser vacuum mmHgV 722 600±60 300±30
H : 0.5±0.05
Pump Suction vacuum mmHgV 730 Packing steam press. bar 0.1~0.2 -
L : 0.05±0.03
Revolution rpm 900 Control oil press. bar 3.0~4.0 2.5±0.1 2.0±0.1

Output kW 30 Brg. Supply oil press. bar 1.0~1.5 0.7±0.07 0.5±0.05

Motor Gear supply oil press. bar 1.0~1.5 0.7±0.07 -
Voltage V AC 440
Bearing. & gear supply oil temp. °C set 45 50±1 -
Cooling surface m2 5
HP & LP Turbine 45~70 75±1
Cooling water quantity m3/h 20.4 HP & LP Turbine Thrust 45~70 75±1
Cooler Tube dia. / Thickness mm 12.7 / 0.5 HP 1st Red. pinion 45~70 75±1
Tube length mm 1,395 LP 1st Red. pinion 45~70 75±1
HP 1st Red. gear 45~70 75±1
No. of tube - 98
Brg. temp. LP 1st Red. gear °C 45~70 75±1 -
HP 2nd Red. pinion 45~70 75±1
LP 2nd Red. pinion 45~70 75±1
7. Gland Condenser : One (1) Unit
Main Gear 45~50 55±1
Main Thrust 45~50 55±1
Type Horizontal Shell Tube
Main Thrust Pad 45~ab.70 90±1
Cooling area m2 25
101.77
Cooling water - Condensate water Over speed (Main shaft) rpm MCR 88 - +0
-2.66
Cooling water inlet temp. °C 49.1
0.5±0.05 *1) 1.0±0.05 *1)
3 HP Turbine 0.2
Cooling water quantity m /h 86.4 (On monitor) (On monitor)
Rotor axial 0.5±0.05 *1) 1.0±0.05 *1)
Cooling tube dia. / Thickness mm 16.0 / 1.0 LP Turbine mm 0.2
displacement (On monitor) (On monitor)
1.1±0.05 *1) 1.6±0.05 *1)
Main Thrust 0.6
(On monitor) (On monitor)
8. Gland Exhaust Fan : One (1) Unit 100±5 130±5
HP Turbine -
µm (On monitor) (On monitor)
Rotor vibration
(p-p) 150±5 180±5
Type Motor Driven Centrifugal LP Turbine -
(On monitor) (On monitor)
Capacity m3/min. / bar 7 / -0.0294 H +300±10
Main Condenser Hotwell level mm NWL *2) -
L -110±10
Motor kW / rpm 3.7 / 1,800
Main steam press. High : 62
bar 58.8 -
(at M.V. inlet) Low : 54.5
Main steam temperature (at M.V. inlet) °C 510 High 525 -
9. Lub. Oil Pump : One (1) Unit Astern. steam chamber temp. °C 30~50 350 *3)
-
LP turbine exhaust chamber temp. °C 33 150 -
Type Main Turbine Driven Gear Pump Main cond. sea water
Dump steam °C 29.3 Set value 70
3 outlet temp. high
Capacity m /h 210 system interlock
Main cond. vacuum low mmHgV 722 Set value 600
Discharge press. bar 3.9
*1) Mark : Including clearance.
*2) Mark : 400 mm from hot well bottom.
*3) Mark : at Astern guardian valve close and delay timer abt. 4H.

Final draft / 2007. 12. 28 1- 2 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

Illustration 1.1a Main Turbine General Arrangement

Final draft / 2007. 12. 28 1- 3 Part 1 Engineering Data for Main Equipment
CLEAN FORCE
1.1.1 Manufacturing Specification
1. General
The turbine unit is of the cross compound type composing of HP turbine and
LP turbine. The HP turbine is of the impulse type 10stages. The LP turbine is of
the impulse-reaction type with 8ahead stages and with 2astern stages..
1) Main Turbine
(1) Casing
The HP turbine casing consists of the upper casing and the lower
casing combined together firmly by bolts on the horizontal flange.
The steam chest is situated on the high pressure side of the lower
casing. Two steam inlets are connected with the maneouvring
valve through the main steam pipes by welding.
The fore end of the casing is connected to the forward bearing
pedestal and rigidly supported on the bed frame.
The after end of the casing is connected to the aft. bearing
pedestal by flange joint and supported by the flexible plates
mounted on the bed frame. So the casing expands to the aft. side.
Then the heat expansion is absorbed by an expansion joint of the
bellows type at the coupling cover between the casing and the
pedestal is fitted with the transverse keys and vertical keys and
the after end joint is the vertical flange and fitted the keys radially.
LP turbine casing is composed of the ahead steam chest, the
ahead casing, the astern casing and the exhaust casing.
The ahead casing and the exhaust casing are one-unit-weld
construction.
The ahead steam chest and the ahead casing are connected by the
vertical flange joint, and split at the horizontal centerline.
The astern casing is arranged and fitted in the exhaust casing.
The astern casing is supported on the horizontal plane of the
exhaust casing by loose bolts and the fore end of the casing is
bolted to the vertical plane of the exhaust casing.
Moreover, the casing is provided with a couple of dowels, one on
top and one on bottom to keep the alignment free from
differential expansion between the astern casing and the exhaust
casing.
The astern steam inlet is located on the upper half of the exhaust
casing and connected with the astern main steam pipe by flanges
through the joint piece of piston-ring type.
The forward and aft. bearing pedestal are connected with the
Final draft / 2007. 12. 28
Machinery Operating Manual
ahead steam chest and the exhaust casing by the vertical flange,
respectively.
(2) Turbine Rotors and Blades
Both HP and LP turbine rotors are solid type. i.e., the discs on the
rotors are turned integral with the rotor shafts.
The disc of the astern 1st stage is of the solid type. The thrust
bearing collar is solid type and integral with the rotor shaft. The
blade roots are fitted into “T” slots on the disc wheel rims.
Considering the centrifugal force, the longest blades, i.e., LP
turbine final two stage, have double “T” for fitting to the rim.
The shroud rings of the 1st and 2nd stage blades of HP turbine and
5th, 6th, 7th ahead stages and astern stage of LP turbine are secured
at the blade tips, but the shrouds of the 3rd stage-10th stages blade
of HP turbine and 1st – 4th ahead stages of LP turbine are
machined out in one-unit from the blades with the labyrinth, in
order to prevent the steam leakage from the blades tips.
However, there is no shroud attached on ahead 8th stage blades.
Blades of the 7th and 8th ahead stages of LP turbine are coated
with satellite by welding in order to prevent erosion due to drain
cutting.
The sealings consisting of labyrinth fin and caulking wire are
provided between casing wall and shroud rings of the 5th, 6th, 7th
ahead stages of LP turbine. The distance between the nozzle exit
and blade entrance shall be adjusted by positioning the turbine
rotor by means of the adjusting liners in the turbine thrust bearing.
2) Main Reduction Gear
The main reduction gear is of the tandem articulated double reduction
type.
The torque generated by the HP and LP turbines is transmitted to the 1st
red. flexible couplings then, to 2nd reduction gear through quill shafts
and 2nd red. flexible couplings.
(1) Reduction gear casing
Reduction gear casing is welded steel construction divided into
the upper and the lower by a horizontal plane including the shaft
center of 1st reduction gears and 2nd reduction pinions. On to
lower casing, main thrust bearing in one unit with gear casing is
installed at fore side, an oil tray is welded to the bottom of lower
casing. The upper casing is divided into 1st reduction upper
casings for H.P and L.P turbine side, 2nd reduction gear cover,
main gear bearing covers and end covers, etc., At a Proper
location on the upper casing, a peep holes are provided for
inspection of lubricating condition on meshing surface of
reduction gear and contact marking condition. A gas extracting
device is placed on the top of the upper casing to remove oil-gas
from the casing by gas vent pipe.
1- 4
(2) Reduction gears
Each reduction gear has a modified involute shape tooth profile,
hob and shaved or ground.
Pinions are turned integral with the shaft. Gears consist of a
forged steel rim and shaft, welded to steel-plate spokes.
(3) 1st Red. Flexible coupling
Both HP and LP flexible couplings are made up with two
coupling sleeves with internal gears and a coupling shaft with an
external gear.
This permits thermal expansion and eccentricity of the turbine
rotor and 1st reduction pinion.
(4) Quill shaft and 2nd Red. Flexible coupling
The quill shaft is installed inside the hollow shafts of the 1st
reduction gear and 2nd reduction pinion. Its fore-side is connected
to the 1st reduction gear shaft by a flange coupling while the
after-side is connected to the 2nd reduction pinion by a flange
coupling through a gear coupling, with intention to absorb shock-
load arising from gearing functions.
(5) Bearings
All the bearings are divided into upper and lower shells. Bearing
metals are of white metal cast on a backing metal of steel plate.
Thermometers for the bearings are attached to each cover or
casing.
(6) Main thrust bearing
Main thrust bearing is tilting pad-type, constructed in one unit
with the gear casing at fore-side of lower casing.
Pads include eight pieces each for ahead and astern. It is
supported on its protuberance on back to form wedge film shape
freely during operation. The thrust pads are assemblies of steel
segments, tin-base Babbitt and hardened support discs. And thrust
pads are supported on leveling links to distribute the load among
the pads.
(7) Turning gear
The turning gear installed on the after-side of the HP 1st reduction
upper casing. Reduction gear system is composed of planetary
gears and motor being linked by chain gearing system which also
function reducing operation by it-self.
The turning motor is installed on the top of the planetary gear unit
and turns the main shaft one revolution in 6 minutes by means of
the turning gear.
Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

valve position.
(8) Direct driven lubricating oil pump (Main LO pump)
(2) Lever control (from machinery control room)
The LO pump is coupled to the HP 2nd reduction flexible coupling
cover with the flange. The lever control system consists of the revolution control, valve
One helical gear is connected to the pump input shaft, and this position control, and program by-pass control.
helical gear engaged with the gear is set on the out surface of HP
When the revolution control switch on the control console is
2nd reduction flexible coupling sleeve. Through this pair of helical
changed to “BY-PASS” position, the revolution control is
gears, power is transmitted to the LO pump. automatically cut.

3) Main Condenser
The main condenser is of the straight tube, surface cooling type. The
cooling is by the main circulating pump.
(3) Emergency manoeuvring control (from machinery control room)
The main condenser is installed in an athwartship position and
supported on the package frame by its own girder.
The upper port flange is fixed to the LP exhaust casing flange.
The exhaust steam enters here and flows through the nest of the
condenser tubes and finally to the hot well.
When the program by-pass switch on the control console is
changed to “PPOGRAM BY-PASS” position, astern & ahead
program is canceled.
When the select switch on the control console for selection of
manoeuvring method is set to “DIRECT” position, the main
turbine is controlled by means of the direct control switch regulator
with control lever.

The aft. side of the condenser is air cooling zone. The tube sheets are
bolted between shell flanges and water box flanges by collar bolts. The
internal surface of water boxes is lined with neoprene in order to
prevent the corrosion. Inlet and outlet side water boxes are provided
steel plates to prevent the corrosion of tube sheet.
4) Vacuum Pump
The vacuum pump unit consists of a motor driven rotary type vacuum
pump, a water separator, a seal water cooler and a bed frame.
Non-condensed air in the main condenser is pumped up by the vacuum
pump, and exhausted to the atmosphere through the water separator.
(4) Spinning
When the change over switch for auto spinning is set to “ON”
position and the main shaft revolution is decreased between +1
rpm and -1rpm during navigation, auto-spinning is automatically
done.
Change over switch (“ON”, “OFF”) is provided on the machinery
control room console.
Also warming through mode is provided for safe operation during
hand spinning for completion of warming up of main turbine.

6) Main Turbine Control System

The remote control system serves for controlling main turbine from
navigation console or in the machinery control room.

In conventional operation, according to manoeuvring orders the engine

telegraph lever on the bridge or manoeuvring lever in the control room
is set to desired position.

When any trouble occurs in the engine telegraph or manoeuvring lever

system, the main turbine is controlled by the direct control switch regulator
on the machinery control room console.

(1) Telegraph control (from navigation console)

The telegraph control system consists of the revolution control and

Final draft / 2007. 12. 28 1- 5 Part 1 Engineering Data for Main Equipment
CLEAN FORCE
1.1.2 Main Turbine Operation Instructions
1.1.2.1 Preparation for Start-up
1. Confirmation Procedure
1) Confirm that the steam source (main steam, auxiliary steam, etc.), air
and electrical sources are in operating condition.
2) Confirm that all gauges and meters are normal.
3) Check the emergency manual handle of the manoeuvring valve with
main steam valve is at the shut-off condition.
4) Check that manoeuvring lever is at the stop condition, and switches of
bleeder valves, drain valves and etc. on the control console are at the
engine stop condition.
5) Confirm water level of main condenser hotwell.
6) Confirm working level of the LO by the LO tank level gauge.
7) Confirm water level of vacuum pump seal water.
8) Confirm water level of central cooling F.W.exp.tank.
9) Put electric source to the control console, and open up air source to
each control device.
10) Check indication lamp by lamp test button on the control console.
11) Check that each valve position and lamp indication is to be the same
position.
12) Set operation switch “auto” for drain valves, astern guardian valve,
bleeder valves, and spray water valves.
13) Check no leakage of lub. oil, steam, drain, etc.
14) Check manual-handle position of control valves.
a. open position : astern guardian valve, drain valves, packing steam
make-up valve
b. close position : packing steam spill valve, bleeder valves, main
condenser recirc. Valve, warm –up valves
c. Locking position with a stopper : spray water valve for steam
dump, spray water valve for ast. Operation
15) Check that by-pass valves of the control valves are closed.
Final draft / 2007. 12. 28
Machinery Operating Manual
16) Check and record axial position of HP and LP turbine rotors at cold
condition.
2. Start-up of Lube Oil System
1) Confirm level of Lube oil in the sump tank.
2) Check oil temperature.
If it is below 30°C, preheat oil to minimum 30°C.
3) Open all valves and cocks in the Lube oil system.
At the same time, check that normally closed valves are in correct
position.
4) Operate Lube oil temperature control valve.
5) Start the Aux. LO pump.
6) Eliminate air bubbles via air vent valves in the system.
7) Open cooling water valves for the Lube oil coolers.
8) Check oil pressure and oil flow in all sight glasses.
9) Recheck the oil level in the sump tank.
10) Check overflow of the gravity tank.
11) Confirm oil pressure of pump discharge, bearings, and gears for the
turbine.
12) Then, turning motor of the main turbine is could started.
Caution
Never turn on turning motor switch while the handle for hand-turning is
inserted into motor shaft end.
3. Vacuum-up Procedure
1) Supply packing steam by opening stop valve on auxiliary steam line
and both inlet & outlet stop valves for packing steam pressure control
valve for make-up. Confirm that bypass valves of the packing steam
pressure control valves are closed.
2) Start gland exhaust fan either before supplying packing steam or
immediately after.
3) Supply cooling water to vacuum pumps.
4) Check level in water separator for vacuum pump suction.
1- 6
5) Open suction valve and its bypass valve for vacuum pump suction.
6) Start vacuum pump. When condenser vacuum reaches 300mmHgV,
close the suction valve leaving the by-pass valve open and keep
condenser vacuum in the range of 250~300mmHgV.
4. Start–up of Condensate System
1) Open valves in main sea water circulation system.
2) Start Main S.W circulating pump.
3) Open air vent valves on the water boxes of main condenser and
eliminate air bubbles in the systems.
4) Fill the main condenser hotwell up to the normal working level with
condensate / distilled water.
5) Operate level controller for the main condenser hot well.
6) Open suction valves for the condensate pumps.
7) Open valves in the pressure balancing and gland sealing line for the
condensate pump.
8) Start the condensate pump.
9) Open the condensate pump delivery valves. And confirm that
condensate line is pressurized.
10) Confirm that the hotwell level is controlled properly by the level
controller.
5. Confirmation of Cooling Water System
1) Confirm that central cooling system is operated normally.
2) Confirm that cooling sea water system is operated normally.
3) Check no leakage , no abnormal vibration, and no abnormal noise are
observed on central cooling and cooling sea water system.
6. Function Check of Manoeuvring Device
1) After confirming that the main steam valve is in the full shut-off
position, reset the main turbine by pushing the reset-button until the
reset lamp lights.
2) Operate the manoeuvring valve hydraulically by the manoeuvring
lever in order to check the manoeuvring device function.
Part 1 Engineering Data for Main Equipment
CLEAN FORCE
3) After resetting, push the trip-button to confirm normal operation of the
trip. After this, Reset is not necessary; leave in the tripped condition.
7. Warming – up
1) Case 1 (Cold Start)
Stage 1
(1) Confirm that the manoeuvring valve is in the trip condition and
the main steam stop valve is closed.
(2) Confirm that drain valve and astern guardian valve are closed.
(3) Engage turning gear.
(4) Start the turning motor and rotate the turbine.
Caution
Never turn on turning motor switch while the handle for hand-
turning is inserted into the motor shaft end.
(5) Start the gland exhaust fan.
(6) Supply packing steam by opening the stop valve on the auxiliary
system and both inlet & outlet stop valves for the packing steam
control valve. Shut off bypass valve of the automatic packing
steam control valve.
(7) Supply cooling water to the vacuum pump.
(8) Check level in the water separator for the vacuum pumps.
(9) Open the suction valve and its bypass valve for the vacuum pump
suction.
(10) Start the vacuum pump.
When condenser vacuum reaches 300mmHgV, close the suction
valve leaving the bypass valve open and keep the condenser
vacuum in the range of 250 ~ 300mmHgV for one and a half.
(11) Open the by-pass valves for the main steam stop valves from
boiler to turbine. And warm up the main steam pipe by opening
the drain valves of the main steam line.
(12) Open the warming up valves for main turbine.
(13) Warm up the turbine for at least one hour.
(14) Close the warming up valve for main turbine.
Final draft / 2007. 12. 28
Machinery Operating Manual
(15) Open the suction valve for vacuum pump and close its by-pass (4) Stop the turning motor, set the lever to disengaged position and
valve. lock it in position.
(16) Confirm the condenser vacuum to be above 722mmHg. (5) After disconnection of the LNG loading pipe at harbor and so on,
steam spinning may be carried out over 30minutes, in the
(17) To “Before Sail Out” stage 2. ahead/astern directions.
(The temperature of the HP turbine steam chest should then be
Caution about 300°C.)
Higher vacuum during the warming up period would lengthen the ime
required to warm up the turbine and might cause inequalities in 1.1.2.2 Running
temperature that would result in distortion of turbine rotors.
1. Stand-by
2) Case2 (In harbour)
(1) Within three (3) minutes after disengaging the turning gear, start try-
Stage 1 engine.
During ship’s loading/unloading period, turbine condition should be Caution
kept as follows. Do not stop the turbines for longer than 3 minutes in the hot condition.
(1) Condenser vacuum should be kept at above 722mmHgV. (2) Confirm that there is no abnormal noise inside of the turbine and the
reduction gear casing during the try-engine.
(2) Engage turning gear and start turning after stopping the engine.
(3) Continue the idling until further information comes from the bridge.
(3) Close the main steam stop valves of main steam line from boiler The warming-up condition is maintained on the main engine by this
to turbine. idling. (The temperature of HP turbine steam chest is had to keep
about 300℃.)
(4) Open by-pass valves of main steam stop valves.
(4) Check the both nozzle valves to be set to fully closed.
(5) Keep the warming-up valve for main turbine close in order to
keep the main turbine hot condition as long as possible. 2. Starting and Ahead Operation
When the steam chest temperature of HP turbine is down to
150°C, open the warming up valves to supply warming steam to 1) Start ahead operation by operating the manoeuvring lever with the
the turbine. program control. The program is shown in the following figure. In
case of manual control the speed should be increased according to the
(6) To “Before Sail Out” stage 2. program.
MCR load
88rpm
Stage 2 (Before Sail Out)
(1) Open the drain valves and allow 30minutes warming through of
the main steam pipe before starting the turbine. 1/2 load
abt.
69.8rpm
Note Propeller
“ Judgment of complete warming up” : Colour of drain steam
revolution
from the drain valves will change to transparent from white on
completion of warming-up.
free min. 40 minutes time
(2) Set the manoeuvring lever in the neutral position and confirm that
the emergency manual handle is in neutral.
2) Power may be increased regardless of the time limit up to 1/2 output
(3) Open the main steam stop valve and shut off its bypass valve. (main shaft revolutions about 69.8rpm.)
From 1/2 output to full output a minimum of 40minutes is required.
1- 7 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

3) Control valves are closed or opened automatically according to their
setting values.
4) Sea water circulating pump is stopped and the scoop inlet valve is
opened automatically
5) Aux. motor driven LO pump is stopped over abt. 79.2rpm
6) Check the turbine unit is operating normally according to the
characteristic curve of the main turbine
8) When converting to ahead running after long periods of astern running,
avoid sudden increases of ahead load. It should be increase gradually.
In addition, continuous maximum output operation shall be carried out
after approximately 40minutes of ahead running.
9) Confirm that motor driven circulation pump is started and the scoop
inlet valve is closed
10) Astern operations should be carried out under program control if
ordinary astern operation is sufficient for manoeuvring the ship.
valve and shutting-off of bleeder valves.
2) Confirm complete stop of the main engine (propeller revolution), then
engage turning gear.
3) Start turning motor. Ensure that engine turning is carried out within
three minutes of a complete stop. Turning for engine cooling-off is
required for at least six hours.
4) Shut off main steam stop valve completely.

7) For slow-down during the voyage and throttling the manoeuvring
handle, all control valves are closed or opened automatically
according to the setting values. The electric motor driven lub oil pump
will start automatically as required.
3. Astern Operation
1) Confirm that bleeder valves are shut off before starting astern
operations.
11) Pay attention to the upper temperature limit of the LP turbine exhaust
chamber, which is not to exceed 150oC.
12) In the event that the astern spray system does not function correctly,
running at Full Astern (61.6rpm) is to be restricted to 30 minutes.
The upper temperature limit of the LP turbine exhaust chamber under
these circumstances is 230oC.
4. Speed operation
5) After change over of the auxiliary exhaust to the atmospheric
condenser, stop the vacuum pumps.
6) Keep the packing steam supply on until the condenser vacuum reaches
atmospheric pressure.
7) After confirming that make-up and spill etc. from all auxiliaries led to
main condenser, heater, gland condenser, etc. have stopped, stop the
gland exhaust fan and condensate pump.

2) Confirm that the astern guardian valve is open.
3) Confirm that turbine drain valves are open.
4) Restriction on the astern operation is shown in the following diagram,
and carry out astern operation within this restriction
AHD Shaft Revolution
The nozzle control valves shall be used for changing the turbine load condition
between NCR and MCR.
If turbine load reducing is ordered during MCR running, the manoeuvring
valve may be throttled at first because it can be controlled through AHD.
MCR~AST. Full while keeping the nozzle control valves open.
It is recommended to close nozzle control valves during long periods of
operation at NCR or less load conditions.
8) After six (6) hours of the engine cooling period have passed, stop the
turning motor and set-off the turning clutch and lock it up.
9) After confirming stop of turning motor, stop lub. oil pumps.
10) Switch off electric source and air source to control console for
extended stop periods.

0 rpm Valve condition No. of Max. Output Main Shaft

1) 2)
No.1* No.2* Nozzles (PS) RPM
“D” rpm
AST Open 21+6+9 39,000PS(MCR) 88
Manoeuv. Valve Lift close open 21+9 37,900PS Abt. 87.2
AHD

③&④ open close 21+6 35,100PS(NCR) Abt. 85.0

Valve Close close 21 27,700PS Abt 78.5
“E” mm ⑥
⑤
Remarks : “Output” shall be obtained at bleeding condition.
AST Steam chest press at abt. 24.5 bar
“D” rpm : Astern torque Limit
*1 : Starboard side => 6 nozzles
“E” mm : Manoeuv. Valve lift to limit astern steam chest pressure *2 : Port side(LPT side)=> 9nozzles
③,④,⑤ & ⑥ : Manoeuv. Valve lift is controlled by time program.

5) Maintain the condenser vacuum at the normal value. Caution

6) During running, pay particular attention to noise from within the
turbine, temperature of the LP turbine exhaust chamber wall, vibration,
noise and bearing temperatures.
If nozzle valves are kept in the same positions for a long time, the valve
rod may stick. Therefore, move these valves by a few millimetres once a
day
1.1.2.3 Finished with Engine

7) Running at Full Astern (61.6rpm) must not exceed 2hours. In addition, 1) Upon receiving an order for Stop and Finished with Engine, slow
after intermittent full astern running, total full astern running is not to down and put manoeuvring lever in the stop position.
exceed 2hours. During slow down, confirm opening of drain valves, astern guardian

Final draft / 2007. 12. 28 1- 8 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.2 Main Boilers 2. Performance for Main Boiler at F.O Firing

1.2.1 Main Boilers Planning Data Item Unit NOR MCR

1. Design Condition Steam Evaporation kg/h 52,000 68,000
SH outlet steam temp. ℃ 515 515
1) Boiler type : Kawasaki UME 68/52 two-drum water tube natural
Air temp. at F.D.F. inlet ℃ 38 38
circulation boiler Temperature *
Air temp. at S.A.H outlet ℃ 120 Abt. 115
2) Quantity : Two boilers per ship
Feed water temp. ℃ 145 145
3) Fuel
a) Bunker “C” oil (Design fuel oil) SH outlet bar 60.3 60.3
Pressure
Carbon (%) 87.75 Drum bar 68.7 70.6
Hydrogen (%) 10.50 *
Boiler efficiency based on high calorific % 88.5 Abt. 88.3
Sulpur (%) 1.2
*
Oxygen (%) 0.4 F.O consumption(design fuel) kg/h 3,733 4,877
Nitrogen (%) 0.15 * 2
Firing rate in furnace kg.FO/m h 48.8 63.7
Moisture (%) -
*
Standard corrected higher calorific value : 43,040 kJ/kg(10,280 kcal/kg) Boiler total draft loss excluding air and gas ducts at
mmAq 417 712
b) Low grade oil excess air of 10%
ISO-FRM55H or equivalent Reference (Performance for fuel gas firing)
Viscosity : Max. 7.00 cSt at 50℃
Sulpur : Max. 5% Methane gas burning quantity (based on higher
kg/h 3,227 4,217
Vanadium : Max. 600ppm calorific value of 12,600kcal/kg)
c) L.N.G. boil-off gas
Higher calorific value : 55,600 kJ/kg (13,280kcal/kg)
4) Pressure : Design pressure: 75.5bar Note
Hydrostatic test press: 113.3bar Marked * values are shown at the design fuel oil
Steam press. At SH outlet: 60.3bar
5) Temperature : SH outlet steam temp.: 515℃
FW temp. at economiser inlet: 145℃
Air temp. at forced fan inlet: 38℃
Air temp. at steam air heater out: 120℃
6) Evaporation : Max. Evaporation: 68,000kg/h
Nor. Evaporation: 52,000kg/h
7) Heating surface Water wall (half periphery): 139m2
Generating tubes: 717m2
Economiser(including fin plate):1,419m2
Primary S.H: 231m2
Secondary S.H: 72m2
Steam air heater (including fin plate): 708.5m2
Total: 3,286.5m2
8) Boiler efficiency at F.O firing (Nor. Evap): 8.5%
9) Furnace volume: 52.7m2
10) Firing rate at NOR. Evaporation: 48.8 kg F.Om2 / h
11) Safety valve set press
Drum high set: 75.5bar
Drum low set: 75.3bar
Superheater: 64.7bar

Final draft / 2007. 12. 28 1-9 Part 1 Engineering Data for Main Equipment
CLEAN FORCE
3. General Specification
Each boiler is of the two drum type construction, with one steam drum and one
water drum and consists of the boiler proper, boiler casing, superheater,
economiser, air heater, fuel and gas firing equipment, mountings, fittings and
other accessories.
The Boiler pressure parts are consist of steam drum, water drum, boiler tubes,
water wall header, superheater, desuperheater, and economiser.
1) Drum
The drum internals are fitted in the steam drum, such as steam separator
baffles, swash plates, feed distribution pipes, chemical feed pipe, dumping
chamber for feed water regulator and sampling pipe and auxiliary
desuperheater.
Bottom blow-off pipe and superheater steam temperature control
desuperheater are fitted in the water drum. Nozzles are welded to the drum
for the attachment of mountings. Thermal sleeve of the air cooling type is
provided for the nozzles of feed water inlet, desuperheater inlet and outlet,
and chemical feed.
2) Furnace
The furnace walls are of the membrane construction. The tubes forming the
furnace sides, floor and roof and front and real walls are of 63.5mm
diameter.
The re-moving door for superheater tube is provided at the front wall. Two
peep holes are provided in the side wall to watch furnace condition.
Two rows of screen tubes are provided at furnace outlet and the tubes are of
63.5mm outer diameter inline arrangement.
The Steam generating tubes are arranged in larger pitch “staggered” and
expanded to the drums, and the tubes are of 45mm outer diameter.
The external down comer tubes are arranged at the outside of the boiler
casing. The down comer tubes are arranged to keep stabilized water
circulation. The boiler is designed so that the divided water circulation
circuits are established for furnace front wall, furnace rear wall and
generating tube bank where the rate of heat adsorption is different.
The headers are of carbon steel pipe and fitted with a round hand-hole and
one oval hand-hole which are provided on the end plate of header for
inspection and cleaning.
3) Superheater
The superheater is arranged behind the screen tubes. The superheater is of
vertical U tubes of 38.1mm outer dia. and in line arrangement to prevent
slugging. Each tube is welded to sub-header and forms tube panel. Each
sub-header is welded to main headers by connecting tubes. The clearance of
each straight tube is maintained by small ally metal spacers. Each tube
panel is supported by the support tubes (63.5mm) and screen tubes.
Final draft / 2007. 12. 28
Machinery Operating Manual
The spacers and support metal are suitable alloy metal for the maximum number of burners is automatically operated by the automatic combustion
temperature and welded to the superheater tubes or support tubes to secure control signal, and remotely operated by pushbutton when necessary.
minimum metal temperature and to prevent from high temperature
corrosion loop of the superheater forms a walk-in space for inspection and 9) Seal Air Fans
cleaning. Two seal air fans are supplied, the connection lines from each boiler are
Materials for tubes and headers are suitable for operation at the designed made common before the suction side of the fans, only one fan will be in
maximum steam temperature. The main headers are arranged at the bottom operation with the other set to standby. The seal air fan provides cooling
of boiler to secure easy access and maintenance. The main headers are fitted and sealing air to the burner flame eyes, sootblowers and glands.
with a oval hand-hole on each section to inspect the header inside. The seal air pressure is monitored by the IAS, an audible alarm operates
when the pressure falls to below the set point of 35mbar.
4) External desuperheater for temperature control
A temperature control device for main steam system is fitted on external
desuperheater type. The desuperheater with an automatic temperature
control valve is designed to control the steam temperature of 515 ± 5°C in
the range of boiler normal evaporation and more, and is furnished between
the primary and secondary superheaters.
5) Economiser
A finned extended surface type economiser is placed above the boiler tube
bank. The economiser is made up of loosely spaced, continuous loop
elements, welded to the terminal headers at each end. Each element tube is
of 38.1mm diameter carbon steel with a spiral steel fin, connected by U-
bands to form an integral loop. All the elements are arranged in a staggered
pattern and welded to the inlet header (upper) and outlet header (lower).
The outside of the terminal headers are provided with hand-holes to allow
access. The economiser is insulated and surrounded by a steel casing with
large removable access panels.
Feed water enters the inlet header at the top and flows through the elements
to the bottom header and from there to the boiler steam drum. This is
counter to the gas flow which passes upwards over the elements and so
prevents a high temperature difference across the economiser tube.
6) Forced Draught Fans
Two fans are situated on main deck and are controlled by adjustable vanes,
automatically positioned by the combustion control equipment. The fans are
arranged to supply their respective boilers. One forced draught fan can be
put into service on two boilers by manually opening the crossover
connections on the air supply trunking. When put into service after opening
and closing the respective crossover valves, the selection switch on the
boiler control panel must be changed over to the correct position in order
that the combustion management system can control the vanes.
8) Combined Oil and Gas Burners
The boiler is fitted with three combination fuel oil and gas burners mounted
in the furnace roof wall. The fuel burner is a steam assisted pressure jet type
consisting of atomiser gun, forced draught air register and a fuel oil shut-off
valve. The fuel is distributed to the burners from a burner manifold and
branch valve. The fuel is distributed to the burners from a burner manifold
and branch connection pipe. The operation of increasing or decreasing the
1 - 10 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

4. Alarm & Trip List

Press Temp Press Temp

Item Tag.No. Description Remark Item Tag.No. Description Remark
bar ℃ bar ℃
Feed Water N2 Gas
A-104 PX-102/202 Feed water press 84.0 High Alarm A-907 PS-021 N2 gas supply pressure S/W 2 Low Alarm/Purge Stop
57.0 Low Alarm Furnace Air
Drum A-805 TX-143/243 Wind box air temperature 195 High Alarm
A-204 PX-116/216 Drum pressure 73.5 High Alarm A-656 TX-142/242 ECO outlet gas temperature 250 High Alarm
53.9 Low Alarm Drum Level
Main SH steam A-703 Monitor S/W for drum level mm
A-312 PX-113/213 Main SH steam pressure 63.7 High Alarm LX-103/203 MS-103/203-1 +200 High High Turbine Trip
53.9 Low Alarm LX-103/203 MS-103/203-3 +180 High Main Feed Water V. Close
A-303 TX-113/213 Main SH steam Temperature 525 High Alarm LX-102/202 MS-102/202 +160 High Auto Slow Down
A-304 TX-114/214 Main SH steam Temperature 550 High Trip LX-103/203 MS-103/203-2 +150 High Turbine Interlock
Atomising Steam LX-103/203 MS-103/203-3 +140 Main Feed Water V. Open
A-625 PX-011 Atomising steam supply pressure 17..5 High Alarm LX-102/202 +140 High Alarm
12.0 Low Alarm LX-102/202 -150 Low Alarm
A-609 PX-114/214 Atomising steam pressure 9.8 High Alarm LX-103/203 MS-103/203-1 -170 Low Auto Slow Down
2.0 Low Alarm LX-103/203 MS-103/203-2 -200 Low Low Boiler Trip
Fuel Oil LX-102/202 MS-102/202 -200 Low Low Boiler Trip
A-605 PX-132/232 FO pressure 2.5 Low Alarm/FO
2.0 Low Alarm/Dual
A-622 PS-131/231 FO header pressure S/W(for FO) 2.2 Low Low FO Trip/FO
A-623 PS-132/232 FO header pressure S/W(for Dual) 1.8 Low Low FO Trip/Dual
A-606 TX-131/231 FO temperature 140 High Alarm
80 Low Alarm
A-607 TS-131/231 FO temperature S/W 70 Low Low FO Trip
Fuel Gas
A-435 PX-121/223 FG differential pressure 0.67 High Alarm
0.015 Low Alarm
A-437 PX-122/222 FG differential pressure 0.72 High High FG Trip
0.012 Low Low FG Trip
A-432 TX-122/222 FG temperature 50 High Alarm
10 Low Alarm
A-431 TS-022 FG main line temperature S/W 0 Low Low FG Main V. Trip

Final draft / 2007. 12. 28 1 - 11 Part 1 Engineering Data for Main Equipment
 CLEAN FORCE Machinery Operating Manual

5. Performance Curve

TYPE UME 68/52 MAIN BOILER OIL FIRING FUEL GAS BURNER PERFORMANCE CURVE (100% CH4) FUEL OiIL BURNER PERFORMANCE CURVE
ESTIMATED PERFORMANCE CURVE GAS FIRING

90 8000 700

EFFICIENCY (OIL FIRING) 7000 20

85
rs

FUEL OIL CONSUMPTION (kg/h)

r
ne rs

ne
6000 600 ur rne

ur
)B Bu

)B
EFFICIENCY (GAS FIRING) o(
2 ( 3)
BOILER EFFICIENCY ( % )

urner

(1
rs

rs
80 Tw ree

ne
15

urne
Th

rne

O
5000

Bu
One (1) B

F.O Pressure (bar)

(2) B

(3)
ee
4000

Two
75

Thr
500 10

MCR 4877 kg/h

Nor. 3733 kg/h
FO CONSUMPTION
3000
70

2000 5

F.G Pressure (mbar)

Min. Press. (F.O Only) : 2.2 bar
FG CONSUMPTION 400 Min. Press. (F.O/F.G) : 1.8 bar
65 Boiler Trip. (F.O Only) : 1.5 bar
Boiler Trip. (F.O/F.G) : 1.0 bar
NOR

1000

60 MAX 0
0
500 1000 1500 2000 2500 3000 3500 4000 4500 5000
5 10 15 20 25 30 35 40 45 50 55 60 65 70 F.O Flow (kg/h)
300
EVAPORATION (TON/H)

600 1000

200
550 SH TEMP. (GAS FIRING)
900

500 515 C 800

SH OUTLET STEAM TEMP. ( C )

450 SH TEMP. (FO FIRING) 700

DRAFT LOSS ( mmAq )

Max. 4217 kg/h

100

Nor. 3227 kg/h

400 600

Min. Press. : 26 mbar

350 500
F.G. Trip. : 11.1 mbar
300 400
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DRAFT LOSS (3-Burners)
250 300
F.G Flow (kg/h)

200 200
NOR

MAX

150 100

100 0
5 10 15 20 25 30 35 40 45 50 55 60 65 70

EVAPORATION (TON/H)

Final draft / 2007. 12. 28 1 - 12 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.2.2 Instructions for Main Boiler Operation supply hydrazine to feed water. (C) Combustion air and flue gas line

1.2.2.1 Putting Boiler in Service Note 1) Damper position in air duct.

1. Inspection and checking items prior to filling boiler with water
1) All internal parts of the boiler and piping should be clean and free of
foreign matter.
2) The furnace gas passages and air passages should be clean and free of
foreign matter.
3) Check dampers for operation and indicators.
Feed water to be supplied through economiser and until water
appears in the water gauge glass. Caution
Confirm that the dampers are positioned to permit the correct supply of
2) Open eco. vent valve and close it after air vent. combustion air to each boiler
Control damper operations using the push buttons on the damper remote
3) Change over to main feed line in order to ensure main and aux. feed panel on the Boiler Gauge Board (BGB)
water line.
2) Close manually inlet vane of FDF for operating BGB manual loader.
4) Fill boiler with distilled feed water through main feed water line until
water level rises 100mm in water gauge. 3) Start F.D.F.

Note 5) Blow water through water gauge valves in order to check the operation (D) Chemical feed & blow down line
Following dampers to be checked : All dampers in air passage and of the level gauge.
gas passage. 1) Test of boiler water
(B) Fuel oil line - pH
4) Close drain valves of level gauge. - Electrical conductivity (µ S/cm)
< Start the fuel oil service pump> - Phosphate (PO4-)
5) Check operation of safety valve. - Hydrazine (N2H4)
1) Confirm that fuel oil Circulation (Use DO for cold start). - Chloride ion(Cl-)
Note
Put in proper operating order after hydraulic test. 2) Confirm that fuel oil pressure (approx. 28bar at F.O pump outlet). 2) If above items is overlimit, then Supply boiler compound or operate
“blow down”.
6) Check that the following are closed: 3) Confirm that fuel oil temperature.
- Manholes of drum - Hand-holes of header 3. Lighting the burner and raising steam pressure
Note
7) Check that the following are closed: If using heavy oil, keep fuel oil temp. at levels from which a In case of cold start
- Boiler access doors - Header casing doors viscosity of RW no.1 can be obtained within 80 seconds using the
- Access doors for air duct and gas duct F.O heater Leave the following valves open :
- Root valves of start-up piston valves
2. Inspections and setting prior to putting boiler in service 4) Confirm that atomising air(steam) pressure. - S.H header drain valves
- Steam drum vent valve
(A) Main boiler & feed water line Note
For atomising air, confirm that the air supply pressure is 7.0 ~ 9.0 1) Burner lighting – up for using diesel oil and normal tip with air
< Open the following valves> bar and that atomising air press. is maintained within the range 3.0 atomising.
- Water gauge valves - Steam drum vent valves ~ 8.0bar. For atomising steam, confirm that the steam supply
- S.H. vent & drain valves - Press. Gauge valves pressure is approx. 17.0bar 2) Furnace pre-purge by manual..
- Feed water inlet valves - Press. Signal for safety interlock
5) Confirm that F.O emergency shut off valve close. Re-purge switch in the BGB inside to be “ON (BY-PASS)” and push
Note the No.1 burner “ON” button. After furnace purge, re-purge switch turn
S.H vent valves to be opened at cold start (steam press. is less 6) Confirm that F.O piston valves close. on “NOR”.
than 15.0bar)
7) Check out and inspect burner atomiser. 3) Push the base burner button on BGB.
< Close the following valves>
- Bottom blow-off valves - Surface blow-off valves 8) Open the F.O cut-off cock for burner carrier. 4) Confirm that all burner air registers open and F.D.F inlet vane fully
- Main stop valve - Water wall header drain valves open.
- Eco. Vent valves and drain valves Caution
Confirm that fuel oil is not leaking into the furnace 5) Confirm that Furnace pre-purge for approx. 80 sec.
1) Fill boiler with distilled feed water through aux. feed water line and

Final draft / 2007. 12. 28 1 - 13 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

6) Furnace purge finish. Illustration 1.2.1a Starting Up Curve (with Continuous Fire)

7) Confirm that all burner register close. Starting Up Curve (with Continuous Fire)
Type UME 68/52 Main Boiler
8) Confirm that F.O emergency shut off valves open. 280

260 80.0
9) Confirm that ACC F.O control vale and F.D.F inlet vane are set at 240 70.0
ignition position automatically. 220 60.0

Boiler Water Temperature (℃)

Drum Pressure (bar)

200 Drum 50.0
Note Pressure
180 40.0
In case the manual loaders are in “LOCAL” F.O control valve and
160 30.0
F.D.F inlet vane shall be manually set up at the ignition position. Boiler Water Temperature
140 20.0

Caution 120 10.0

Ignition interlocks of combustion air and fuel oil supply are provided 100 0
as described below. 80
Approx. 3.5 ~ 20mbar air supply interlock is provided for burner 60
ignition sequence . in case of too low(3.5mbar) or too high(20mbar) 40
draft at wind box before ignition, the ignition sequence does not 20
progress, and an alarm will be issued. 0
Fuel oil supply interlock is provided for burner ignition sequence. In 0 1 2 3 4 5 6 7

case F.O pressure at ignition is more than 8.0bar, the ignition ab't 3 Hr ab't 2 Hr ab't 2 Hr

sequence does not progress, and an alarm will be issued. 1) Nor. atomizer L806S 1) Nor. atomizer L806S 1) Nor. atomizer L806S

Burner & Fuel

(air atomizer) (air atomizer) (air atomizer)

10) Check that Diff. Press. between wind box and furnace. 2) Diesel oil 2) Diesel oil 2) Heavy oil

3) Continuous fire 3) Continuous fire 3) Continuous fire

11) Check that Retractable igniter is inserted and heated up. 4) F.O consumption : 4) F.O consumption : 4) F.O consumption :
about 160 kg/hr about 200 kg/hr depend on the ho1
(F.O press. 2.2 bar) (F.O press. 2.7 bar) start program.
12) Confirm that F.O piston valves open.

60.3 bar
13) Burner flame eyes catch the flame.

50.0 bar
Steam Consumption

10.0 bar
2.0 bar
2.5 bar

12.0 bar

18.0 bar

30.0 bar
Pressure
Warm-up Operation

Dump
14) Burner air register opens. Turbo Generator
Warm-up Operation
15) ACC F.O control valve and F.D.F inlet vane ignition position are
Aux. steam & Fresh water pump
released automatically.
Fully open

16) Retractable igniter is pull out. Manual start-up valves (BV-305/311) Close at steam press over 15 bar
Fully open Start-up piston valve (BV-322) is closed
Valve Handling

automatically by ACC
17) No.1 burner firing condition. Start-up piston valve (BV-322)
Fully open Slightly open the drain V. BV-323
18) Adjust F.O press and air atomising pressure. SH & Desh drain valve
(BV323, 309, 315, 316, 319) To be fully closed after drain out
Fully open
Note
Steam drum air vent valve (bv-212) Fully close
Keep F.O. Press at minimum press(2.2bar) and atomising air press
0 1 2 3 4 5 6 7 8
at 3.2bar on the atomising steam line press. gauge. Operating Time (Hour)

19) Steam raising with continuous fire in accordance with the “Main start- Note
up curve”. Take care not to avoid supplying excessive fuel oil to raise pressure.
Keep F.O. Pressure at min. levels (2.2bar). Refer to the chart attached for “BURNER TIP OF STEAM ATOMISING PERFORMANCE CURVE”

Final draft / 2007. 12. 28 1 - 14 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

20) Confirm that F.O temperature. Illustration 1.2.1b Characteristic Curves of Y-jet Type Steam Atomiser

21) Confirm and check that drum water level and generation of steam Characteristic Curves of Y-jet Type
before blowing down of the gauge glass. Steam Atomizer

Notes
22) Confirm that escaping of approx steam press 2.0bar and close steam Used Oil : Heavy Oil
drum vent valve. Oil Viscosity : R.W. No.1 80 sec (18 cSt)
Atomizer Steam : Ratio Control Pressure
Cold Start Use
23) Check that drum water level because the boiler warm up, the level in the Used Oil : Diesel Oil
gauge glass will rise. The water level may be lowered by using the Atomizer Steam : Ratio Control Pressure
surface blow valve. Atomizer Air Consumption : Max. 2.75 Nm3/min
2000

24) Confirm that steam press. rises to approx. 12bar.

Note
When steam press. rises to approx.12bar, start warming up the
auxiliary steam line and start the steam air heater. Close the
superheater drain valves at a steam press. of 10~12bar. SH outlet
drain valve to be kept opened.
1500

S
25) Close superheater drain valves.

06
L8
26) Circulate heavy oil through FO heater and drain the atomising steam
line.

ate
wR
Fuel Oil Flow Rate (kg/h)

Flo
27) Change the fuel to heavy oil and the air atomising to steam atomising.

Oil
(bar) (kg/cm2)

el
Fu
28) Confirm that steam press. rises to approx. 15bar. 1000 10 10.2 200

Minimum F.O Press

9 9.18 180
Note Atomizing Steam
Pressure
After steam press. rises to approx. 15bar steam raising is 8 8.16 160
proceeded by hot start program of ACC fuel oil flow and air flow

Atomizing Steam Consumption (kg/h)

quantities are controlled by ACC 7 7.14 140

Atomizing Steam Pressure

6 6.12 120
29) Confirm that steam press. rises to approx. 18bar.
500 5 5.10 100
30) Start the feed water pump.
4 4.08 80
Atomizing Steam
31) Changed and adjust fresh water controller(FWC) to “AUTO” operation. Consumption
3 3.06 60

32) Close SH vent valves. 2 2.04 40

1 1.02 20
33) Leave open superheater vent valve(Start up valve).
0
0 2 4 6 8 10 12 14 16 18 20 bar
34) Steam press. rises to approx. 50 bar, and start the turbo generator.
Fuel Oil Supply Pressure
35) The start – up piston valve is closed by air combustion controller(ACC)
when steam flow quantity is at setting valve.

Final draft / 2007. 12. 28 1 - 15 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

4. Supply Steam

1) Change steam temperature controller(STC) to “AUTO” operation.

2) Pressure rise to working steam press.

3) Open the drain valves in the main steam press.

4) Open the main steam by-pass valve for warming up of main steam
pipe steam line.

5) Keep the drum water level at normal

Caution
While the main steam stop valve is opened, if the water level is
high or main steam stop valve is opened rapidly, carry-over may
occur

6) Open slowly the main steam stop valve.

7) Proper steam flow to be kept through superheater..

Note
Confirm the superheater outlet steam temperature

8) Fully close superheater air vent valve (Start up valve).

Note
The start-up piston valve is controlled by ACC.

9) Confirm ACC, FWC and STC in “AUTO” operation and adjust if

necessary.

5. Start from Hot Condition (Steam pressure over 15.0bar)

Raising steam pressure procedure can start from corresponding pressure.

In case of using diesel oil and steam atomising, the fuel oil flow rate of burner
is more than that of C-heavy oil and steam atomising.

Flow rate of diesel oil and air atomising is almost same as that of C-heavy oil
and steam atomising.

Therefore, C-heavy oil and steam atomising or diesel oil and air atomising is
recommended for raising steam pressure from warm condition.

At initial ignition of first burner, neither diesel oil and steam atomising nor C-
heavy oil and air atomising is permitted to secure the burner ignition.

Final draft / 2007. 12. 28 1 - 16 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.3 Generator Turbine 2. Alarm and Trip List

1. Technical Data

1) Turbine Item Dimension Normal Alarm Trip

Type: SHINKO RG92-2
Multi-stage, Impulse type with
ELECTRIC *1,980±20
Reduction gear
Number of units: 2 sets OVER SPEED r/min(rpm) 1,800 -
Rate output (Electrical Load): 3,850 kW MECHANICAL *2,000±20
Turbine rated speed: 8,145 rpm
Generator rated speed: 1,800 rpm
Rotation (Viewed from turbine): Clockwise VAC. mmHgV *300±40
Main steam condition: 58.8 bar (60kg/cm2) at 510°C
HIGH EXH.PRESS - * 1.0±0.1
Turbine exhaust Steam: 710 mmHg
Permanent speed variation: within 4% ATM bar *0.7±0.1

2) Reduction Gear *Valve set value

SENTINEL VALVE bar - -
Module: 5 0.7±0.1
Pressure angle: 20°
Helical angle: 14° LUB.OIL PRESS. bar 1.0~1.5 **0.6(+0 -0.1) *0.5(+0 -0.1)
Pitch circle diameters: Pinion 206.123 mm
Wheel 712.258 mm
Number of teeth: Pinion 40 LO SUPPLY TEMPERATURE ℃ 35~48 *53±3 -
Wheel 181
Revolutions per minute: Pinion 8,145 rpm
BEARING TEMPERATURE ℃ 46~77 *75(+3 -0) -
Wheel 1,800 rpm
Gear ratio: 4.525

TURBINE ROTOR AXIAL MOVEMENT mm - *0.5±0.1 *0.7±0.1

3) LO Tank
Capacity: 2,400 litre

TURBINE ROTOR VIBRATION µm p-p - *80±10 *140±15

4) Approximate Weight
Turbine (Upper casing, Rotor, Pinion): 2,000 kg
Reduction gear (Upper Casing): 210 kg *Normal level
LOW LO TANK LEVEL mm Normal level
(Wheel with wheel shaft): 1,470 kg -60 ±10
Governor Unit: 140 kg
Lub. oil cooler (Net dry): 680 kg bar
SEALING STEAM PRESSURE 0.01~0.2
Total weight (Not including generator weight): 20,000 kg mmHgV *Low (0 ~ -13.3)

*START *STOP
5) Governor PRIMING LO PUMP START & STOP bar
0.4(+0 -0.1) 1.0 ~ 1.5(+0 -0.1)
Type: WOODWARD UG-10D
TURNING LO PRESS. INTERLOCK(at T/G STOP) bar *0.2~0.9 *0.2±0.05 ***

INLET STEAM PRESS bar - *54 bar

* Mark to be supplied by maker

** Mark to be supplied by shipyard
*** This signal is used for interlocking condition of turning, not for alarm

Final draft / 2007. 12. 28 1 - 17 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

3. Construction
1) Turbine
(1) Casing
The casing consists of the upper casing and the lower casing
combined together firmly by bolts on the horizontal flange.
The steam chest is casted with the high pressure side of the upper
casing and provided with the main trip valve and governing valve.
The governor side of the lower casing is bolted to the vertical joint
face of the turbine bearing pedestal, which is supported by the
flexible plates.
(2) Nozzle and Diaphragm
The thrust bearing face is divided by many separate fan-shaped
thrust pads, each of which is inclined by fulcrum and thus wedge-
like oil film is formed and thrust load is taken by this film.
(7) Rotor
The turbine rotor is solid of the discs and shaft.
The governor side of the rotor is provided with the worm and
worm wheel for driving the governor, the overspeed trip device
and the axial excessive displacement trip device.
Illustration 1.3.1a Governing system
The rotor is connected to the pinion shaft by the Thomas type
flexible coupling.
The critical speed of the rotor is about 1050rpm at the generator
(2) Governing Valve
The governing valve is of the bar lift type having 3valves and
controlled by the governor through the connecting rod and the
lever. The valve stem is connected with the lever at the top end and
also is connected with the valve beam.
The valve lift is regulated by the hydraulic servo piston through the
connecting rod lever valve stem and valve beam to control the
steam quantity in order to keep the turbine revolution constant.
Main Steam
Inlet
Main Stop Valve

The first stage nozzle of the turbine is secured to the upper casing shaft. So take care never to stay near the critical speed during the Limit Switch
for ESV Close SHUT
by the bolts, and the part of nozzle plate periphery is fitted in the starting of the turbine (ACB Trip)

casing. The 2nd stage ~ 6th stage have nozzles welded to the OPEN

diaphragms and the 7th stage ~ 9th stage have nozzles cast in the (8) Blade Governor
Starting
Lever
Valver
diaphragms. To Nozzle
M
Trip
The Blades are installed in T groove, which are groove on Lever

The upper half of diaphragms are fitted to the upper casing on the peripheries of rotor discs and fixed firmly by the stopper blades Trip
Cylinder Limit Switch for
UG10D
Woodward
GOV. Valve Full Open
horizontal plane by set screws, so they can be lifted with the and liners that are secured carefully after installation. Governor
Hydraulic
upper casing for overhauling. Limit Switch for
Overspeed Indication
Servo Motor

2) Governing System
(3) Diaphragm Packing Solenoid
Valve Reset
Knob
To L.O. Tank
The governor is o f the hydraulic type and the system consists of the
The 2nd ~ 9th stage diaphragm packing are solid and spring back woodward UG-10DM speed governor, the hydraulic servomotor, and
type and the packing of each stage are divided into four segments the governing valve. Orifice

on which the springs are provided.

The governor detects the fluctuation of the turbine revolution and
(4) Gland Packing
functions to keep the turbine revolution constant by adjusting the steam To L.O. Tank
Control oil
Strainer

Gland Packings are solid and spring back type and they are fitted quantity by means of the governing valve through the lever mechanism
in groove of packing cases, and supported on the horizontal joint. and the hydraulic servomotor. Press. Adjust. Valve
To Bearings
For Lub. Oil
The Packing cases are separative upper and lower. The packing Press. Adjusting Valve
For Control Oil
cases are bolted at the horizontal joint by bolts and the lower The quantity of steam is controlled by the governor valve so as to
To L.O.
halves of cases are fitted to the turbine casing by set screws on maintain turbine speed at constant value through the hydraulic servo Check Tank
the turbine horizontal joint. motor and lever mechanism. Valve
Duplex L.O.
The packings are divided into four segments on which the springs Main
Stariner

L.O. Pump
are provided. (1) Speed Governor
Priming
L.O. Pump
Check
M Valve
(5) Radial Bearing UG-10DM type woodward governor is adopted which is provided Cooling
with standard mechanisms of speed synchronization, speed droop Water
Turbine bearing is of plane type, which has good stability for high L.O. Cooler
and load limit. This speed governor is installed on the top of
speed revolution. Turbine bearing has lubrication from the holes
on top and both sides of the horizontal connection, and the bearing box in front of the turbine.
lubricating oil discharges from the both sides.
The output spindle of the speed governor is connected, via linkage,
(6) Thrust Bearing with the hydraulic servomotor, the output spindle of which makes a
stroke in accordance with the magnitude of speed governor output.
The thrust bearing for turbine rotor is fitted at the front bearing
pedestal and tilting pad type thrust bearing is adopted.

Final draft / 2007. 12. 28 1 - 18 Part 1 Engineering Data for Main Equipment
CLEAN FORCE
3) Emergency Trip System
The over speed trip, the low lub.oil pressure trip, the low vacuum trip
and turbine rotor excessive vibration trip devices are furnished on this
turbine.
In the emergency cases such as the turbine runs overspeed, the lub.oil
pressure drops, the vacuum lowers, the rotor vibrates excessively each
trip device functions to close the main trip valve and governing valve to
stop the turbine.
(1) Main Trip Valve
The main trip valve is fitted horizontally on the turbine steam chest
and steam is led into the turbine through the valve.
The valve is composed of the main and sub. valves so as to have less
lifting force in the valve, and sub. valve is made in one unit with the
valve stem.
(2) Emergency Trip Device
a) Low lub.oil pressure trip and low exhaust vacuum trip devices.
The low oil pressure trip and the low exhaust vacuum trip
equipment consists of a respective pressure switch to detect the
oil pressure from the bearing oil system and turbine exhaust
vacuum and the solenoid valve in the main trip valve oil line.
Under normal running as long as the bearing oil pressure
remains normal and steam vacuum in turbine exhaust chamber is
normal, the solenoid valve stays closed, but it opens to function
through the pressure switch as soon as the oil pressure drops or
the turbine exhaust vacuum downs.
b) Mechanical Overspeed Trip
When turbine revolutions exceed the rated value for some
reason and reach 110 ±1% of the rated revolutions, this device
provided at the end of the turbine shaft actuates to stop the
turbine.
When turbine speed reaches 110±1% of the rated speed the
eccentric force of the trip spindle overcomes the compressive
force of the sprig and the trip spindle comes out and hits one end
of the trip lever.
c) Electric Overspeed trip
When the turbine speed increases excessively, speed monitor
detect it an trip solenoid valve is activated by its signal.
Final draft / 2007. 12. 28
Machinery Operating Manual
Accordingly control oil pressure is lost then turbine stops by
means of shut the main stop valve.
(3) Sentinel Valve
This valve is fitted to the turbine casing and serves to issue alarm
by detecting abnormal rise in the exhaust pressure.
3) Reduction Gear
The reduction gear is of the single reduction single helical type. The
pinion and the gear wheel shaft are connected to the turbine rotor and
the generator rotor by means of the flexible coupling. On the turbine
side of the gear wheel shaft, the main oil pump is fitted.
(1) Gear Casing
The gear casing is composed of the upper casing, and lower
casing. The turbine side of the lower casing is combined with the
turbine lower casing on the vertical surface flange as mentioned
before. The lower casing is opened to the oil tank, which is a part
of the common bedplate.
(2) Bearing
The pinion bearing of turbine and generator sides are ordinary
plane type and have two oil inlets on the split plane. Thrust collar
is shrink-fitted on the pinion shaft end.
The thrust bearing of the taperland type is fitted at the pinion
generator side. The metal surface of the thrust bearing consists of
the taper and flat plane, and makes the effective oil film.
(3) Oil Sprayer
The oil is supplied to meshing surface of the reduction gear by
the oil sprayer. The sprayer is of the perforated nozzle injection
type and fitted in the gear casing wall.
(4) Turning Equipment
It is constructed that this turning equipment is able for motor
turning and manual turning.
For the motor-turning, only start the turning motor, the clutch
automatically engage when the turning motor start.
When the turning clutch is engaged, the clutch automatically
disengage when the motor is rotated by the turbine rotor.
1 - 19
4) Lubricating System
The generator turbine is equipped with a lubricating oil system. The
oil piping arrangement is made up of a high pressure line for the
control oil and of a low pressure line for the bearing and the reduction
gear lubrication. Oil is sucked from the oil tank in the common bed
and pressurized by the main oil pump and adjusted its pressure by the
oil pressure adjusting valve and supplied to the high pressure line for
the control oil and of the low pressure line for the lubrication.
(1) Main Oil Pump
The main oil pump is of the gear type. The pump is driven by the
turbine reduction gear wheel shaft through the gear. A valve
serving as the safety valve is fitted on the pump casing. The valve
is composed of the spindle and spring, and regulates the pump
delivery pressure directly.
(2) Priming Oil Pump
The priming oil pump is of the gear type and driven by the motor.
The pump is used for the turbine start and stop.
The pump is started and stopped automatically. In case the switch
of the starter is “AUTO”, the pump is started automatically at abt.
0.04bar of the bearing oil pressure and stopped automatically at
0.09~0.15bar.
Note
It is important to confirm that the priming oil pump is started
and the bearing oil pressure is normal at turbine starting
(3) Oil Pressure Adjusting Valve
A part of oil sent from the oil pump is adjusted by the control oil
pressure adjusting valve to the 6.37 ~ 9.32bar and acts as control
oil, and the remaining oil is adjusted by the L.O. pressure
adjusting valve to 0.98~1.47bar and acts as lubricating oil. For
adjusting valve the oil pressure, remove the cap and turn the
adjusting screw. Clockwise turning of the adjusting screw makes
the actuating oil pressure up and vice versa.
Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

Illustration 1.3.1b Control Oil Press. Adjusting Valve normal value. operation of turbine.

6) Supply the air to the sealing controller and check the sealing steam (1) Confirm the pressure, temperature, vibration, etc. of all the parts
Control supply. in normal conditions.
L.O Pressure
Oil Pressure (2) Turn the main stop valve handle clockwise for about a 1/2
Adjusting
Adjusting (1) Confirm the packing steam pressure 0.01~0.2bar. revolution after the valve stem reached the stopper (full open).
Valve (3) Try overspeed trip test at no load if chance is offered.
Valve
7) Open the needle valve for gland steam exhaust.
Adjusting 15) Close the drain valves on main steam line.
(1) Take care the packing steam pressure not to be in vacuum.
Screw
(2) Prevent the steam from abnormal leaking at penetrating parts 16) Close the drain valve on the main stop valve.
between rotor and turbine casing.
(1) Take care of the drain, since the remainder of the drain often
8) Fully open drain valves of the main stop valve and on main steam brings into accident.
piping.
17) Adjust the voltage and frequency.
9) Put turning device on.
18) Put the turbine speed in parallel with the other generator with the
(1) Check there is no abnormal sound in the turbine. synchronizer on the electric panel.
(2) After turning, take off the turning device fully after turning.
19) Shift the load gradually.
10) Remove air gathering in the governor.
(In case that the turbine has been in a stand still for a week or longer.) During Operation

(1) Set the knob of load limiter to the indication of “10”, and move 1) Watch and take the indications of the gauges, thermometers and other
4. Preparation for Operation the governor output shaft back and forth completely, and air instrument with scheduled intervals.
gathering in the governor can be removed.
Starting (Start operation under Cold condition)
(At this time, the load indicator moves “0” to “10”) 1) If the turbine tripped automatically, carefully check the cause before
(2) Carry out this procedure two or three minutes. resetting the trip.
1) Confirmation and preparation before Starting
11) Set the synchronizer to the indication of “0” by turning the synchronizer. 2) Operate the main stop valve slightly once a day during operation to
(1) Confirm the steam source and electric source are ready for
operation. prevent the sticking.
12) Open the governor valve by the starting lever.
(2) Check all gauges indication zero point.
(3) Check the oil level in oil tank at “NORMAL”. 3) If the bearing temperature rises to 75ºC, check the oil and cooling
(1) Confirm the governing valve opened. water temperature. If the temperature rises more abruptly, stop the
(4) Check the circuit breaker is open.
turbine and check the cause.
13) Open the main stop valve by hand.
2) Start the priming LO pump.
4) Check the oil level in oil tank.
(1) Start the turbine gradually and drive at about 400rpm and keep it
(1) Confirm the bearing oil pressure reaches approx. 0.2~0.3bar.
for about 25min. for warming. If there are any vibration of 5) Change over the duplicate oil strainer at least once a day during the
abnormal sound at this time, stop the turbine and check the cause. first voyage, and clean the strainer with air jet.
3) Open the cooling water inlet and outlet valve on LO Cooler.
(2) If there are some abnormal conditions at turbine starting, stop the
turbine and within 3 minutes after complete stop, turning should 6) Check the leakage of oil, water, steam and etc. all over the unit,
4) Start the cooling water pump and send the cooling water to the LO
be commenced. specially loosing of the flange bolts.
cooler.
(3) Confirm delivery pressure of the main oil pump and bearing oil
pressure increase as the turbine speed increase. 7) Confirm there is no abnormal vibration and sound on the turbo-
(1) Open the vent valves on the water heads of the LO cooler and
(4) Confirm the priming LO pump stops automatically when the generator.
confirm the cooling water is flowing.
bearing oil pressure gets to normal pressure.
5) Check the steam pressure and temperature before the main stop valve.

14) Fully open the main stop valve after confirming the governing
(1) Don’t start the turbine if the steam press. And temp. are lower than

Final draft / 2007. 12. 28 1 - 20 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

8) Confirm the oil flow with the sight glasses provided on the generator Illustration 1.3.1c Time Schedule for Starting of Generator Turbine
bearing outlet and turbine bearing outlet.

9) Take care of drain from main steam piping especially. When the drain
goes into the turbine set, shift the load to other generator and stop the
turbine, then, check the thrust bearing and the other parts.
(Model : RG92(-2))
1,800 rpm
Speed Up by Gov.
Stop Operation (100%)

1) Shift all the load to the other generator. 1,710 rpm (95%)

2) Cut off the circuit breaker.

1,450 rpm (80%)

(rpm)
3) Shut the main stop valve by the handle or hand trip lever.

(1) Confirm the priming L.O. pump starts automatically when the

Revolution
Critical Speed 1,000 rpm ~ 1,350 rpm
turbine speed down.
E.S.V. Close

4) Open the drain valves on main steam line.

Turbine
900 rpm
5) Open the drain valve of the main stop valve and the casing drain valve.
750 rpm
(1) Drain off fully and don’t leave the drain in the turbine set.
600 rpm

6) Open the drain valve of exhaust valve.

400 rpm

7) Rotate and turn the shaft.

Turning
(1) Carry out the turning for 120 min. or over.
Stand-by Idling
Warming Warming Speed Up
When the generator turbine has to be started within 2hours after
stopping, idling time should be extended than normal starting, ab.
1 10 1 1 4~10 Turning
then increase the speed slowly while carefully watching the ~60 min. Min.. Over 25 min. 10 min. sec. 5 min. 5 min. min. min. min.
vibration & noise, etc. If there is an abnormality, stop the turbine
Preparation
immediately by hand trip. Before 20~30 min.
Starting
(2) Carry out the turning until the temp. indicated on the local inlet
steam thermometer lowers to 100ºC.

8) Stop the sealing steam supply.

9) Stop the cooling water pump.

10) Stop the priming L.O. Pump.

(1) Drive the priming L.O. Pump for about 90min. after turbine stop.

11) Close all valves.

Final draft / 2007. 12. 28 1 - 21 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.4 Main Feed Water Pump Turbine 2. Specification 3. Performance curves

1. General Maker: COFFIN Turbo Pump, Inc.

Type: DEB-16 Expected Characteristic Curve
The turbo pump unit consists of four sections; turbine housing, bearing casing, Capacity: Normal: 145 m3/h, Maximum: 170m3/h
governor gear and oil pump, and pump housing assembly. Between the turbine Total developed head: 865 m Total Head = 865 m, Suction Temperature = 127 ℃, Suction Head = 25 m
Steam Inlet Pressure = 59 bar at Temperature = 510 ℃ , Exhaust Pressure = 1.8 bar
housing, bearing housing and pump housing assembly sections there is a void air N.P.S.H.R: 12.6 m 1000 50
space, so any fluid leakage will be to the atmosphere rather than from one Steam inlet: 59 bar 900 TDH 45

Total Developed Head (m)

section to another. Initial temp.: 510°C 800 40
Exhaust: 1.8 bar 700
Minimum
35
Flow
The driving steam enters the single stage, impulse, two (2) bucket row, velocity HP/kW: 704/525

NPSHR (m)
28.4 m3/hr
600 30
compound, axial flow turbine through the top of the unit by way of the fitted Rpm: 7,325 at 865 m TDH
500 25
steam strainer, through the steam chest, and is guided to the nozzle block by Rated design rpm: 10,000
400 20
means of the steam chest manifold and external nozzle piping. After expanding
300 15
through the turbine wheel, the steam exhausts in an axial direction from the Overspeed trip: Set 8,200 rpm NPSHR
Turbine sentinel valve: Set 3.4 bar 200 10
upper portion of the turbine casing directly above the turbine end cover.
Back pressure trip: Set 4.1 bar 100 5

A single shaft passes through the turbine housing, bearing casing and pump Aux. LO pump remote start pressure switch: Set 2.2 bar 0 0

housing. It is supported by two roller bearings located in the bearing casing, and High oil temperature - Trip: Set 80 °C 0 25 50 75 100 125 150 175
a steady bearing of the thruster type located on the outboard end of the pump Low oil pressure switch - Alarm: Set 2.2 bar 7400
7200
housing. The pump rotating parts are supported between one roller bearing and - Trip: Set 1.7 bar RPM
7000

RPM
the outboard thrust bearing. The turbine is overhung in the turbine housing to the Turbine rotor vibration - Alarm: Set 7.1 mm/sec RMS 6800
right of the roller bearing. - Trip: Set 11.2 mm/sec RMS 6600
6400

The main shaft serves the additional purpose of providing power to the 8000

horizontal governor drive shaft through a worm and worm gear. This horizontal

Exhaust Enthalpy (kcal / kg)

7000

Steam Inlet Flow (kg / h)

shaft is connected to a vertical shaft through a set of spiral mitre gears to drive
the centrifugal speed governor and gear-type main oil pump.
6000 740
Exhaust Enthalpy
730
Control of the turbo-pump is in all cases exercised through operation of the 5000 720
single balanced governor steam valve which is affected by pump discharge 710
pressure, constant pressure regulator, centrifugal speed governor and electric 4000 700
actuator. Steam Flow 690
3000 680
The pump assembly is of the centrifugal type. The fluid pumped enters at the 670
first stage of the unit, travels downward through the suction passage, is directed 2000 660
axially into the impeller, discharged radially into the 1st stage diffuser and is then 0 25 50 75 100 125 150 175
directed by the pump casing to the 2nd stage impeller, through the second stage < Hand Valve Closed Hand Valve Open >
diffuser, and finally out through the pump discharge flange.
Feed Water Flow Rate (m3 / hr)

Final draft / 2007. 12. 28 1 - 22 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.4.1 Operating procedure (3) The steam inlet valve should not be opened before the governor 5) Check routinely during each engine room tour to ensure the pump is
balanced valve. It is recommended to slowly and gradually open operating normally. The customer/operator is encouraged to develop a
1. Starting the valve whenever possible. standard checklist and gauge reading schedule to monitor the unit.

1) Steam inlet, exhaust, oil cooling water, seal flush, pump suction, and
pump discharge systems must be in the starting condition as outlined in
the pre-start up procedure provided in this manual. This condition must
be verified by the operator through suitable means provided in each
system prior to starting the turbo pump; for example, gauges and sight
glasses.
2) Various oil line valves supplied in the turbo pump lube. oil system (for
service reasons only) must be open. Throttle hand wheel must be
positioned wide open. Turbine trip lever located at the governor
assembly must be reset if positioned otherwise.
3) Open the oil cooler cooling water supply valve.
4) Open the turbine casing drain valve.
5) Open the steam chest drain valve. Use of this valve, or a steam trap,
may not be necessary with a well drained steam line.
6) Open the pump discharge stop valve, the pump suction valve, and the
turbine exhaust valve if closed.
7) Open the pump vent valve (when an automatic air vent valve is not
installed by the customer) and close when all air is expelled from the
pump housing.
Note
At this point, either the operator or automatic programmer must
provide a finite delay period for complete venting and draining when
automatic vents or traps are not installed.
10) Press the auxiliary oil pump motor start button, ensuring that the
auxiliary L.O pump auto-stop functions and that discharge pressure is
established.
11) Should the auxiliary oil pump not function for any reason, or manual
starting of the turbo pump be required, proceed as follows. Lift the oil
relay, and start the lever by placing a screwdriver or similar tool under
the lever at the link end. This will raise the balance governor steam
valve permitting the turbine to start. Hold in this position only until the
turbo pump’s integral oil pump develops pressure to hold the steam
valve.
12) At this point the unit will be running either.
(1) At a low rpm, if the steam inlet valve was partially opened.
(2) At a discharge pressure established by the constant pressure
regulator setting, if the steam inlet valve was fully open. If the
steam inlet valve was partially open, it may be fully opened to
place the unit under the control of the pressure regulator after a
delay period established either by the operator’s preference or
experience.
13) Close all non-automatic vent or drain valves if not already closed.
14) Check all alarm circuits that may have been turned off or by-passed
during starting to avoid abnormal signals. Re-energise these circuits to
ensure proper protection and monitoring.
2. Operation
3. Turbo Pump Shut-Down
This procedure is for normal turbo pump shut-down. Instructions are as follows:
1) Close the turbine steam inlet valve.
2) Close the oil cooler water supply valve and the recirculating line valve.
3) At this point, the following valves may be left open or closed depending
on local conditions or procedures.
(1) Pump discharge stop valve.
(2) Pump suction valve.
(3) The turbine exhaust may be closed if the exhaust temperature is
over 175°C as shown by the exhaust enthalpy value on the
performance curve, or it may be open if exhaust temperature is
lower.
Note
It is not recommended that these valves be closed except for
service work or abnormal conditions.
4) Shut-down for a prolonged period of time.
Repeat the above procedure. Additionally, close all valves named above,
including pump discharge stop valve and pump suction valve. Drain the
pump housing through the pump housing drain valve, and drain the oil
sump through the sump drain valve.

8) Open the pump recirculation valve (Unless an automatically controlled 1) Close the pump recirculation valve when pump capacity exceeds the
valve is used). minimum rate specified by the provided Pump Performance Curve.

9) Open the turbine steam inlet valve, either partially or fully.
Recommendation as follows:
(1) The Turbo Pump may be started by first starting the auxiliary oil
pump motor to supply the bearings with pre-lubrication. Then crack
the steam inlet valve slightly to start the Turbo-pump slowly.
(2) After a while, the valve can either be opened gradually in
incremental steps until it is fully open, of opened fully as operating
conditions or operator preference dictates.
2) It is recommended that a visual check of the unit, including all oil sight
gauges, be conducted as soon as possible after starting the unit. Check
the entire unit for any abnormal conditions. If the pump operates
abnormally, shut down and attempt to remedy the problem.
3) When stable operating conditions exist, the turbine hand valve should
be used for maximum steam economy as indicated by the pump’s
performance curve.
4) The pump constant pressure regulator may also need to be adjusted for
maximum steam economy, and for the minimum pump discharge
pressure that will maintain adequate feed water capacity.

Final draft / 2007. 12. 28 1 - 23 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.5 Diesel Generator Engine local reading and for the most essential pressure, manometers are, together 6) Lubrication Oil System
with tachometers, centralized in an engine-mounted instrument panel.
1. Principle Particular All moving parts of the engine are lubricated with oil circulating under
The numbers and types of parameters with alarm functions are chosen in pressure in a closed built-on system.
Vertical in-line, 4-cycle, direct injection, single acting, trunk piston type with accordance with the requirements from the classification societies.
exhaust turbocharged and charge air cooled design The built-on lubricating oil pump is of the gear wheel type with pressure
As standard, the engine has shut-down functions for low lubricating oil control valve. The pump takes the oil from the sump in the base frame, and
- Engine Model : 9L32/40 pressure, high cooling water temperature and for overspeed. on the pressure side the oil passes through the lubricating oil cooler (plate
- Number of Cylinder : 9 type) and the filter which both are mounted on the engine.
- Cylinder Bore : 320mm 3) Turbocharger System
- Piston Stroke : 400mm Cooling is carried out by low temperature cooling water system. The
- Rated Output : 4053kW (5,510PS) The turbocharger system of engine, which is a constant pressure system, temperature is controlled by a thermostatic three-way valve on the oil side.
- Rated Speed : 720rpm consists of an exhaust gas receiver, a turbocharger, a charge air cooler and The engine is a standard equipped engine with an electrically driven pre-
- Mean Piston Speed : 9.6m/s a charge air receiver. lubricating pump.
- Mean Effective Pressure : 23.35bar
- Max. Combustion Pressure : 180bar The turbine wheel of the turbocharger, which is of the ratial type, is driven 7) Cooling Water System
- Rotating Direction (seen from flywheel) : Clock-wise by the engine exhaust gas, and the turbine wheel drives the turbocharger
- Dry Weight of Gen-set Complete : Approx. 104.5ton compressor, which is mounted on one shaft. The compressor sucks air The cooling water system consists of a low temperature system and a high
- No. of Diesel Engine : 1set / ship from the engine room through the dry air filters. temperature system.

2. Engine Characteristics The turbocharger pressure the air through the charge air cooler to the The water in the low temperature system is passed through the charge air
charge air receiver. From the charge air receiver, the air flows to each cooler, the lubricating oil cooler. The low temperature media is freshwater.
1) Engine Performance cylinder through the inlet valves.
The high temperature cooling system cools the engine cylinders and the
- Combustion Air Consumption : 32,934kg/h (±5%) The charge air cooler is as compact tube-type cooler with a large cooling cylinder head. The high temperature media is always cooled by fresh water.
- Exhaust Gas Flow : 33,720kg/h (±5%) surface. From the exhaust valves, exhaust gas is led through a water-
cooled intermediate piece to the exhaust gas receiver where the pulsatory
- Exhaust Gas Temperature : 350℃
pressure form the individual cylinders is equalized and passed to the
- Allowable Exhaust Gas Back Pressure : Max. 0.025bar
turbocharger as a constant pressure, and further through the exhaust
- Minimum Ambient Temperature for Stating : 5℃
system and silencer arrangement.
- Load-up limit : 33% of engine rated power
- Overspeed :
The exhaust gas receiver is made of pipe sections, one for each cylinder,
Blocking of the output for engines at 110% of the rated output. Overload
connected to each other, by means of compensators, to prevent excessive
more than 100% may only be run for a short time for recovery and
stress in the pipes due to heat expansion. Between the cylinder head and
prevent of a frequency drop in case of load application.
the exhaust gas line quick release couplings is mounted, which permits
raped disconnection.
2) Capacity
To avoid excessive thermal loss and to ensure a reasonably low surface
- Stating Air Consumption per Start : 2.85Nm3
temperature, the exhaust gas receiver is insulated.
- Engine Radiation Heat : 206kW
- Capacity of Engine Driven Pumps
4) Compressed Air System
Lubricating Oil Pump : 113 m3/h
HT-Cooling Water Pump : 54 m3/h
The engine is started by means of compressed air of 30bar
3. General Descriptions
5) Fuel Injection System
1) General
The built-on fuel oil system consists of the fuel oil filter and the fuel
injection system. The fuel oil filter is a duplex filter. The filter is equipped
The engine is a turbocharged, single – acting four stroke diesel engine of
with a three-way cock for single or double operation of the filters.
the trunk piston type with a cylinder bore of 320mm and a stroke of a
400mm. The crankshaft speed is 720rpm for 60Hz.
Waste oil and fuel oil leakage is led to a leakage alarm which is heated by
means of the inlet fuel oil.
2) Monitoring and Control System

All media systems are equipped with thermometers and manometers for

Final draft / 2007. 12. 28 1 - 24 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

Illustration 1.6.1a Fresh Water Generator

Feed Water
Preheater Key
Steam Line
Condensate Line
Condensate for
Condensate for Desuperheating Fresh Water Line
Desuperheating Max. 13bar & 50 ℃
Max. 13bar & 50 ℃ Vacuum Line
Sea Water Line
Air Inlet Air Inlet Air Line
Air Inlet Air Inlet 5-9bar 5-9bar
5-9bar 5-9bar

No.1 F.W.Generator No.2 F.W.Generator

Max. Condensate Inlet
Vacuum Release Pressure : 13bar Vacuum Release
PIC

PIC
Valve(VA-E1-01) 33 ℃ Valve(VA-E1-01)
Opening Pressure Opening Pressure
(VA-CO-02) Max. 1bar (VA-CO-02) Max. 1bar
H

H
PI TI PI TI

H
H TI Condenser H TI Condenser
Solenoid PIC Solenoid H PIC
Back Pressure Valve Back Pressure Valve

H
H

PI PI

PI TI PI TI PI TI PI TI

Flow Flow
Reg. Reg.
Max. 3bar G & Max. 300 ℃

Max. 3bar G & Max. 300 ℃

Valve(VA-SS-02) TC PC Valve(VA-SS-02) TC PC
Design 1.1bar & 300 ℃

Design 1.1bar & 300 ℃

Evaporator Evaporator
Limited Switch

Limited Switch
Condensate Fresh Water Condensate Fresh Water
Pump Pump Spring Orifice Pump Pump Spring Orifice
(PU-SS-01) (PU-FR-01) Loaded (PU-SS-01) (PU-FR-01) Loaded
Valve H Valve H
525

525
PT PI PT PI
Min. Press. Min. Press.
QT 3.5bar Flow QT 3.5bar Flow
Indicator Indicator

Flow Flow
Solenoid Reg. Solenoid Reg.
H

H
Valve Valve Valve Valve
FG FG
H H
H H
Feed Water Feed Water
H

H
Shut-off Treatment Shut-off Treatment
TI TI
Valve Valve
FQ (VA-FT-01) FQ (VA-FT-01)
H

H
H

H
FG FG FG FG
H H
PI Non Return Over Board PI Non Return
Valve Max. Back Pressure Valve Over Board
0.6bar Max. Back Pressure
0.6bar
Low Points PI PI
Low Points PI PI
On Steam Line H On Steam Line H
To be Drained TI To be Drained TI
H

H
PI PI
Brine / Air Ejector Brine / Air Ejector
H

H
Ejector Ejector
Pump Pump
PI PI
H H H H
Control Control
Panel From Sea Panel From Sea

To Condensate Tank/Well To Fresh Water Tank Air Inlet To Condensate Tank/Well To Fresh Water Tank Air Inlet
Max. Back Pressure Max. Back Pressure 5-9bar Max. Back Pressure Max. Back Pressure 5-9bar
1.6bar 2.5bar 1.6bar 2.5bar

Final draft / 2007. 12. 28 1 - 25 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.6 Fresh Water Generator Pressure drop of Sea water flow: 0.2bar (1) Open valve to freshwater tank.
Steam flow: 2,742kg/h
1. General Steam pressure: 0.7bar (2) Start freshwater pump.
Electric source (Main, Control): 3 x 440 x 60Hz, 220V
The combined brine/ejector driven by the ejector pump creates a vacuum in the Salinometer model: DS-205 Note
system in order to lower the evaporation temperature of the feed water. The freshwater pump pressure must be between 1.2 and 1.6
3. Operating Procedure bar.
The feed water from the ejector pump is introduced into the evaporator section
through an orifice, and is distributed into every second plate evaporation Caution Caution
channel. The hot water is distributed itself into the remaining channels, thus Before starting, please follow the instructions for feed water treatment, After starting the freshwater pump the flow sight glass in the air
transferring its heat to the feed water in the evaporation channels. see “Chemical dosing of scale control chemicals”. suction pipe muse be empty.

Having reached boiling temperature, which is lower than at atmospheric 1) Starting 4) Stopping the Fresh Water Generator
pressure, the feed water undergoes a partial evaporation and the mixture of
generated vapour and brine enters the separation vessel, where the brine is (1) Open the valves on the suction and discharge side of the ejector (1) Close the steam pressure regulating valve VA-SS-02 by adjusting
separated from the vapour and extracted by the combined brine/air ejector. pump. the set point for the steam pressure controller in control panel
(2) Open the overboard valve for combined brine / air ejector. slowly (step-wise) to 0.0bar.
The cooling water supplied by the combined cooling/ejector pump on No.1 (3) Close the air screw VA-E1-01 on the separator. (2) Close the valve for air inlet.
FWG and supplied from the condensate pump on No.2 FWG distributes itself (4) Start the ejector pump to create a vacuum of min. 90% and ensure (3) Close the main steam shut-off valve.
into the remaining channels, thus absorbing the heat being transferred from the that the pressure is over 3.5bar at the combined brine / air ejector (4) Close the valve for condensate for desuperheating inlet.
condensing vapour. The produced freshwater is extracted by the fresh water inlet and the back pressure is not over 0.6bar at the combined (5) Close the valve for feed water treatment VA-FT-01.
pump and led to the fresh water and distilled water tanks. brine / air ejector outlet. (6) Stop freshwater pump PU-FR-01 and condensate pump PU-SS-01.
(7) Stop the ejector pump, after approx. 10min.
If the salinity of the produced freshwater exceeds the chosen maximum value, For VSP-36-125CC only (8) Open the air screw VA-E1-01.
the dump valve and alarm are activated to automatically dump the produced (9) Close all valves on the suction and discharge side of the pump.
fresh water into the separator vessel. (5) Open the condensate inlet, outlet and by-pass valves. (10) Close the overboard valve for combined brine / air ejector.
(11) Close the valve to freshwater tank.
2. Specification of Fresh Water Generator (6) Start condensate supply to condenser by adjusting the by-pass
valve incrementally until the desired condensate flow is reached. Caution
Type: VSP-36-125CC All valves must be shut while the distiller is out of operation,
(Condensate Cooled) 2) Evaporation except for the vacuum break.
Number of units: 1set
Capacity per unit: 60 ton/day When there is a minimum of 90% vacuum (after maximum 10 min.).
Condensate water temperature inlet: 33.6°C
Condensate water temperature outlet: 61.3°C (1) Open valve for feed water treatment VA-FT-01.
Condensate water flow: 53m3/h (2) Ensure that the air inlet for steam pressure regulating valve VA-
Max salinity: 1.5ppm SS-02 and flow regulating valve VA-CO-02 is open ( 5.0~9.0bar).
Pressure drop of Cooling water flow: 0.5bar (3) Ensure that the condensate inlet for desuperheating is open
Steam flow: 3,031kg/h ( maximum 13.0bar ).
Steam pressure: 0.75bar (4) Open the valve for condensate to atmospheric drain tank.
Electric source (Main, Control): 3 x 440 x 60Hz, 220V (5) Open the main steam shut-off valve.
(6) Open the steam pressure regulating valve VA-SS-02 by adjusting
Type: VSP-36-125SWC the pressure controller in the control panel step-wise 0.1bar, until
(Sea Water Cooled) the specified steam pressure is reached (Max 0.75bar).
Number of units: 1set
Capacity per unit: 60ton /day 3) Condensation
Sea water temperature inlet: 32°C
Sea water temperature outlet: 48.3°C After approx. 3minutes the boiling temperature will drop again, and
Sea water flow: 90m3/h normal vacuum is re-established.
Max salinity: 1.5ppm

Final draft / 2007. 12. 28 1 - 26 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

Illustration 1.7.1a Bow Thruster Illustration 1.7.1b Bow Thruster

ENGINE ROOM BRIDGE

G G
ELECTRONIC
CABINET

CONTROL
PANEL

GRAVITY STARTER
TANK CABINET
THRUSTER ROOM

WING(P) WING(S)

SERVO

ELECTRIC
MOTOR

AUTO.
TRANSFORMER

E SERVO
PUMP UNIT
A
ELASTIC L
COUPLING
S
S

MOTOR
FRAME

THRUSTER

Final draft / 2007. 12. 28 1 - 27 Part 1 Engineering Data for Main Equipment
CLEAN FORCE Machinery Operating Manual

1.7 Bow Thruster through the pipes in the propeller shaft, resulting in the reciprocal movement of Remote control system
the servomotor piston.
1.7.1 Technical Specification This movement of the piston is converted into rotary movement of the blades Type: Electric-hydraulic, follow-up control type
by the sliding block mechanism. Wheel house: Master control panel x 1 set
Shaft sealing mechanism, which is attached to the gear case, is adopted for the Wings: Wing control panel x 2 sets
1. General
propeller shaft.
Additional circuit: Over load protection device
The side thruster is a transverse propelling device with its propeller mounted in Power supply: AC 220V, 60 Hz
The propeller blades are carefully designed with proper area and thickness to
the lateral through tunnel in the hull such that the water jet generated by this DC 24V as back up source for indicating system
have sufficient strength and to withstand cavitation.
propeller gives a lateral thrust to the hull. Thus facilitating the departure of the
ship from and its coming alongside the pier. Also helping improve the ship’s
Operating Limits
manoeuvrability when it is running at a low speed or in a narrow waterway. 1.7.2 Remote Control System
Kawasaki’s KT-B type side thruster is a controllable pitch thruster having
(1) Be sure to observe the specified draft.
incorporated in it a propeller pitch controlling mechanism. So planned that the
(For the specified draft refer to the separate “Technical data”.) This thruster (controllable pitch propeller type) remote control system is
propeller pitch can be remote controlled from the control stand on the bridge.
If the draft is insufficient, it is not only interferes with the thruster designed to control the thruster blade angle by operating any of control dials
This device is composed of the actuating section comprising a drive motor.
exhibiting the specified performance but also causes cavitation or air provided in the wheel house (W/H) and wings due to employing
Flexible coupling and thruster proper and the propeller pitch control device. Its
drawing, and the resultant vibration may possibly cause damage to the microcomputers with overload protector (OLP) function for the main motor; in
features being as follows:
device. addition, the main motor and auxiliaries can be started and stopped from the
(Air drawing can be detected as marked hunting of the drive motor W/H.
(1) Adoption of 4-bladed skewed controllable pitch propeller which is effective
ammeter.)
for reducing vibration.
(2) In some cases, it is also possible that air drawing is caused when the ship’s
The system also provides blade angle indicators, ammeters for the main motor,
speed is below 5 knots. If it is the case, the propeller pitch is to be so
(2) Highly rigid construction and compact design. Hence easy installation. and indication and alarm circuits necessary for operation. In case of emergency
controlled that there is no risk of air drawing with the lower blade pitch
zone. such as trouble with the follow – up control, the system provides a non-follow-
(3) Propeller pitch is controllable. This allows the use of a constant speed up control mode by which the blade angle can be controlled manually from the
motor with its revolving direction fixed.
2. Specification of Bow Thruster W/H.
(4) The possibility of controlling propeller pitch also enables continuous and
quick change of the thrust in either port or starboard direction. Thruster unit 1. Control Position Changeover

(5) Easy operation for all operation controls from that for starting the motor to Maker: KAWASAKI HEAVY IND. LTD Pressing the button switch on the W/H stand enables the control position to
that for regulation of the propeller pitch are collectively arranged in the No. of sets: 1 SET change over from the W/H to a wing. Before changing over the control position,
control stand on the bridge. Model: KT-219B3 match a control dial that will be given the control with the actual blade angle.
Type: 4 bladed, skewed, Controllable Pitch type The blade angle indicators in the W/H and wings always show the actual blade
(6) The propeller blade are capable of dismantling in the thruster tunnel by Input power: 2,000 kW angle.
means of removing the blade bolts.
Propeller diameter: 2,600 mm
Position of propeller blade: Starboard side 2. Control Mode Changeover
The thruster can have its performance retained over a long period, if simple
preoperational checking and the recommended routine maintenance and Input shaft speed: 880 min-1
Volume of fluid: approx. 560 L/unit Pressing the button switch on the W/H Stand enables the control mode to be
checking procedures are observed.
changed over. Before changing over the control mode from non-follow-up to
This manual is intended to give cautions and hints on the operation of the
thruster to be observed as well as the maintenance and inspection standards. Main motor : One (1) Unit follow-up, match the control dial with the actual blade angle.

Controllable pitch propeller Type: Vertical type, squirrel cage, induction motor 1) Follow up pitch control
Output x Revolution: 2,000 kW x 880 min-1
Power is transmitted form the prime mover through the flexible coupling, input Voltage x frequency: AC 3ø x 6,600 V x 60 Hz When operating a control dial, the position of potentiometer provided
shaft, bevel gears to the propeller shaft, rotating the propeller in a constant Starting method: Auto transforming starting in the differential voltage between them will be amplified to energise a
direction. solenoid valve, actuating a cylinder in the thruster.
The propeller part consist of four propeller blades, a propeller hub with a
Control service pump : Two (2) Unit
hydraulic servomotor and the sliding block mechanism. At the same time, as the potentiometer in the local blade angle
The propeller blades are connected to blade carriers by blade bolts and this transmitter that is driven by a chain mechanism agrees with the control
assures easy exchange of blades in the thruster tunnel. Type: Vertical screw type
Capacity: 51.7 L/min x 45 bar x 1,750 min-1 dial position, which means the differential voltage becomes zero, the
The gear case, which carries propeller part, is connected to the thruster tube by
solenoid valve will be de-energised. Thus, the thruster blade angle
bolts and this assures easy overhauling all part inside tube.
Pressurized oil form the solenoid valve is fed to the hydraulic servomotor Flexible coupling SF coupling 1 set / vessel always follows the control dial’s order value correctly.

Final draft / 2007. 12. 28 1 - 28 Part 1 Engineering Data for Main Equipment
CLEAN FORCE
2) Non-Follow-up pitch control
Pressing the non-follow-up button switch on the W/H stand causes a
solenoid valve in the hydraulic unit to be energised, moving the blade
angle in a direction for which the button switch is pressed. When the
button is released, the solenoid valve will be de-energised to stop the
blade angle move.
3. OLP (Overload Protector) Function for Main Motor
When the main motor’s load current exceeds the load current preset by the
portable keyboard, the blade angle will be reduced automatically to decrease
the load current in order to protect the main motor from being overloaded with
the MOTOR FULL LOAD indicator lamp lit on the W/H Control Panel.
As the main motor’s load current decreases, the blade angle will automatically
return to a blade angle equivalent to the control dial position, which causes the
MOTOR FULL LOAD indicator lamp to go off.
a) Rating current of main motor, 213 Amp.
b) CT ratio for OLP, 400 Amp. / 1 Amp. (CT : AC1A / 40VA)
Caution
Keep the CT for OLP away from CTs for other devices.
4. Controller Operation
1) Button Switch “ CONTROL POWER ON” and “CONTROL POWER
OFF”
Pressing the CONTROL POWER ON button switch supplied electric
sources to the system. As the CONTROL POWER OFF button switch
is pressed, the electric sources will be turned off.
Caution
Before the turning off the power sources, press the STOP button
switch to stop the main motor and auxiliaries.
2) “PUMP STOP” Button Switch
Pressing the PUMP STOP button switch stops pressure oil pump when
they have been running. The stop action also outputs a momentary and
normally “closed” no-voltage contact signal.
3) “PUMP RUN” Button Switch
Pressing the PUMP RUN button switch sends starting signals to the
pressure oil pump and fan starter, which causes the pressure oil pump
and fan to start. Running of the pressure oil pump causes the PUMP
RUN indicator lamp to light up and the running of fan causes the FAN
Final draft / 2007. 12. 28
Machinery Operating Manual
RUN lamp to light up. The starting action also outputs a momentary
and normally “open” no-voltage contact signal.
4) “THRUSTER STOP” Button Switch
Pressing the THRUSTER STOP button switch when the main motor
has been running causes the main motor to be stopped. The stop action
also outputs a momentary and normally “closed” no-voltage contact
signal.
5) “THRUSTER RUN” Button Switch
After checking that the READY TO START indicator lamp is lit,
pressing the THRUSTER RUN button switch sends a starting signal to
the main motor starter, which causes the main motor to start. When the
main motor is running, the THRUSTER RUN indicator lamp will light
up. The starting action also outputs a momentary and normally “open”
no-voltage contact signal.
6) “CONTROLLER ABNORMAL” Alarm
If the CONTROLLER ABNORMAL alarm is given when the control
position has been the W/H or a wing, the blade angle before the alarm
is given will be maintained. It is recommend to change over the
control mode immediately from follow to non-follow.
Alarm causes simultaneously given to the W/H and both wings are as
follows:
- Blade angle transmitter’s potentiometer is damaged.
- Control or alarm electric source fails.
- CPU fails.
The following alarms are given in a control position where the
control right is given:
- W/H control dial’s potentiometer is damaged.
- Starboard wing control dial’s potentiometer is damaged.
- Port wing control dial’s potentiometer is damaged.
7) “POWER REQUEST” Button Switch
Pressing the POWER REQUEST button switch sends a main motor
power request signal to the power management system (PMS) with
the POWER REQUEST indicator lamp lit.
When the main motor is stopped or power available on , the POWER
REQUEST indicator lamp will go off to release the main motor
power request signal. (the release method can be chosen with a ten
key) Besides that, pressing the POWER REQUEST button switch
again before the main motor runs cancels the signal.
1 - 29 Part 1 Engineering Data for Main Equipment
CLEAN FORCE
Part 2 : Machinery System
2.1 Steam Systems ......................................................................................... 2 - 2
2.1.1 Superheated Steam System ................................................... 2 - 2
2.1.2 Desuperheated Steam & Steam Dump Systems ................... 2 - 4
2.1.3 Bleeed System ...................................................................... 2 - 6
2.1.4 6 bar Steam System .............................................................. 2 - 8
2.2 Condensate and Feed Water Systems .................................................... 2 - 10
2.2.1 Main Condensate System.................................................... 2 - 10
2.2.2 Aux. Condensate Water System ......................................... 2 - 14
2.2.3 Boiler Feed Water System .................................................. 2 - 18
2.3 Sea Water Systems ................................................................................ 2 - 22
2.3.1 Main Sea Water Circulating Systems ................................. 2 - 22
2.3.2 Cooling Sea Water Service System .................................... 2 - 24
2.3.3 Marine Growth Preventing System .................................... 2 - 24
2.4 Centralised Fresh Water Cooling System .............................................. 2 - 26
2.5 Boiler Water Sampling and Treatment Systems .................................... 2 - 28
2.6 Fuel Oil and Fuel Gas Service Systems ................................................. 2 - 32
2.6.1 Fuel Oil Bunkering and Transfer Systems .......................... 2 - 32
2.6.2 DO Purifying and G/E Fuel Oil System ............................. 2 - 36
2.6.3 Boiler Fuel Oil Service Systems ......................................... 2 - 38
2.6.4 Boiler Fuel Gas Service System ......................................... 2 - 42
2.6.5 I.G.G and Incinerator Fuel Oil System ............................... 2 - 44
2.7 Lubricating Oil Systems ........................................................................ 2 - 46
2.7.1 Main Turbine Lubricating Oil System ................................ 2 - 46
2.7.2 Stern Tube Lubricating Oil System .................................... 2 - 50
2.7.3 Lubricating Oil Transfer & Purifying System .................... 2 - 52
2.8 Engine Room Bilge System ................................................................... 2 - 56
2.9 Compressed Air Systems ....................................................................... 2 - 60
2.9.1 Control Air System ............................................................. 2 - 60
2.9.2 Starting Air System............................................................. 2 - 62
2.9.3 Working Air System ........................................................... 2 - 64
2.9.4 Emergecy Shut-off Air System ........................................... 2 - 66
2.10 Steering Gear ....................................................................................... 2 - 68
2.11 Electrical Power Generators ................................................................ 2 - 70
2.11.1 Turbine Generator ............................................................. 2 - 70
2.11.2 Diesel Generator Engine ................................................... 2 - 74
2.11.3 Emergency Diesel Generator ............................................ 2 - 76
2.12 Electrical Power Distribution .............................................................. 2 - 78
2.12.1 Distribution and Loading .................................................. 2 - 78
2.12.2 Turbine Generators ........................................................... 2 - 83
2.12.3 Diesel Generator ............................................................... 2 - 84
2.12.4 Batteries & Battery Charger ............................................. 2 - 86
2.13 Accommodation Services .................................................................... 2 - 88
2.13.1 Provision Refrigeration System ........................................ 2 - 88
2.13.2 Accommodation and Air Conditioning Plant.................... 2 - 92
2.13.3 Package Air Conditioner ................................................... 2 - 96
2.14 Fresh Water General Service Systems ................................................. 2 - 98
2.14.1 Fresh Water General Service System ............................... 2 - 98
2.14.2 Distilled Water Filling Service System ............................. 2 - 98
Machinery Operating Manual
Illustrations
2.1.1a Superheated Steam System ................................................................. 2 - 1
2.1.2a Desuperheated Steam & Steam Dump System ................................... 2 - 3
2.1.3a Bleed System ...................................................................................... 2 - 5
2.1.4a 6bar Steam System .............................................................................. 2 - 7
2.2.1a Main Condensate System .................................................................... 2 - 9
2.2.2a Aux. Condensate Water System........................................................ 2 - 13
2.2.3a Boiler Feed Water System ................................................................ 2 - 17
2.3.1a Main Sea Water Circulating System ................................................. 2 - 21
2.3.2a Cooling Sea Water Service System................................................... 2 - 23
2.4a Centralised Fresh Water System .......................................................... 2 - 25
2.5a Boiler Water Sampling and Treatment System .................................... 2 - 27
2.6.1a Fuel Oil Bunkering and Transfer System.......................................... 2 - 31
2.6.2a Diesel Oil Purifying and G/E Fuel Oil System ................................. 2 - 35
2.6.3a Boiler Fuel Oil & Fuel Gas Service System ..................................... 2 - 37
2.6.5a IGG and Incinerator Fuel Oil System ............................................... 2 - 43
2.7.1a Main Turbine Lubrication Oil System .............................................. 2 - 45
2.7.2a Stern Tube Lubricating Oil System................................................... 2 - 49
2.7.3a Lubricating Oil Transfer System....................................................... 2 - 51
2.7.3b Lubricating Oil Purifying System ..................................................... 2 - 53
2.8a Engine Room Bilge System ................................................................. 2 - 55
2.8b Bilge Water Seprarator System............................................................ 2 - 57
2.9.1a Control Air System ........................................................................... 2 - 59
2.9.2a Starting Air System ........................................................................... 2 - 61
2.9.3a Working Air System ......................................................................... 2 - 63
2.9.4a Emergemcy Shut-off Air System ...................................................... 2 - 65
2.10a Steering Gear Hydraulic Diagram...................................................... 2 - 67
2.11.1a Turbine Generators Control Oil System ......................................... 2 - 69
2.11.1b Turbine Exhaust Steam System ...................................................... 2 - 71
2.11.2a Diesel Generator Engine ................................................................. 2 - 73
2.12.1a Distribution and Loading ................................................................ 2 - 77
2.12.2a Turbine Generators ......................................................................... 2 - 83
2.12.3a Diesel Generator ............................................................................. 2 - 84
2.12.6a Battery Charger Alarm Display Monitor ........................................ 2 - 85
2.13.1a Provision Refrigeration System ...................................................... 2 - 87
2.13.2a Accommodation and Air Conditioning Plant .................................. 2 - 91
2.13.3a Package Air Conditioner ................................................................. 2 - 95
2.14.1a Fresh Water General Service System .............................................. 2 - 97
Part 2
Machinery System
Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.1.1a Superheated Steam System

To Funnel Top IAS For F.W Press.

A shipside nozzle (400A) in engine room
Key to be used for steam blowing. Steam Drum PI
Control
PIC
TIAH PX PX
TI TX
Superheated Steam Line IAS Press. BGB IAS

1V
2V
Desuperheated Steam Line This valve to be removed and blanked To Atmos.
Drain Line by blind flange after steam blowing. Drain Tank BV201 BV202

BV212B
BV214

Control

BV305

BV212A
BV318

BV213
Sett. Sett.
L.P 75.5 bar 75.3 bar

Air

BV311
Turbine To Atmos. BV320

BV319
PAL TIAL
Steam Drum
IAS IAS Drain Tank
BV317

S
For D/G
Auto Start
PS TX BV321

To Desuperheated
Steam Line
616V

BV323A, B
BV322
PAL TI 606V ABC BV309
IAS
For Master BV309
PS
LS Controller For Boiler Trio To Atmos.
655V PX Temp. High-high TI TIAH Drain Tank
T-66A BV301 Second. S.H. Primary S.H.
614V 602T 641V

PI 659V 658V For I.P Bleeder

ABC BGB IAS
PS

BV306
Gov. 653V 608T 654V Valve Operation Sett.

604V
On GBD

BV307
TI 64.7 bar TX TX TI #5 #4 #3 #2 #1
Valve A626
615V

T-66
613V 612V PX
PI
BV314

BV308
No.2 IAS TIAH BV304A, B TX A301

A307 BV222H
A307 BV222L
TX
G/T
On IAS To Atmos.

BV303

BV302
PI
ECP
TI Drain Tank ABC BV309

CV211
TI
TX
IAS T-63
PI PX
BV315
To Atmos. PX
IAS PI
Drain Tank BGB P Water Drum
On ECP On PI E
PI
ECP ABC
To Atmos. IAS
PI
H.P

BV316A,B
T-3
Drain Tank FX
PX Turbine LS BV313
To Atmos.

BV310

BV310
PI
IAS Drain Tank

602V
No.2 Main Boiler
To Atmos.
PAL TIAL
IAS IAS
Drain Tank
For D/G
Auto Start
PS TX 666V 667V
To Atmos. To Atmos.
611V

PAL TI 605V Drain Tank Drain Tank

IAS

PS 652V
608V 607V To Atmos.
Drain Tank

601V
609V 601T 643V

PI

BV310

BV310
650V 607T 651V To Atmos. No.1 Main Boiler

T-639V
On GBD Gov.
Drain Tank
610V

Valve
661V 660V

BV316A,B
BV313
FX
No.1 PI
G/T E ABC
IAS P
PI Water Drum

BV222L A307

BV222H A307
To Atmos. BGB

CV111
PX
Drain Tank BV315 BV309
To Atmos.

BV303

BV302
BV304A, B
Drain Tank To Atmos. ABC
Drain Tank

BV308
TX
BV314 A301
PI PI
PI PI

BV307
BV306
A626
603V

To Desuperheated
IAS IAS Sett. TX TX TI #5 #4 #3 #2 #1
669V

668V

64.7 bar
633V 622V
634V

623V

ABC TI TIAH Second. S.H. Primary S.H.

No.2 Main Feed LS M 628V No.1 Main Feed LS M 617V PX BV301 For Boiler Trio BGB IAS

Steam Line
BV309
Water Pump Water Pump LS For Master Temp. High-high To Atmos.

BV323A, B
Turbine Turbine Controller Drain Tank

BV322
TI TI BV309
ABC BV317
635V

624V
630V

619V

637V 626V
BV320
632V

621V
605T

603T

BV318
638V 606T

627V 604T

S
Steam Steam
To Atmos.

BV311

BV319
Chest Chest Steam Drum
Drain Tank
636V

625V

BV321
631V

620V

Control
Air

BV305
Sett. Sett.

BV212A

BV213
75.5 bar 75.3 bar

BV212B
BV214
To Atmos.
Drain Tank To Atmos. BV201 BV202
To Atmos. To Atmos. Drain Tank
Drain Tank Drain Tank
Steam Drum PX PI PIC
From No.2 F.W.P.T. From No.1 F.W.P.T. Press. BGB
PX
IAS
Exh. Steam Drain Exh. Steam Drain For F.W Press.
To Funnel Top IAS
Control

Final Draft / 2007.12.28 2-1 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.1 Steam Systems 3. Control and Alarm Settings

2.1.1 Superheated Steam System IAS

Description Setting
Tag No.
1. Boiler Details
Maker : Kawasaki Heavy Industrial BS703 MB 1 STEAM DRUM PRESS H/L 76.5 / 50 bar
No. of Sets : 2 BS712 MB 1 SHTR OUT STEAM PRESS H/L 62.5 / 54 bar
Model : UME 68/52
Maximum Evaporation : 68,000 kg/h BS720 MB 1 DSHTR OUT STEAM TEMP 400℃
Normal Evaporation : 52,000 kg/h 530/400℃
BS723 MB 1 SHTR OUT STEAM TEMP H/L
Steam Condition : 60.3 bar superheated steam at 515°C
BS702 MB 1 DESHR OUT STM PRESS H 64.0 bar
Safety Valve Settings
BP702 MB 2 DESHR OUT STM PRESS H 64.0 bar
Drum High Set : 76.5 bar
Drum Low Set : 76.0 bar BP703 MB 2 STEAM DRUM PRESS H/L 76.5 / 50 bar
Superheater : 64.5 bar
Economiser : 95.6 bar BP712 MB 2 SHTR OUT STEAM PRESS H/L 62.5 / 54 bar

BP720 MB 2 DSHTR OUT STEAM TEMP 400℃

The superheater is of the vertical, interbank, convection type arranged for
multipass steam flow. Superheater elements are arranged in groups of six BP723 MB 2 SHTR OUT STEAM TEMP H/L 530/400℃
concentric hair pin loop elements, the ends of which are welded into the inlet-
outlet headers and intermediate headers. The arrangement of elements is such 4. IAS Display
that the superheater tubes are parallel to the boiler generating tubes. Guide
castings welded to the superheater elements and two inch generating and screen
tubes form a sliding joint which aids in tube alignment. The superheater inlet,
outlet intermediate header run parallel to the water drum through the depth of
the boiler. Each header is sectioned internally by welded steel diaphragms to
direct the steam through five consecutive passed between the headers. Complete
drainage is provided by a small opening in the lower edge of plates allow access
for inspecting and cleaning the superheater internally.

Taking steam from the primary superheater and leading it through the
temperature control desuperheater, situated in the water drum, regulates the
outlet temperature of the superheated steam for main propulsion, generator, and
main feed water pump turbine. The control valve then regulates steam flow
from the desuperheater to the secondary superheater section in accordance with
the temperature signal from the superheated steam. To ensure that there is
always a flow through the secondary superheater, a line fitted with an orifice
bypasses the temperature control desuperheater and the control valve. The
temperature control valve also has a bypass orifice.

The main stop valves 601V and 602V interconnect both boilers and the
common line and supply the main turbine with superheated steam. Each boiler
has an auxiliary machinery stop valve 604V and 603V, which supplies both
main boiler feed water pumps and turbo generators. The circuit is designed to
supply the auxiliary machinery from either side of the manifold, giving greater
flexibility for maintenance. Warming through bypass valves are provided at all
the principal stop valves.
Steam from the superheater outlet is led to the internal desuperheater, situated in
the steam drum, from where it is distributed to the various steam service.

Final Draft / 2007.12.28 2-2 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.1.2a Desuperheated Steam & Steam Dump System

To 1st Stage Feed

Water Heater
PI PI
PX PX
IAS IAS

Condenser
A613

To Main
LS TI LS Feed Fan
113V

112V
Drive Unit
Air In To Main Boiler
Forced Draft
Fan (A650) Soot Blower
TI
TX BV223
IAS
To 3rd Stage Feed To 1st Stage Feed
131V
No.2 Water Heater Water Heater High Temp. TIAH
TX
A613 PX
Alarm : 140℃ IAS
Steam TI
Forced Draft Air PI TI

Water System
Fan (A649) TI Heater VPI (Inter-locking) 217V
Feed Fan

Condensate
From Main
IAS PI
Drive Unit To Safety

Control
PI On ECP
TI PIAH
BV231 A821 BV231
108V
TI Manifold IAS PX PI IAS IAS
PX

Air
IAS
TI PI Control I Multi Plate
TX TX TI
ABC P

T-67
S Air
BV232 No.1 External
Desuperheater

732V
731V 726V 226V

ORI-5
PIC LS LS
BV321 IAS 168V
121V To Main 730V No.1 Excess Steam
TX
Sett. Temp. :
PX
167V Condenser Dump Pressure Below 130℃
From No.2 M/B BV302 PI
Sett.
To Deaerator & Control Valve
(Desuperheated 7.5 bar
TI 60.3/4.5 bar Distilling Plant To Safety Control PI
Steam) I
712V
Pressure PI Air P
TX
TIAH Manifold IAS IAS
IAS Reducing

713V ORI-6
705V Valve For IP Bleed
711V
Control Air
PIAH PX V/V Operation PS

Turbine
PX 171V

Astern
IAS IAS
I
172V PI On ECP LP Turbine

T-66A
PI On BGB Control I IAS P PI TI
P PI
Air IAS
721V ORI-4 T-66
710V

Sett. PX
7.5 bar 102V TI
702V 718V 719V 720V LS M
IAS

TX

Water System
Spacer
701V 60.3/9.8 bar 60.3/3.2 bar 143V 102T 142V 101V (Inter-locking)

Condensate
O-1

From Main
Pressure Pressure (For H.P Turbine
Reducing Reducing Solo Running)
706V

Valve Valve 144V TIAH TX

IAS
To Atmos. To Atmos. IAS
60.3/15.7 bar Control I
Drain Tank
(L.P Turbine Solo Running)

Drain Tank O-22 TI

714V
ORI-7 709V

Air P
Pressure No.2 External
704V Reducing To I.G.G. Atomiz. ORI-8
Valve To Atmos. T-63
728V Desuperheater 227V
707V

ORI-1 717V

PIAH
PX
IAS Steam Heater Drain Tank To Main PI
PX LS
BV321 IAS IAS IAS
PI On BGB Condenser
302V 301T 303V
715V

PIC On ECP PX
708V

Control I I 722V No.2 Excess Steam

Air P P IAS
TIAH Dump Pressure
TX
IAS
304V
From No.1 M/B BV302 Control Valve
716V

TI 165V Control PX PI
(Desuperheated PI To Safety Air

Spacer
PI
Steam) Control PI
301V

TI I
Manifold IAS

760V 611T 758V

159V

PIC 169V IAS Air P

PX
IAS
PI T-69
PI PI PX
PIC TX

759V
PX
BV232 IAS
PX 166V PX IAS TI

T-62
163V

16.3/10.3 bar LS

From Main Cond. Pump

or Cond. Drain Pump
PIC Pressure PI

T-3
IAS
BV231 A821 BV231 Reducing On ECP
164V ORI-2
162V

TI Sett. To Safety Valve HP

TX 17.3 bar PI Ahead V/V Ast. V/V
ABC Turbine
Manifold IAS IAS
107V TI Control I PX
PI To Atomizing Air P To Atmos. On
PI TIAHL
T-61C T-61
Drain Tank TIAH ECP TX PX

T-64
IAS
160V

No.1 Steam for 170V

T-61A
TI IAS T-64A
Steam TI PI
Main Boiler 110V PS PI PIAHL
PX On ECP IAS

T-64C
Air LS M
TX TI
TI
Heater PX To Deck
111V Main Steam Press.
Scupper 114V
153V 101T 152V To Main Control Low Low
TI Sett. To Atmos. Key
IAS
TX BV223 13 bar 141V Condenser
Forced Draft Drain Tank ORI-3 723V 724V Superheated Steam Line
154V
Air In Fan (A650) Desuperheated Steam Line
A613 148V Condensate Line
To Auxiliary Steam
106V

LS TI LS Feed Fan From Desuperheated Main Steam Supply Air Line

Drive Unit Desuperhater (9.8 bar) 173V 103T 174V
PI Steam (15.7 bar) From Main Boiler Drain Line
PX
IAS For M/T Warming-up To Atmos. Drain Tank

Final Draft / 2007.12.28 2-3 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.1.2 Desuperheated Steam & Steam Dump Systems (9) The system is now ready for use. The main piston valve and the Spray Valve Split Range
control valves will be controlled from the ACC.
1. Desuperheated Steam System Auto/Man
TIC PV
3. Steam Dump External Desuperheater Temperature Control Ext. DSH Operation
PID
Superheated steam from each boiler’s outlet is led to an internal desuperheater, Discharge Temp.
Temp. SP Control High
which is fitted in each boiler’s steam drum. Surplus steam, produced by excess steam pressure during load changes or Operator Sel.
excess boil off from the cargo part, is dumped to the main condenser or aux. High No.1 Spray
These desuperheaters discharge to a common line and supply the following condenser via the steam dump external desuperheaters. Sel.
Valve
services:
100% ABC No.2 Spray
The steam dump control valves are controlled from the ABC. The IAS aims to Dump Valve
The LP turbine solo running operation control the external desuperheater downstream steam at 160°C. Higher CTRL
No.1 No.2
Valve
The main dump steam system temperatures may overheat the condenser and to prevent this IAS is controlling Valve Valve
Pos.
The main boiler soot blowers flow through spray valves. Spray water is supplied from the main condensate
The general service and heating steam make-up pumps or condensate drain pumps. If the condenser is supplied with too high 0%
0% 50% 100%
The bleed steam system make-up steam temperature, the condenser vacuum will decrease and thereby reduce the
Controller Output
condenser efficiency. Steam temperature too low will include water and may
2. Steam Dump Desuperheaters cause water hammering or, dump nozzle inside the condenser may be damage.

The main boilers burn excess boil-off gas which is produced from the cargo. If The two spray valves, one per dusuperheater, are PID controlled in a split range 4. Control and Alarm Settings
the boil-off gas produced exceeds the requirements for normal steam production, control. The initial controller output 0~50% will open the first spray valve
then the steam production is increased and the excess steam produced is 0~100%. Controller output 50~100% will open the second spray valve 0~100%, IAS
Description Setting
dumped to the main condenser or auxiliary condenser via the main dump while valve no.1 remains fully opened. However, the final split ranges should Tag No.
external desuperheaters. The spray water for the desuperheater sprays are be the same as ABC output signal to dump steam control valves. In order to
MD011 MAIN CONDENSER VACUUM L 600 mmHg
supplied from the discharge of the main condensate pump and the drain pump. react to sudden changes in dumping rate initiated from the ABC, a high
Desuperheaters can discharge to the auxiliary condenser whenever the main selection function is added to the spray valve control. The ABC PID controller ST016 AUX ST EXT DSHTR TEMP H/L 205/170℃
condenser is unavailable. The temperature at the outlet from the desuperheater output to dump valves is compared to the PID controller output to spray valves.
BC747 DUMP STEAM OUT TEMP H 400 °C
is measured and a corresponding signal is transmitted to the spray control valve, The comparator selects the highest as valid spray valve control signal.
which alters the water supply accordingly. BD749 DUMP STEAM OUT PRESS H 5.0 bar
To prevent damage of external desuperheater in case of manual discharge
1) Procedure for the Operation of the Steam Dump Desuperheaters valves are accidentally closed, there are closed position limit switches available
to IAS. Any of these two valves being closed will not give steam dump
(1) Make sure the instrument and gauge valves are open and instrument available. Steam dump can be automatically overridden by closing the steam
air is supplied to the control units. dump piston valve. Override conditions depends on which condenser is being
used.
(2) Open the inlet and outlet valves of the line drain traps before the
piston valve. Steam Dump Control

(3) Make sure that the spray control valves are in auto mode. STM D Piston Valve Trip
Dump Available

ABC BCP
(4) Line up the spray water line from the main condensate pump or drain Steam Dump Available Logic
PID
Control
pump. IAS
Air
High
Sel.
Logic From Main Condensate Water
(5) Open the desuperheater discharge valve to the main condenser. Temp.
PID Discharge Pump / Drain Pump
(IAS) No.1 Spray
Valve Multi Plate
From Main Boiler
(6) Open the main supply valve to the desuperheaters 727V. TIC No.1 Steam Desuperheated Steam
Dump Valve

(7) Open the excess steam dump press control valve inlet and outlet No.2 Spray
Valve Multi Plate
TS PS PS
valves on each desuperheater 726V, 728V, 226V, 227V.
No.2 Steam
Dump Valve
Auxiliary
Main Condenser Condenser
(8) Make sure that the dump steam flow control valves are in auto mode.

Final Draft / 2007.12.28 2-4 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.1.3a Bleed System

126V

PI PI
PX PX
IAS IAS To Safety
A613
LS TI LS Feed Fan Manifold
113V

112V
To Distilling
Drive Unit TI
Plant
161V

120V
Air In PI
Forced Draft
Fan (A650)
TI
TX BV223 3rd Stage Feed From Main
IAS
Water Heater Condensate
131V To be Fitted
1st Stage Feed Water System
A613 No.2 PX Reversely Water Heater IAS
Steam TI Control
Forced Draft Air PI IAS I
P Air
Fan (A649) TI Heater Control VPI TI
127V
Feed Fan I
P IAS
Air To Atmospheric
Drive Unit PI To Safety LX On ECP
TI Drain Tank
108V Manifold

128V
BV231 A821 BV231 TI
145V 146V 104V IAS PX PI
TI LX
TX TX TI
ABC

T-67
BV232 147V Constant

103V
TIAH I
IAS Level Pot For Steam IAS P Control Air

ORI-5
PIC To Deaerator Press. Cont. T-25 T-302 T-24
BV321 IAS 168V TI TX
To Soot Blowing 121V PX
& Dump Steam PX 122V
System 167V T-26
From No.2 M/B BV302 PI
Sett.
To Deaerator & T-71A
7.5 bar From
(Desuperheated Distilling Plant 1.8 bar &
Steam) TI 60.3/4.5 bar To Safety

Packing Steam
I
712V PI P Control Air F.W.P.T
TIAH Pressure Manifold
TX IAS Exhaust
IAS Reducing T-28 T-303

713V ORI-6
705V Valve For IP Bleed Steam
711V
Control Air
PIAH PX V/V Operation PS

Turbine
PX 171V

Astern
IAS IAS T-27
I
172V PI On ECP LP Turbine T-29

T-66A
PI On BGB Control I IAS P PI TI
P PI
Air IAS
721V ORI-4 T-66 O-35
710V

Sett. PX From Water

7.5 bar 102V TI Seal
702V 718V 719V 720V LS M
IAS
To Atmos. Drain Tank
TX

Spacer
701V 60.3/9.8 bar 60.3/3.2 bar 143V 102T 142V 101V
Pressure
O-1
Pressure (For H.P Turbine
Reducing Reducing Solo Running)
706V

Valve Valve 144V

To Atmos. To Atmos.
60.3/15.7 bar Drain Tank
(L.P Turbine Solo Running)

Drain Tank O-22 X-75V O-32 O-33 TIAH

714V
ORI-7 709V

Pressure TX
IAS
704V Reducing To I.G.G. Atomiz. ORI-8 Gland Leak-off Reservoir TI
Valve To Atmos.
707V

ORI-1 717V

PIAH
PX
IAS Steam Heater Drain Tank To PI
BV321 IAS IAS O-31 Bilge
IAS
PI On BGB O-30 T-63 O-36

302V 301T 303V

715V

PIC
708V

Control I I 722V To Gland PX

Air P P IAS
TIAH
TX
IAS Condenser T-51

304V
From No.1 M/B BV302 PI
716V

TI 165V Control PX PI
On ECP O-11 LS
(Desuperheated PI To Safety Air

Spacer

HP Drain Pocket
Steam)
301V

Manifold

760V 611T 758V

159V

PIC 169V
PX
IAS
PI T-69
PI TI
PIC T-52

759V
PX TX
BV232 IAS
PX 166V PX IAS IAS TI PI
PX
PI
T-62 IAS O-12 LS
163V

16.3/10.3 bar
PIC Pressure PI
IAS O-20
BV231 A821 BV231 Reducing On ECP
164V ORI-2
162V

TI Sett. To Safety Valve HP

T-3
TX 17.3 bar PI Ahead V/V Ast. V/V LS
ABC Turbine
Manifold IAS IAS
107V TI Control I PX
O-21 T-53 Main
PI To Atomizing Air P To Atmos. On
PI TIAHL
T-61C T-61 O-13 LS Condenser
Drain Tank TIAH ECP TX PX

T-64
IAS
160V

No.1 Steam for 170V

T-61A
TI IAS

LP Drain Pocket
T-64A
Steam Main Boiler PS PI PIAHL T-54
TI PI 110V PX On ECP IAS O-14 LS

T-64C
Air LS M
TX TI
TI Main Steam Press.
Heater PX Control Low Low
To Deck
Key 111V
Scupper T-55
153V 101T 152V 114V O-15 LS
Superheated TI Sett.
Steam Line IAS
TX BV223 13 bar
To Atmos.
141V
Desuperheated Forced Draft Drain Tank ORI-3 723V 724V
154V T-59 T-58 T-60
Steam Line
Air In Fan (A650)
Condensate Line A613 148V Main Steam Supply
To Auxiliary Steam
106V

Air Line LS TI LS Feed Fan From Desuperheated From Main Boiler From Dist. W. Tank
Drive Unit Desuperhater (9.8 bar) 173V 103T 174V
Drain Line PI Steam (15.7 bar) or Drinking W. Tank
PX
IAS For M/T Warming-up To Atmos. Drain Tank (For Initial Charge)

Final Draft / 2007.12.28 2-5 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.1.3 Bleed System HP Bleed System The low pressure turbine aft side gland pockets are connected, respectively in
turn from the forward side, to the L.P. bleeder chamber, the gland seal steam
1. High Pressure Bleed System A&B Sensor receiver and the gland leak-off condenser, while the forward side gland pocket
Selector

PIC PIC
PID are connected to the gland seal steam receiver and to the gland leak-off
The HP bleed steam shut - off motor valve is opened by manual, to acknowledge 6 bar Steam condenser.
System
bleed off point through press transmitter. The normal bleed steam pressure joins 60.3/9.8 bar
ATM ST Press
A&B Sensor
9.8/6 bar
Pressure Reducing
Valve

the general service & heating steam system, through auxiliary steam The gland seal steam receiver is connected to the auxiliary steam system and the
desuperheater. The H.P bleed motor valve opens at a pressure of 14.0bar and PID
flash chamber whereby the auxiliary steam being supplied to the receiver during
Aux. Steam Ex. From Boiler
closes at 11.0bar. The HP bleed motor valve can automatically be closed when Desuperheater Feed Pump
the no load or low load operation and being discharged to the flash chamber
bleed steam pressure is decreased to 11bar.

Aux. Steam Ext.

TIC
during the high load operation.

A&B Sensor
DSHTR A&B

Selector
Sensor
(Opening is only permitted in operator manual ) Interlock
PID
TIAHL

PIC PIC
To Cargo Steam System & 7. Main Turbine Gland Steam Pressure Control
2. Intermediate Pressure Bleed System From
HP Bleed MT HP Bleed
Motorized Valve
15.6/10.3 bar
Pressure Reducing
FWD. H.F.O. Bunker Tanks

Boiler F.O Heater, etc

IP bleed steam is bled from the crossover pipe between the HP and LP turbine. Valve

100%
The IP bleed steam shut - off motor valve is opened by manual, to acknowledge A&B Sensor
Selector

to bleed off point through press transmitter. The normal bleed steam pressure PIC PIAL
PID
Valve
Make-up
Valve
Spill
Valve

joins the 3rd stage feed water heater. The IP bleed motor valve opens at a Main Boiler Desuperheated
Steam
Position
60.3/9.8 bar 60.3/9.8 bar

pressure of 3.5bar and closes at 2.5bar. The IP bleed motor valve can ATM ST Press
A&B Sensor
Pressure Reducing
Valve
0%
0% 50% 100%
automatically be closed when bleed steam pressure is decreased to 2.5bar. 0 bar 0.1 bar 0.2 bar

(Opening is only permitted in operator manual )

Operator SP
IP Bleed System Proportional
Action Only
PID
P=1
3. Low Pressure Bleed System Auto/Man A&B Sensor
LP bleed system is supplied directly to the 1st stage feed water heater. A control Operation Selector
Gland Steam
valve on the heater’s drain outlet maintains the level of the 1st stage feed water PIC PIAHL Pressure
heater. The drains from the steam air heater are normally led through the 1st stage Deaerator
Transmitter
(30 m3) Split Range Gland Steam
feed water heater, but they can be diverted directly to the atmosphere drain tank 1.8 bar Air Fail to Open Reservoir
PID
From 9.8 bar
as well. Steam System Gland Steam
PIC 2.1 bar Make-up Valve Air Fail to Close
Main Condenser
To Main
Main Feed Water
4. IAS Control System Pump Turbine
1.8 bar
Make-up
2.1 bar/
722 mmHG
1.8 bar Dump Steam
Gland Steam
Spill Valve
Condenser

Steam
The HP bleed normally supply the 10.3bar line with steam. And this line supply

5.7/1.8 bar
steam to the auxiliary steam external desuperheater. Feed water is used to Interlock PID HS

desuperheat the steam and the temperature of the output is maintained with a PIC
PIC 5.7 bar A&B Sensor

From Dump Selector

The main turbine gland steam pressure is maintained by controlling two air
regulating valve, controlling the flow of feed water. The desuperheated 9.8 bar IP Bleed MT IP Bleed
Steam
PID
Motorized Valve PIC PIAHL
operated valves. Theses two valves IP-converters are set up in split-range. At
steam is supplied to the cargo steam system, aft HFO bunker tanks heating, 6 bar Main Boiler
Desuperheated low gland steam pressure, the make up valve where steam is supplied from the
steam system boiler FO heater, etc. When steam supply from HP bleed is 60.3/3.2 bar
DSHTR ST Press
60.3/3.2 bar Steam

A&B Sensor 9.8bar steam system. When gland steam pressure rises, the make up valve will
insufficient to maintain pressure in the 9.8bar steam line, steam will be supplied
PID first close, and then the steam gland spill valve will open for spill to main
from main boiler desuperheated steam line across the 60.3 / 9.8bar reduction PIC
condenser. The above functionality depends on valves being selected to auto
valve (10.3bar make-up) No. 1&2 Steam Air Heater &
Main Boiler
3rd Stage Feed Water Heater 60.3/4.5 bar
Desuperheated
Steam
operation mode. When valves are selected to manual mode, the operator can
freely position the valves within the 0~100% operating range.
To achieve the above described functionality a PID controller is used for each of
the reduction valves. The 1.8bar make-up and dump valves operate in split -
6. Main Turbine Gland Steam System 4. Control and Alarm Settings
range to avoid make-up and dump simultaneously. In addition to maintain
pressure on 1.8bar line the1.8make up valve also work as a 5.7bar line. A high
selector (HS) will be used to select between control signal from 1.8make up and The part of the casing where the rotor extends through is provided with the IAS
metallic labyrinth packing to minimize the steam leakage from the casing and the Description Setting
5.7bar dump PID, making it differentiate between the valve being a dump and a Tag No.
make up valve. With this setup there will be situations, depending on steam load air leakage into the casing.
MT110 MT GLAND STM PRESS H/L 0.35/0.0bar
that both 1.8bar make up and dump valves are open simultaneously.
PID controllers can be selected to auto or manual operation. In manual operation, The high pressure turbine forward side gland pockets are connected, respectively MT105 MT HP INLET STM TEMP H/L 530/430℃
the operator can position the valve by a 0~100% output order, and in Auto the in turn from the aft side, to the high pressure turbine exhaust chamber, the gland
seal steam receiver and the gland leak-off condenser while the aft side gland MT106 MT HP INLET STM PRESS H 70bar
controller will change valve position based on the PID controller algorithm.
pockets are connected to the gland seal steam receiver and to the gland
condenser incorporated with main air ejector.

Final Draft / 2007.12.28 2-6 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.1.4a 6bar Steam System

To No.1 To No.2 To No.1 To No.2
To Safety Main A/C Main A/C Aux. A/C Aux. A/C
(For Tank
Manifold Accom. TI
Cleaning
E/Casing) No.1 Air
E/R
Condition

423V
S Unit for
IAS
TI MSBR/ECR
Control I
467V
Air P PX PI PX 455V Incinerator Waste
406V Oil Service Tank

422V
402V 403V 405V Sett.
From 401V
7 bar
9.8 bar
To Atmos. TI
Steam

411V

463V
9.8/6 bar TI 445V
P.R.V. To Deck G/T L.O. Settling Tank Drain Tank No.2 Air
404V Scupper Condition
(For 2nd S Unit for
ORI-41 Deck (P)) MSBR/ECR
Boiler Sprayer TI 425V 436V
G/E L.O. Settling Tank
Cleaning Device 471V
(For 2nd
435V
Deck (S))
To Boiler Calorifier
Purge Drain Line

428V
487V
407V TI 427V (For 3rd

465V
To Deoiler M.L.O. Settling Tank
Deck (S))
TI (Back Flushing) (For Gen. Service
2nd Deck(P))
426V
Inspection TK
BV416 BV416

Smothering
410V Steam

Jacket Heating Steam

Sludge Tank
464V

TI

H.F.O Trans. Pump

TI
Low Sulphur F.O. 448V No.1 Main Boiler No.2 Main Boiler
431V Tank(S) TI
(For Tank Cleaning 451V Low Sulphur F.O.
466V

Purifier Room) Sett. 65°C Tank(P)

430V 429V
Sett. 65°C
L.O. Out Sett. 85°C 437V 438V
413V IT
412V H.F.O. Settling
No.2 L.O. 457V
Tank (S) TI
Purifier Heater H.F.O. Settling
486V
Tank (P)

408V
TI AFT H.F.O. Bunker 433V
Tank (S)
Sett. 85°C TI
L.O. Out 441V AFT H.F.O. Bunker
417V 416V 434V Tank (P)
No.1 L.O. (For 4th
Purifier Heater TI 443V Deck (S)) 442V
H.F.O. Overflow Tank (For Tank Cleaning
4th Deck(P))
444V
(For Tank Cleaning
TI 454V Floor FWD (P))
(For Tank Cleaning 446V TI
F.O. Drain Tank
420V Floor AFT)
Oily Bilge Tank
470V

439V

Control
Air Key

456V
TC Desuperheated Steam Line
452V

450V

449V

447V
TI TX (For S/C (For S/C
TI Sett. Condensate Line
40°C 421V Steam Steam
409
Bilge Holding Tank Blowing) Blowing) (For Sea Chest Sea Water Line
H.S.C.(S) for H.S.C.(S) for L.S.C.(Mid) L.S.C.(S) for
M.L.O. S.W. Service for S.W. Service Steam Blowing) Air Line
480V Main
Sump Tank & Ballast Condenser Main & Ballast
System Condenser System Drain Line

Final Draft / 2007.12.28 2-7 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.1.4 6bar Steam System 2) Accommodation

1. General Service Steam System (1) 422V

Via the boiler internal desuperheaters a common pipeline is supplied with 60.3 - Main air conditioner unit
bar desuperheated steam. The 60.3bar steam pressure is reduced to 9.8bar by a - Aux air conditioner unit
control valve, supplying both boilers with atomising steam. Each boiler also has
individual pressure reducing valve.

And 9.8bar steam pressure is reduced to 6.0bar by a control valve (402V),

supplying. 6bar steam is provided to heaters of general , etc

The service steam is distributed as follow :

1) Engine Room

(1) 466V

- Sludge Tank heating

- LO Purifier heaters

(2) 464V

- Oily bilge Tank heating

- Main turbine LO sump tank heating
- Bilge holding tank

(3) 463V

- HFO overflow tank heating

- AftFO bunker tank (S) heating
- HFO settling tank (S) heating
- Low sulphur FO tank (S) heating
- FO drain tank heating

(4) 465V

- Aft HFO bunker tank (P) heating

- HFO settling tank (P) heating
- G/T LO settling tank
- For tank cleaning 4th Deck(P)
- For tank cleaning Floor FWD(P)
- FO drain tank (P) heating
- Low sulphur FO tank (P)

(5) 435V

- Calorifier heating

Final Draft / 2007.12.28 2-8 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.2.1a Main Condensate System

E Control Air Mechanical Seal Housing Bracket

P Main Cond. Hot Well Drain (Inboard Leakage)
T-42 Level Control Valve
45V 44V 40V 41V IAS
To Deaerator or PI
Distilled Water Tank
39V FS

16V
28V No.2 Main Feed
TIAL Water Pump
IAS Turbine
FS
TI TX 43V
Mechanical Seal Housing Bracket
1st Stage Drain (Outboard Leakage)
TI 42V
Feed Water Heater E Control Air
P Main Cond. Inboard Mechanical
T-43 IAS Seal Flush Water
37V 36V Recirculating Valve PI
(Recirculation Line)
FS

47V
46V No.1 Main Feed
38V
Water Pump
TIAH Turbine
For Vacuum
Breaker
IAS FS

IAS TI TX 34V
T-41B Outboard Mechanical
Seal Flush Water
T-41A
Gland Condenser

35V
33V

Vacuum Pump Unit

PI
I Control No.2 External
P Air No.2 13V
Air 15V Desuperheater

57V
24V 25V
Main Condenser Sealing I Control

12V
Tank P Air
55V Air
(Balancing Line)

52V Ejector No.2 Distilling Plant (60 Mesh) IAS

TI (60 ton/day) PI
TX No.1 External
LAHL ESLD TI 32V Desuperheater
T-112

Temp. Strainer : Cooler for

49V

58V

IAS IAS

56V
Seal Water 26V 27V
Element Shall Be I Control
Removed After LI LX LX P Air

29V
TI 30V
Sea-trial.
T-113

(60 Mesh)
48V

59V

I Control IAS
P Air
Air No.1 11V
14V

31V
53V
Sealing
From Condensate

10V
TI TX Tank

23V
54V Air For Air Drain Pump
TI Ejector Vent
IAS TI

Cooler for

20V
69V

CI PI Seal Water
67V

(Make-up & Seal

3V 4V

Water Supply)
Control To Oil Content
I Air Monitor (Deoiler)
CI P Control
22V No.2 (A) 18V 19V

17V
Air
T-57 Deoiler Sampling To Inspection

64V
To Astern 62V LS 61V
(A) Cooler Tank
T/B Water
SIAH Spray O-26
IAS PS PS To Bilge To No.1 Distilled To No.2 Distilled
Temp. Strainer :
Well
68V

CI PI Element Shall Be Plant D.S.Heater Plant D.S.Heater

66V

SX Removed After
1V 2V
63V
6V

8V

Sea-trial.

50V

51V
21V No.1 (A) Control Air
7V
5V

Key
(A) Temp. Strainer : CI From Main Condensate
Element Shall Be Condensate Line
Main Condensate Pump T-56 Water System
To Water Removed After

60V
63V LS 65V Air Line
(110 m3/h x 95 MTH) Seal Valves Sea-trial. To Main Condensate Dump
Steam Steam Water Spray Drain Line
O-27

Final Draft / 2007.12.28 2-9 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.2 Condensate and Feed Water Systems Condensate water is supplied to following systems. 3. Main Condenser Level Control (IAS)

2.2.1 Main Condensate System - Spray water for No.1 and No.2 dump desuperheaters
- Spray water for main turbine astern steam
100%
1. General Description - Water spray to dump steam chamber Recirculating
- Condensing water for Fresh water generator Calculated
Valve Level
Control

To Deaerator
Valve
The main condensate system, as part of the closed feed cycle, is the section - To mechanical seal water for feed water pump Position Valve

concerned with the circulation of feed water from the main condenser to the Control Recirculating 0%
-125mm 0% 125mm
main feed pumps via the deaerator. The deaerator is a contact feed water heater, feed water deaerator and feed Valve Valve
Level Set Point Deviation
Exhaust steam from the main turbines, turbine generators, dump steam and system header tank, providing a positive inlet head for the main feed pumps.
other auxiliaries is condensed under vacuum in the sea water cooled main Non condensable and associated vapour is drawn to the gland leak-off Operator SP PID Proportional
P=1 Action Only
condenser. condenser and away through the fan. Auto/Man
Operation LT
1st Stage Feed
The condensate water is extracted by a main condensate pump and circulated The steam cycle is a dynamic system and variations in flow require condensate Level Control Water Heater
Valve
through various heat exchangers before entering the deaerator which is located make-up or spill. The deaerator level is controlled by the spilling of excess Recirculating
Valve

at a high point in the engine room. Water in the deaerator provides the main condensate back to the distilled water tanks at deaerator high level signal, and
Main Condenser
feed pumps with a positive suction head. by accepting make-up to the system from the distilled water tanks at low level
signal. The unit is also fitted with a low-low level alarm. Gland
Condenser
During the process of circulation from the main condenser to the main feed
pump inlet, the condensate temperature is raised from approximately 33°C to A sampling and analysis cooler permits the monitoring of the condensate before
127°C. This increase is gained by the use of otherwise waste heat in the gland and after the deaerator. Hydrazine injection into the system is arranged prior to
No.2 Fresh
condenser, condensate cooled type fresh water generator.. the main feed pump suction. Water
Generator

The glands of the two condensate pumps are water sealed to prevent air ingress, 2. Capacities and Ratings Condensate
Pumps
with a balance line returning to the main condenser from the highest points of
the pump inlets in order to prevent the formation of flash steam in the service Main Condenser: KHI
pump. Cooling area : 3,360m2
The main condenser level is controlled by level control valve and re-circulation
The main condensate pump discharge pressure is alarm monitored, with low- Main Condensate Pumps: Shinko control valve. These valves are fitted into lines after the gland condenser, ensuring
low pressure initiating change-over of the pump. No. of sets: 2 this has a condensate flow through it at all times.
All valves from condenser outlet to main condensate pump inlet have Model: EVZ130M
condensate water sealed glands to maintain main condenser vacuum. Flow: 110m3/h The signal from the condenser level transmitter is compared in a level control block
in IAS, with the output signal operating either level control valve and the re-
The main condenser is a potential source of feed water contamination due to Deaerator: Dong-Hwa Entec circulation valve. At normal working conditions, with the main turbine having high
possible cooling sea water leakage. A sample point and salinity monitoring Type: Spray Scrubber type steam flow, the level control valve will be open, allowing condensate through the
system continually check condensate quality in the combined pump discharge No. of sets: 1 1st stage feed water heater to the deaerator. At low main turbine loads, this valve
line. Capacity: 30m3 will close, and the recirculation valve open, ensuring water level in the condenser
at all times and that the condensate pumps do not run dry.
Condensate discharge flows through the condensate cooled type fresh water 1st Stage F.W. Heater: Dong-Hwa Entec
generator and the gland condenser. These units condense the distilled vapour Heat transfer area: 100m2 An open loop level control scheme is provided to maintain main condenser level as
from the fresh water generator and the vapour from the gland leak-off systems proportional to predefined control curve. Open loop control means that it does not
of the main feed pumps, turbine generator and main turbine. The drains Vacuum Pump: Shinko compensate the error, this is the deviation between the set point value and current
produced flow through a U tube water seal to the atmosphere drains tank. No. of sets: 2 value, with a feedback signal. This means that it will open control valve to a degree
Model: UVT13 that corresponds to the condenser level percent. If the level is 50% of the
Air and other non-condensable are extracted from the gland condenser by the Flow: 12.7m3/h measuring range, control valve will open to 50%.
gland exhaust fan, which discharges to atmosphere.
Direct operation of the control valves can be achieved by changing the controller to
During ship operation, dump steam is produced by burning excess boil-off gas. Manual Mode. If the controller fails, the control valves position will be maintain at
This steam is desuperheated and dumped to the main condenser. A water spray its last position.
is arranged in way of this exhaust to the main condenser.

Final Draft / 2007.12.28 2 - 10 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.2.1a Main Condensate System

E Control Air Mechanical Seal Housing Bracket

P Main Cond. Hot Well Drain (Inboard Leakage)
T-42 Level Control Valve
45V 44V 40V 41V IAS
To Deaerator or PI
Distilled Water Tank
39V FS

16V
28V No.2 Main Feed
TIAL Water Pump
IAS Turbine
FS
TI TX 43V
Mechanical Seal Housing Bracket
1st Stage Drain (Outboard Leakage)
TI 42V
Feed Water Heater E Control Air
P Main Cond. Inboard Mechanical
T-43 IAS Seal Flush Water
37V 36V Recirculating Valve PI
(Recirculation Line)
FS

47V
46V No.1 Main Feed
38V
Water Pump
TIAH Turbine
For Vacuum
Breaker
IAS FS

IAS TI TX 34V
T-41B Outboard Mechanical
Seal Flush Water
T-41A
Gland Condenser

35V
33V

Vacuum Pump Unit

PI
I Control No.2 External
P Air No.2 13V
Air 15V Desuperheater

57V
24V 25V
Main Condenser Sealing I Control

12V
Tank P Air
55V Air
(Balancing Line)

52V Ejector No.2 Distilling Plant (60 Mesh) IAS

TI (60 ton/day) PI
TX No.1 External
LAHL ESLD TI 32V Desuperheater
T-112

Temp. Strainer : Cooler for

49V

58V

IAS IAS

56V
Seal Water 26V 27V
Element Shall Be I Control
Removed After LI LX LX P Air

29V
TI 30V
Sea-trial.
T-113

(60 Mesh)
48V

59V

I Control IAS
P Air
Air No.1 11V
14V

31V
53V
Sealing
From Condensate

10V
TI TX Tank

23V
54V Air For Air Drain Pump
TI Ejector Vent
IAS TI

Cooler for

20V
69V

CI PI Seal Water
67V

(Make-up & Seal

3V 4V

Water Supply)
Control To Oil Content
I Air Monitor (Deoiler)
CI P Control
22V No.2 (A) 18V 19V

17V
Air
T-57 Deoiler Sampling To Inspection

64V
To Astern 62V LS 61V
(A) Cooler Tank
T/B Water
SIAH Spray O-26
IAS PS PS To Bilge To No.1 Distilled To No.2 Distilled
Temp. Strainer :
Well
68V

CI PI Element Shall Be Plant D.S.Heater Plant D.S.Heater

66V

SX Removed After
1V 2V
63V
6V

8V

Sea-trial.

50V

51V
21V No.1 (A) Control Air
7V
5V

Key
(A) Temp. Strainer : CI From Main Condensate
Element Shall Be Condensate Line
Main Condensate Pump T-56 Water System
To Water Removed After

60V
63V LS 65V Air Line
(110 m3/h x 95 MTH) Seal Valves Sea-trial. To Main Condensate Dump
Steam Steam Water Spray Drain Line
O-27

Final Draft / 2007.12.28 2 - 11 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

4. Operating Procedures 5. Control and Alarm Settings

1) Check the system is ready for use. Start main sea water circulation IAS
pump through the main condenser. Description Setting
Tag No.
MD011 MAIN CONDENSER VACUUM LOW 600 mmHg
2) Check the quantity of any condensate already in the condenser. If
necessary, drain the condensate side of the condenser to the bilge to MAIN CONDENSATE P/P OUTLET
CN011 4 PPM
preclude any risk of feed contamination. SALINITY HIGH
MD014 MAIN CONDSR LEVEL H/L 300/-110 mm
3) Isolate the condenser level alarms from the condenser, drain the lines
to prove clear, and return to service. CN032 GLAND CONDSR OUT TEMP H 55℃

4) Initial filling of the main condenser is by direct drop from the distilled
6. IAS Display
water tanks through filling valve

5) Ensure the main condenser re-circulation valve is operational, inlet and

outlet valves open, gland condenser bypassed, with drains and seal line
to the main condenser.

6) Ensure that control air is supplied to all control valves in the system.
Check the condenser level transmitter and level gauge are on line.

7) With both condensate pumps isolated, check for rotation by hand.

Open one of the pump's suction, balance line and gland seal valves.
Open the pump discharge valve and line to the salinity probe.

8) Start the pump and check its operation.

9) Check and start one main vacuum pump, bringing it into operation to
raise the condenser vacuum.

10) Ensure the condenser level control valve is operating correctly.

11) Open the feed inlet to the gland condenser, vent off the unit, open the
outlet valve and close the bypass and vent valves.

13) Open the astern water spray steam and dump steam water spray.

14) Open all valves on the second condensate pump, place it in stand-by
mode. Check that the auto cut-in operation is working when opportune.

15) Check all seal water and condensate water lines to ensure that valves
open correctly.

16) Continue to raise the main condenser vacuum, bringing into service the
gland steam system.

Final Draft / 2007.12.28 2 - 12 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.2.2a Aux. Condensate Water System

Pump Recirculating Line

From Boiler Feed Water
To Main Feed Water

114V
Steering Gear
Room

113V
Drinking Distilled

Pump Suction
Water Water

117V 116V 115V

IAS
Tank (P) Tank (S)
Control I
Air P

118V
To Auxiliary Grease
131V 11S 130V

Extractor TI
Feed Water Line
For Main Boiler (80 m3)
132V

(For Boiler Feed

PI
Water Filling)
Reservoir Reservoir

M-45V

Bag Filter

Bag Filter
Bag
LIAHL
Filter IAS LX LX IAS

LI
BGB
PI

From 1st Stage Feed Water

Heater & Main Condensate
Pumps
No.1 Boiler F.D No.2 Boiler F.D
Water Pump Trip LS LS Water Pump Trip
Diff. Press.

121V 120V 119V

IAS Gauge

127V
Control (On Body)
I
Air P DPI

122V

129V
Deaerator (30 m3)

126V
From Main
Condensate
125V 124V
Water System

107V 108V 109V

IAS
Control I
Air P

110V
Atmos. Drain Tank
Level Control Valve

ORI-11
To Main Turbine Flash
Chamber Make-up

Condenser
To Auxiliary

To External Desuperheater

SIAH
IAS SX
Level Switches to be
Located at Same Level
IAS
For Dump Drain
102V 104V 106V LD100S
LS Pump Start

Cabinet 2 LS For No.1 Condensate

Drain Pump Start
Atmospheric LS For No.2 Condensate
Drain Pump Start
128V Drain Tank
PI PI PI LAH
(8 m3) LS
Condensate IAS
Dump Drain Pump
No.1 No.2 Drain Pump
Key (80 m3/h x 85 MTH) LS
LAL
(30 m3/h x 85 MTH) IAS
Condensate Line CI CI CI

138V
101V

103V

105V
Air Line
Drain Line

To Deck Scupper

Final Draft / 2007.12.28 2 - 13 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.2.2 Auxiliary Condensate Water System 2. Capacities and Ratings 4. Control and Alarm Settings

1. General Description Dump drain pump: Shinko

IAS
Model: EVZ130MH Description Setting
Tag No.
Condensate from the auxiliary steam services is returned to the atmosphere No. of sets: 1
drain tank for recirculation of the main cycle and drains water is pumped by the Flow: 80m3/h x 85 MTH CN026
CONDENSER DRAIN PUMP OUTLET
14 PPM
SALINITY H
drains pump. Drains that are free of any possible contamination are led directly
Condensate Drain Pumps: Shinko
to the atmosphere drain tank. Other service line drains which have a potential CN027 DEAERATOR LEVEL H/L 450 / 400 mm
Model: EVZ70MH
for hydro-carbon and other contamination, are segregated and are only led to No. of sets: 2 FE048 DEAERATOR OUT TEMP L 120℃
the atmosphere drain tank after suitable testing and inspection. Flow: 30m3/h x 85 MTH

This system operates in conjunction with the main condensate system, whereby 3. Operating Procedures of Atmosphere Drain Tank System
the condensate from both systems join together before entering the deaerator. It
is owing to the combination of both systems that the deaerator make-up and 1) Open the instrument air supplies to all control valves and level
spill control valves operate. indicators. Stroke all valves to prove operation on local control.

When the main recirculation cycle needs some water, the water from the
distilled water tank enters the atmosphere drain tank via the make-up valve
which is controlled by deaerator level signal. A direct line from the distilled
water tanks to the main condenser permits the initial filling of the condenser.
The atmosphere drain tank has two normal condensate drain pumps. The
atmospheric water is pumped by the in-use pump, through the atmospheric
water drain tank control valve 108V, which maintains the atmospheric water
drain tank level. The pumps have a re-circulation line back to the atmospheric
water drains tank, via an orifice plate, which ensures the pumps do not run dry.
Should the tank level become high, then the second condensate drain pump will
auto cut-in and stop again when the level returns to normal.
2) Test the water in the distilled tanks for contamination and, when
satisfactory, open the outlet valve on one of the tanks, ensuring that the
outlet valve on the other is closed.
3) With the drain pumps isolated, check for free rotation by hand. Line up
the valves on the pumps, ensuring that the pump and line recirculation
valves to return water to the drain tank are open.
4) Open up the inlet and outlet valves on the grease extractor.
5) Ensure that the inlet and outlet valves to the make-up, spill and
atmosphere drain tank level control valves are all open.

The atmosphere drain tank also has a larger capacity dump drain pump. This 6) Allow the atmosphere drain tank to fill to normal level. When the level
pump auto starts on drain tank high-high level and when the main dump is reached, start up the in-use drain pump to discharge water to the
external desuperheater is in operation, as there is a high capacity of water deaerator. When the correct deaerator level is achieved, the spill valve
flowing to the drain tank. should open to maintain this level.

The discharge from the drains pumps can be used for the initial filling of the
main boilers by opening the valve, through the auxiliary feed line.
Potentially contaminated drains pass through the engine room drains cooler,
which is itself cooled as part of the fresh water cooling system. From the drains
cooler, the condensate passes through an oil content monitor and finally to the
atmospheric water drain tank.
These drains are normally from steam used to heat bunker fuel, lube oil
purifiers, sludge tanks, deck steam machinery etc, where the drains have a
greater chance of entraining oils and other impurities.
7) When the system is operational, vent off the grease extractor element.
8) Check that the system is operating satisfactorily. Ensure that there is
no water or air leakage. Check that the drain tank salinity probe is
reading correctly.
9) As soon as operational conditions permit, function test the system high
and low alarms and check the drains pump auto changeover operation.
All such operations must be carried out with care and be closely
monitored.

The condition of the water after the drains cooler is monitored by an oil
detection unit, which will initiate an alarm, should there be any contamination.

Final Draft / 2007.12.28 2 - 14 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.2.2a Aux. Condensate Water System

Pump Recirculating Line

From Boiler Feed Water
To Main Feed Water

114V
Steering Gear
Room

113V
Drinking Distilled

Pump Suction
Water Water

117V 116V 115V

IAS
Tank (P) Tank (S)
Control I
Air P

118V
To Auxiliary Grease
131V 11S 130V

Extractor TI
Feed Water Line
For Main Boiler (80 m3)
132V

(For Boiler Feed

PI
Water Filling)
Reservoir Reservoir

M-45V

Bag Filter

Bag Filter
Bag
LIAHL
Filter IAS LX LX IAS

LI
BGB
PI

From 1st Stage Feed Water

Heater & Main Condensate
Pumps
No.1 Boiler F.D No.2 Boiler F.D
Water Pump Trip LS LS Water Pump Trip
Diff. Press.

121V 120V 119V

IAS Gauge

127V
Control (On Body)
I
Air P DPI

122V

129V
Deaerator (30 m3)

126V
From Main
Condensate
125V 124V
Water System

107V 108V 109V

IAS
Control I
Air P

110V
Atmos. Drain Tank
Level Control Valve

ORI-11
To Main Turbine Flash
Chamber Make-up

Condenser
To Auxiliary

To External Desuperheater

SIAH
IAS SX
Level Switches to be
Located at Same Level
IAS
For Dump Drain
102V 104V 106V LD100S
LS Pump Start

Cabinet 2 LS For No.1 Condensate

Drain Pump Start
Atmospheric LS For No.2 Condensate
Drain Pump Start
128V Drain Tank
PI PI PI LAH
(8 m3) LS
Condensate IAS
Dump Drain Pump
No.1 No.2 Drain Pump
Key (80 m3/h x 85 MTH) LS
LAL
(30 m3/h x 85 MTH) IAS
Condensate Line CI CI CI

138V
101V

103V

105V
Air Line
Drain Line

To Deck Scupper

Final Draft / 2007.12.28 2 - 15 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

5. Integrated Automation System (IAS) Control Atm. Drain Tank Level Control

The atmosphere drain tank system supplies feed water to the deaerator. It is
however connected to the main condensate system so that piping from the main
100%
condenser and the drain water system are joined together before entering the
Calculated
Make-up
Valve
Spill
Valve
deaerator. Atmosphere drain tank inlet is supplied from distilled water tanks,
Valve
Position
transferred via deaerator make up valve. The atmosphere drain tank level is
controlled by a separate level control valve. A combination of deaerator spill /
Spill Make-up 0%
Valve Valve 0% 40% 51% 100% make up valve and the atmosphere drain tank level control valve is used
Level Set Point Deviation
maintaining the deaerator level.
Operator SP PID Proportional
P=1 Action Only A PID controller is utilized to maintain the atmosphere drain tank level. Set point
From Main
Auto/Man Condensate can be adjusted by operator while operating in Auto mode. For direct operator
Operation LT Pump control, controller must be set to Manual mode.

Distilled Deaerator 6. IAS Display

Water
Tank (S)
Spill Valve Level Control
Valve

Condenser
LT Drain Pump
Make-up Valve

Drinking No.1

Water
Tank (P) Atmospheric
No.2

Dump Tank
Dump Drain
Pump

Deaerator water level control

Due to variations in condensate flow, a level control function is required for the
deaerator. At high deaerator level, excess condensate is dumped to distilled water
tanks through a spill valve. At low level, condensate is provided through a make
up valve circulating water to the deaerator via the atmosphere drain tank and
condensate drain pumps.

The spill and make up valves are controlled according to predefined curves,
based on a level reference point deviation. This is a proportional action open
control loop and any deviation from level reference point is not compensated. To
prevent an unstable or oscillating system, the IAS will foresee a dead band in the
area where both valves closes. By operating a switch, a manual input can be
made, still controlling the valves according to predefined curves.

To achieve the programmed valve response, the valves have to be set to “Auto”
operation mode. For direct independent valve control, valves must be set to
“Manual” mode.

Final Draft / 2007.12.28 2 - 16 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.2.3a Boiler Feed Water System

M-114V
From Auxiliary Condensate
Water System ACC ACC
ABC
PI E E

838V
836V

827V
822V
Control Air P P Control Air

837V

835V

827V

821V
BV109B AC 440V AC 440V BV109B
Pressure BV101
FX FX
BV101 BV109A

BV113

BV113

BV113

BV113
BV109A
PI Buffer BV103 BV102 BV102 BV103
CI PX
IAS Chamber BV110B M M BV110B
Sett. Inlet Header Inlet Header Sett.
TI (ERWS38 12.7T, BV110A BV110A
300A) 94.4 bar CV101 A627 A627 CV201 94.4 bar
BV112 No.1 No.2 BV112
TI
Economizer BV107 FE-101 FE-102 BV107 Economizer
853V 852V

ORI-21
Outlet Header Outlet Header
Deaerator
(30 m3) BV111A BV111A
TI TI
IAS TX BV111B BV111B TX IAS

TI BV104 BV106 BV105 BV105 BV106 BV104 TI

201V

202V

To Atmospheric
203V Drain Tank
To Distilled
TIAL
IAS
TX Water Line Steam Drum Steam
SteamDrum
Drum

204V
830V 831V Spray Water
To Aux. Steam
No.1 Main Boiler Desuperheater No.2 Main Boiler
205V

Sett. 5 bar
Line (For Emergency)
From Distilled Water

Water Drum Water Drum

M-
30
1V
(Sampling Line) To Boiler Water Quality 817V
Flushing Lines to be Insulated where
Management System Necessary Against Personal Damage. TI

3rd Stage Feed

820V
To Boiler Water Quality (For Flushing) 829V
30
2V To Boiler Water Quality Water Heater
M- Management System 818V
Management System

401V

402V
TI
Auxiliary Feed Water Line
832V 833V
Main Feed Water Line
804V 803V

802V 801V

808V 807V

814V 813V
806V 805V

812V 811V
Cold Start
Feed Water Pump 809V 815V

From Condensate Drain Pump

PI PI

(For Boiler Water Filling)

Boiler Feed Water Pump (6 m3/h x 860 MTH)
825V

PS For Run Signal PS For Run Signal

Recirc. W. Shut-off Valve PI
810V

816V
Turbine Remote
LS
826V

824V

Control System
S 212V 214V
Control CI
No.1 Turbine Driven No.2 Turbine Driven Key
(60 Mesh)

Air PI PI
9 bar Boiler Feed Pump Boiler Feed Pump Condensate/Feed Water Line
823V

210V 21S

22S

23S

Speed Controller (170 m3/h x 865 MTH) (170 m3/h x 865 MTH) Distilled Water Line
(2 Sets)
211V

213V

Air Line
Drain Line

Final Draft / 2007.12.28 2 - 17 Part 2 Machinery System

CLEAN FORCE
2.2.3 Boiler Feed Water System
1. General Description
The boiler (or main) feed water system is concerned with the circulation of
water from the deaerator via the feed pumps to the boiler steam drum.
Feed water from the condensate systems enters the 3rd stage feed water heater
and temperature of feed water is raised.
The deaerator breaks the water into very small droplets, resulting in the
liberation of air and any other non-condensable vapour. These, together with
any associated water vapour, are drawn off to the gland condenser, where the
water vapour is condensed and returned to the feed system and the non-
condensable vapours are extracted to atmosphere by the gland condenser
exhaust fan.
The heated feed water is collected in the deaerator, which acts as a system
header tank. The level is maintained in the deaerator by the automatic operation
of the make-up and spill control valves in the condensate system. The location
of the deaerator high up in the engine room provides the main feed pumps with
a positive suction head of water.
Hydrazine chemical is injected into the drop line to the main feed pumps to
remove any remaining traces of oxygen in the feed water. The dosing of
hydrazine is arranged to maintain a reserve amount in the boilers. A sampling
line is fitted on the feed pump suction line to the boiler water analyser cooler.
The water flows through a strainer before entering the feed pump suction
manifold. Two main feed pumps ; one in use with the second unit on stand-by.
The stand-by pump can be used if the duty pump fails. The stand-by pump will
start automatically.
The feed pumps are turbine driven, horizontal, multi-stage units. They have
condensate cooled mechanical seals on the pumps. For initial start, each is fitted
with an electric lubricating oil pump, but once running a shaft driven pump
provides the lubrication oil circulating pressure.
The electric lube oil pump will stop automatically when the shaft driven pump
delivers the correct pressure and prevents the feed pump bearings from running
dry. The electric lubricating oil pump only provides oil pressure to lift the steam
governor valve, and not as a back up to the shaft driven pump. (i.e. it does not
supply sufficient oil to the bearings for full speed running)
Air spaces between the pump and the bearings, and between the turbine and
bearings, are fitted with drain passages to help prevent lubrication oil
contamination.
Final Draft / 2007.12.28
Machinery Operating Manual
The running speed adjustment for the steam flow to the duty feed pump turbine The discharge from the drain pumps for boiler filling is connected to the
is controlled by a loop, which measures and compares the steam drum pressure auxiliary feed line, through valve (829V), which in normal operation is
and common discharge pressure of the feed water pumps. locked shut.
Discharge pipe configuration from the feed pumps is such that any one feed Each boiler is fitted with a three term feed control system whereby signals
pump can supply either boiler or any services. Interconnecting pipelines from the actual boiler level, feed flow and steam flow are compared for
between the pumps, isolated by non-return valves, are arranged to supply four feed pump operation.
common discharge lines.
Similarly, each boiler is fitted with water level transmitters for the level
Final feed into the boilers is through the economisers, where the feed detector and indicator alarm systems.
temperature is increased from 145°C to 224°C. The economisers are placed in
the path of the furnace flue gases in order to extract maximum heat from the 2. Capacities and Ratings
waste gas before it passes out of the funnel.
Cold Start Boiler Feed Water Pump Shinko
In case of an emergency, the water side of the economiser can be bypassed, and No. of sets: 1
feed water is supplied directly to the boiler drum. Should this be necessary, Model: MDH PISTON (HLX6)
Capacity: 6m3/h x 865MTH
steam flow must be restricted. In this case, the economiser should be drained
and vented.
Turbine Driven Boiler Feed Water Pumps Coffin
No. of sets: 2
1) Main Feed Line Capacity: 170m3/h x 865MTH
From the main pump the feed water enters the common discharge line,
at which point there is a signal line to the differential pressure unit for
auto start of the stand-by unit on low pressure. The feed water passes 3. IAS Display
through the feed water control valve (CV101, CV201 closed at boiler
high level), then through the orifice, which measures the feed flow for
the control system. It then passes through the economiser and enters
the steam drum of the boiler.
2) Auxiliary Feed Line
This pipeline is usually used if the main line requires repairs,
especially to the feed control valve or the flow orifice plate. The feed
water can be directed through the economiser, or bypass it and flow
directly into the boiler. Whichever path is selected, great caution must
be taken when auxiliary feed is in use as the feed valve to the boiler is
manually operated and must be attended at all times. The operator
must maintain a careful watch on the boiler level in this mode.
3) Main Feed Pump Re-circulation Line
An air operated control valve opens to allow the feed pumps to
recirculate water back to the deaerator. When the boilers are operating
at low loads with the main turbine in manoeuvring mode, this valve
will open automatically, allowing water through an orifice on the
pump into the water chamber at the bottom of the deaerator.
For boiler filling and very low boiler loads, an cold start feed water
pump is fitted. This unit is electrically driven, but like the main feed
pumps will take its suction from either the deaerator or the main
distilled water tanks and is able to discharge through the main or
auxiliary feed lines to the boiler.
2 - 18 Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.2.3a Boiler Feed Water System

M-114V
From Auxiliary Condensate
Water System ACC ACC
ABC
PI E E

838V
836V

827V
822V
Control Air P P Control Air

837V

835V

827V

821V
BV109B AC 440V AC 440V BV109B
Pressure BV101
FX FX
BV101 BV109A

BV113

BV113

BV113

BV113
BV109A
PI Buffer BV103 BV102 BV102 BV103
CI PX
IAS Chamber BV110B M M BV110B
Sett. Inlet Header Inlet Header Sett.
TI (ERWS38 12.7T, BV110A BV110A
300A) 94.4 bar CV101 A627 A627 CV201 94.4 bar
BV112 No.1 No.2 BV112
TI
Economizer BV107 FE-101 FE-102 BV107 Economizer
853V 852V

ORI-21
Outlet Header Outlet Header
Deaerator
(30 m3) BV111A BV111A
TI TI
IAS TX BV111B BV111B TX IAS

TI BV104 BV106 BV105 BV105 BV106 BV104 TI

201V

202V

To Atmospheric
203V Drain Tank
To Distilled
TIAL
IAS
TX Water Line Steam Drum Steam
SteamDrum
Drum

204V
830V 831V Spray Water
To Aux. Steam
No.1 Main Boiler Desuperheater No.2 Main Boiler
205V

Sett. 5 bar
Line (For Emergency)
From Distilled Water

Water Drum Water Drum

M-
30
1V
(Sampling Line) To Boiler Water Quality 817V
Flushing Lines to be Insulated where
Management System Necessary Against Personal Damage. TI

3rd Stage Feed

820V
To Boiler Water Quality (For Flushing) 829V
30
2V To Boiler Water Quality Water Heater
M- Management System 818V
Management System

401V

402V
TI
Auxiliary Feed Water Line
832V 833V
Main Feed Water Line
804V 803V

802V 801V

808V 807V

814V 813V
806V 805V

812V 811V
Cold Start
Feed Water Pump 809V 815V

From Condensate Drain Pump

PI PI

(For Boiler Water Filling)

Boiler Feed Water Pump (6 m3/h x 860 MTH)
825V

PS For Run Signal PS For Run Signal

Recirc. W. Shut-off Valve PI
810V

816V
Turbine Remote
LS
826V

824V

Control System
S 212V 214V
Control CI
No.1 Turbine Driven No.2 Turbine Driven Key
(60 Mesh)

Air PI PI
9 bar Boiler Feed Pump Boiler Feed Pump Condensate/Feed Water Line
823V

210V 21S

22S

23S

Speed Controller (170 m3/h x 865 MTH) (170 m3/h x 865 MTH) Distilled Water Line
(2 Sets)
211V

213V

Air Line
Drain Line

Final Draft / 2007.12.28 2 - 19 Part 2 Machinery System

CLEAN FORCE
4. Operating Procedures
1) Boiler Water Filling (Using cold start feed water pump)
(1) Check that the steam and water drum drain valves are closed and
that the local drum gauge glass and transmitters to remote level
indicators are open, with their drain valves shut.
(2) Open the drum and superheater vents fully.
(3) Open the pump discharge valve to the auxiliary feed line,
economiser bypass valve and direct feed valve to the steam drum.
Ensure that the boiler drum feed valve from the main line is closed.
(4) Check the pump suction valve, from the deaerator is locked shut
and open the suction valve from the distilled water tank.
(5) Line up recirculation piston valves.
(6) Start the pump and commence filling the boiler. Maintain careful
watch on local steam drum level gauges until the required level is
achieved. Close the direct feed valve.
(7) Open the feed inlet valve to the economiser and the vent valve,
ensuring that the unit drain valves are closed. Open the auxiliary
feed line valve to the economiser inlet. Continue using the pump
until water emerges from the vent, having removed all air from the
economiser.
(8) Arrange for an initial chemical dosage charge to be injected into
the boiler from the chemical dosage pump unit as the boiler is
filling.
(9) The boiler is now ready to flash.
Note
If both boilers are out of service, then there are two other ways to initial
filling them.
(10) By filling the deaerator with the condensate pump, and allowing
the water to directly drop through the emergency feed pump into
the steam drum.
(11) By using the condensate system, opening the valve, which is
locked shut, and filling through the auxiliary feed line as
described above.
Final Draft / 2007.12.28
Machinery Operating Manual
2) Placing Feed System in Use
(1) During the initial flashing of the boilers, there should be enough
steam to place the feed system in use when the pressure reaches
approximately 20bar.
(2) Select the feed pump to be placed in use, and open the suction,
discharge, recirculation, steam inlet, exhaust and gland leak-off
valves. Open the turbine drains, and ensure that all trips are reset.
(3) Open the drop valve from the deaerator and vent the pump to
remove any air.
(4) Supply air to the auto recirculation solenoid valve, checking that
its inlet and outlet isolating valves are open. Due to ‘no flow’
conditions, the control valve should remain fully open.
(5) Line up the valves on the main feed system to the selected boiler.
Supply instrument air to the boiler feed control valve and under
local control check its operation. If satisfactory, transfer to auto
control. Ensure the motorised feed inlet valve to the boiler is open.
(6) Check the lubricating oil sump for any water, and top up the sump
to the required level using the correct grade of oil. Ensure that the
Lubricating oil cooler is opened to the fresh water cooling system,
and that the pump mechanical seals are supplied from the
condensate system.
(7) Crack open the isolating valve from the superheated steam range
to the feed pump and warm through the line. Drain any
accumulated water by use of manual drains and open the
electrically operated main steam stop valve.
(8) Open instrument air supplies to the control system.
(9) To start the feed pump, start the electric lubricating oil pump. This
supplies oil to the oil relay cylinder, which lifts and raises the
balanced governor steam valve off its seat, allowing steam into the
turbine. As the feed pump rev/min increases, so the shaft driven
Lubricating oil pump pressure is raised, at which time the
electrically driven lube oil pump stops. Close the turbine drains
once any sign of entrained water droplets ceases.
Note
As the electrically driven lubricating oil pump does not supply oil to the
bearings, only to the oil relay cylinder. Should the pump not start and
run up to speed within approximately 30 seconds of the start process
being initiated, the electric pump will stop and the feed pump will trip.
2 - 20
(10) Once the feed pump is running satisfactorily, and operating remotely
with the boiler level being maintained at the correct level, thoroughly
check the pump. Ensure that the oil flow through the line sight glasses,
condensate flow through the sealed water line flow meters and the
electrically driven oil pump have stopped. Monitor temperatures and
pressures, and check for excessive vibration.
(11) Line up the second feed pump as the stand-by unit and, when
operational conditions permit, check the auto-change operation by
tripping the duty feed pump.
Note
Though the feed pump manufacturers recommend the testing/checking of
trip and safety functions on a regular basis, the testing of the overspeed
trip should be done only when absolutely necessary. Damage to the pump
internals may occur during the testing of the centrifugal speed governor
and any test of this function must be carried out with due caution and in
strict accordance with manufacturer's detailed instructions.
3) Filling Second Boiler (Main feed pump in use)
Note
During the filling of the second boiler, and in the transition period before it
is brought fully on line, particular attention must be paid to the steaming
boiler water level; constant checks must be made to ensure that it is not
starved of feed water.
(1) With the economiser bypassed, ensure that the steam drum vent
valves are open and the drain valves on the steam drum, water drum
and headers are closed. Check that the remote level indicators and the
boiler gauge glasses are on line.
(2) With the inlet valve to the water level control valve closed, open the
auxiliary feed valve on the steam drum.
(3) Using the manual auxiliary feed check valve, open it slowly until feed
water is entering the boiler. As the boiler fills, maintain a careful
check on the gauge glass, and that the in-use boiler level remains
satisfactory and is not being starved of feed water. Using the boiler
dosing unit, put in the initial chemical dosage as the boiler fills.
(4) When the correct level in the boiler has been achieved, the auxiliary
feed valves can be closed.
(5) Prior to flashing the boiler, the economiser can be vented by filling
through either the main feed line with the control valve manually
opened, or through the auxiliary feed line.
Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.3.1a Main Sea Water Circulating System

15V
LS

(F) Upper Deck Key

Sea Water Line

16V

(F)
Order To Close M.G.P.S Line
Dump Steam V/V
Stationary Em'cy EXP-W02
Hand Pump at 70℃ Over Drain Line
IAS TI TX TI
From Water Ballast Pump IAS
(For Main Condenser Flushing) TS T-105

To Bilge, Fire & 1SF T-108

T-105A
G/S Pump

Main Condenser
T-106
T-109
T-106A

TI TX TI
IAS

EXP-W01
22V
PAL PS From M.G.P.S
IAS Anode Tank
17V 18 PI
From Main C.S.W Pump Saw Dust
Box
Discharge (100 L)
19V

From Seal Water Cooler For Flow

Test

20V
for Vacuum Pump Unit
LS 13V

30V
LS

10V
21V

(F)
TI TI 11V LS
Auxiliary
Condenser (F)
26V

Stationary Em'cy
LS LS Hand Pump
Scoop Inlet
25V

Shell
(F)

(F)
From Domestic
8V

7V
M

M
12V F.W System
LS PI PI

Main S.W Circ. Pump Auxiliary S.W Circ. Pump

(F) (9,000/4,500 m3/h x 5/8 MTH) (9,000/4,500 m3/h x 5/8 MTH)
CI CI 28V
From M.G.P.S
(F)

(F)
6V

5V
From M.G.P.S Anode Tank
From From
Anode Tank IAS 1V
IAS High Sea Chest
LS M (STBD)
29V

LS
(F)
(F)
2V
M

Low Sea Chest

(Mid.)

Final Draft / 2007.12.28 2 - 21 Part 2 Machinery System

CLEAN FORCE
2.3 Sea Water Systems
2.3.1 Main Sea Water Circulating Systems
1. General Description
The main condenser is supplied with sea water cooling via the one main sea
water circulating pump and auxiliary sea water circulating pump. The main &
aux sea water circulating pumps take suction from the high sea chest (S) or low
sea chest (MID), situated in the lower flat of the engine room. The draft of the
vessel will decide which sea chest to use. The discharges from the pumps are
connected together through valve 8V, 7V.
The auxiliary condenser is also cooled by sea water. The sea water is supplied
through the main sea water circulating pump or auxiliary sea water circulating
pump. To ensure that the system is vented of air at all times, the main
condenser water boxes and ship side sea chests have vent valves on them. These
remain open and the pipelines lead to a gooseneck at the upper deck level. The
atmospheric condenser outlet water box can be vented locally, with its valves
closed after venting. The main circulating pump is all vertical centrifugal pump
driven by electric motor. The main and atmospheric condensers are horizontal
shell and tube heat exchangers, with the sea water passing through the tubes.
The main circulating pump discharge valve, main condenser sea water inlet
(10V) and outlet valve (15V) are all hydraulically and electrically operated
motorised valves, and can be operated from either the engine control room or
from a local panel. Minor leaks in the main condenser can be plugged using
sawdust. A sawdust injection unit is fitted for this purpose. The sawdust box is
filled with sawdust and water from the sea water service system. It flushes the
sawdust into the condenser sea water inlet line. The vacuum from the
condensate side of the tube stack will draw sawdust into any hole or crack in a
tube. For the protection of the sea water pipelines in these systems, they are
coated internally with PE or Rubber lining. Sea chests, sea water lines and all
sea water cooled condensers are protected from environmental hazards by an
anti-fouling system. The MGPS system prevents fouling in the sea chests and
throughout the seawater system.
2. System Capacities and Ratings
Main SW Circ. Pump: Shinko
No. of sets: 1 When the pump is running, IAS sends a close command to the scoop inlet valve
Model: CVF1000M
Capacity: 9,000/4,500 m3/h x 5/8 MTH
Aux SW Circ. Pump: Shinko
No. of sets: 1 1) Ensure that the injection unit inlet and outlet valves are closed, and open
Model: CVF1000M
Capacity: 9,000/4,500 m3/h x 5/8 MTH
Final Draft / 2007.12.28
Machinery Operating Manual
3. Preparation for the Operation of the Main SW Circulating System
1) Ensure that the high (S) and low (MID) sea chests are vented.
2) Ensure all the pressure gauge and instrumentation valves are open and
that the instrumentation is reading correctly.
3) At the main sea water circulation graphic screen open the desired
suction main line valve from the operating sea chest.
4) Ensure that the main and aux. condenser water box are vented.
The valves are now set to allow the main sea water circulating system to
operate.
4. Integrated Automation System Control
The main and auxiliary SW circulating pumps are supplied from low and high
sea chest. IAS will have a Duty / Standby function so that the auxiliary pump
will start if there are any failures on the Main pump. There is start interlock on
the pumps from sea chest and overboard valves. From the two pumps the SW
goes to main and auxiliary condenser. The main condenser has two independent
SW supply lines, one from circulation pumps and one from the scoop. The
selection between scoop and pump mode is manual or automatic dependent on
operator selection.
Pump Mode to Scoop Mode
Main turbine RPM>65 at manoeuvring valve 70%≥ and telegraph in
“Navigation Full”, IAS is send an open command to the scoop inlet valve.
When the scoop inlet valve is opened more than pre-set value (70%≥), IAS
sends a close command to the main or auxiliary SW circulation pump discharge
valve depending on the duty / standby selection. When the valve is closed IAS
stops the SW circulation pump. The system is now in scoop mode.
Scoop Mode to Pump Mode
Main turbine RPM<63, Telegraph in “Manoeuvring valve 70% below” or
Blackout. IAS sends an open command to the main or auxiliary SW circulation
valve and start command to the main or auxiliary SW circulation pump.
and when it is closed the system is in Pump mode.
5. Operation Procedure for Condenser Sawdust System
the drain valve to prove that the unit is empty.
2) Close the drain valve and remove the top cover of the unit.
2 - 22
3) Fill with the required amount of sawdust and refit the top cover.
4) Open the unit outlet valve, and the inlet valve to the condenser sea water
inlet line.
5) Open the sea water service line inlet valve to the unit and allow several
minutes to push the sawdust out of the unit and into the condenser.
6) Close all valves once the operation is complete.
6. Back-flushing the Main Condenser
The main condenser has a back-flushing connection from the ballast pump system,
which will enable the main condenser to be back-flushed if it becomes fouled with
marine debris. In most operational conditions the marine growth prevention system
will keep the condenser tubes in a clean condition.
If it becomes apparent that it is necessary to back-flush the condenser, a number of
factors must be taken into account:
- Steam demand from the turbine generators when the atmospheric condenser
is put into service.
- Steam production demand in relation to the BOG and cargo tank pressures,
i.e., will steam dumping be required to maintain the cargo tank pressure.
- Sea state and the necessity to maintain steerage.
The capacity of the diesel generator engine is normally sufficient to maintain the
sea going and harbour load requirements when not carrying out cargo operations,
therefore if necessary the entire ship’s electrical load can be transferred to the
diesel generating set.
7. IAS Display
Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.3.2a Cooling Sea Water Service System

Low
From Bilge, Fire & G/S Sea Chest
Pump Common Suction

105V

(F)
LS

M
To Rudder From
Neck Bearing To Saw Dust Box IAS

PI M.G.P.S Anodes
To be Fitted

157V
TI 155V

(F)
Fresh Water Cooler
No.2 Main Central

(F)
154V
PIAL
(F) (For Pump IAS
Control) PI CI

PS PS PX PI No.2 115V
PI To Sewage Treatment Plant

119V
113V
(Initial Filling/Cleaning)
153V

118V

120V
(F)

TI 142V (F)
PI CI
(F) No.1
114V

117V
(F)
PI
144V

143V
Main Cooling Sea Water Pump
TI 151V (1,300 m3/h x 21 MTH)
No.2

135V

134V
TI TI

(F)

(F)
104V
Fresh Water Cooler
No.1 Main Central

(F)
for Vacuum Pump Unit

for Vacuum Pump Unit

No.2 Seal W. Cooler

No.1 Seal W. Cooler 123V

150V

M.G.P.S Anode Tanks

(F)

CI CI
(F)
Distilled Plant For Scoop System
(F)

No.2

No.1
PI Sea Water
Feed Pump No.1 To High Sea Chest
FI
149V

(90 m3/h x 43 MTH) (For Scoop)

(F)

TI 148V PI PI 113V
124V FI To Scoop Inlet
(F) (F)
FI To Low Sea Chest
TI TI 137V 136V (F)
(For Scoop)
146V

145V

125V

No.2 Distilled Plant No.1 Distilled Plant

TI PI PS PS PI TI
(60 Ton/day) (60 Ton/day)

106V

To Auxiliary Condenser
S.W Overboard Line
LS

108V
152V

(F)

156V

(F)
S

S
PI PI
PI PX PX PI
From Distilled From Distilled
112V

111V
Plant F.W Out TI TI Plant F.W Out From
109V 107V
D-57V

D-19V
IAS

101V

(F)
LS

M
Key
Flowmeter

Flowmeter
Sea Water Line
Dosing Unit

Dosing Unit
Chemical

Chemical
110V

High
(F)

Fresh Water Line

Sea Chest
Drain Line

Final Draft / 2007.12.28 2 - 23 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.3.2 Cooling Sea Water Service System FW Generator: Alfa-Laval The Anfomatic system employs a variation of the well established impressed
No. of sets: 2 current cathode protection principle.
1. General Description Type: Condensate Cooled Type Direct current applied to the copper anode releases a controlled quantity of
Sea Water Cooled Type copper ions into the system to create an environment in which primary forms
Other systems requiring sea water cooling services are supplied from the main of marine life do not grow.
cooling seawater pumps. Capacity: 60 t/day per unit Current applied to the aluminum anodes releases a ‘floc’, a precipitate of
Salinity: 1.5 ppm(max) aluminum hydroxide.
These are vertical electrically driven centrifugal pumps, with one normally in The aluminum hydroxide products reduce corrosion rates on ferrous
use and the other on stand-by. The sea water suction to these pumps is from a Distilling Plant S.W. Feed Pump: Shinko components in the seawater system by modifying the ferrous oxides formed
common supply pipeline, which extends from the stbd side high sea chest to the Model: SVA125-2M and film deposition. The Anfomatic system is automatic, requires minimal
port side low sea chest. No. of sets: 2 maintenance and is environmentally friendly. Mussels are not killed by the
Flow: 90m3/H X 43MTH system: the environment it creates prevents them settling or developing. A
further benefit of the Anfomatic system is that potable water distillation plants
There is a remotely operated ship’s side butterfly valve on each sea chest which
can be operated without interruption.
allows the sea water to enter a line simplex filter. Each sea chest has a vent 3. Operating Procedures
valve which normally remains open, ensuring that the chest is flooded at all Anode functions are as follows :
times. The outlet butterfly valve on each filter allows the unit to be isolated and 1) Open the sea chest suction valve, to high or low suction, depending on
WW-Cuproline: Antifouling
cleaned periodically. vessel’s draft. This valve may be opened remotely, and an indicator light WW-Aloline Reduction in corrosion of steel materials
will show when fully open. Vent off the line suction strainer to prove WW-Ferroline Reduction in corrosion of copper based materials
The discharge from the two pumps is joined into a single pipeline system, full of water.
which in turn allows for feeder lines to each unit requiring the cooling water. 2. Operation & Displays
2) Select the pump to be used and, with the power off, ensure that the
The sea water cooling system provides water to the following units: pump turns freely by hand. Open the suction valve to the pump. Each plug in module controls two individual output channels, usually
configured to supply one anti-fouling anode paired with one corrosion
No.1 and No.2 main condenser vacuum pump coolers 3) Vent off the pump casing and ensure that it is flooded. reduction anode, although other arrangements are possible depending upon
No.1 and No.2 central fresh water coolers operational requirements.
Fresh Water Generators 4) Check the central fresh water coolers and vacuum pump coolers to
Main condenser sawdust box ensure that the drain valves are shut. Open the shipside valve for the Units are supplied with either a 2 amp or 3 amp output capacity per channel and
Marine growth prevention system cooler overboard discharge line. Ensure that the indicator light on the in normal operation each channel will display the current setting for each
individual anode. The majority of Anfomatic systems are designed to give
panel is on at fully open.
100% protection for an assumed 100% protection for an assumed 100% time in
After passing through the central fresh water and main turbine vacuum pump
use. Therefore unless otherwise stated the anode current setting should remain
cooler units, the water is discharged overboard at a remotely operated ship side 5) Select which vacuum pump and central fresh water cooler to use. Open unchanged once commissioning of the system has been completed.
valve 152V the inlet and outlet valves.
In case the valve of the sea water suction strainer / sea chest inlet was closed, the
The central fresh water coolers are of the plate type design, one of which is 6) Start up the pump and, when rotating correctly, slowly open the output current is decreased to 0~50% amps.
normally in use, while the other is retained in a clean condition and ready for discharge butterfly valve until fully open.
use when the other unit becomes dirty. The method of decrease current
7) Check both of the in-use coolers, venting off at the outlet water boxes
There is a MGPS which protects cooling sea water system against fouling to ensure that no air is entrained in the units. Close the vent valves - Adjust by turning knob anti-clockwise.
caused by seawater-borne organism, and the treated sea waters are led to tightly.
whichever seachest is in use. - Current valve indicated on display
2.3.3 Marine Growth Preventing System
In case the valve of the sea water suction strainer / sea chest inlet was opened,
The two F.W.G SW Feed Pumps also sucked sea water from cooling sea water
the output current is increased to setting current.
common main line and supply to the each F.W.G. 1. General
The monitoring modes are all adjusted by a factor of 10 for display purposes.
2. Capacities and Ratings Marine fouling and biological fouling commonly occur in seawater
circulation system. This involves the establishment of marine plants and
animals, and bacterial growths. Hard fouling by mussels, barnacles etc.
Main Cooling SW Pumps: Shinko
most commonly occurs in seawater circuits and can result in interference in
No. of sets: 2
flow conditions, blockage and increased corrosion.
Model: SVA400M
Flow: 1,300 m3/h at x 21MTH

Final Draft / 2007.12.28 2 - 24 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.4a Centralised Fresh Water System

Inspection Cover
Key 128V
107V
Fresh Water Line
Main Central F.W
Air Line Expansion Tank From F.W
127V Hyd. Unit
Drain Line (1 m3) LAL
LS
IAS

129V
23V ORI-3
ORI-2 69V

80V TI TI 76V
No.2 T/G Bearing
PI PS L.O Cooler
TI 15V TI
Jacket Preheating Unit
No.2 Main Air-Con. To Deck Scupper
Condenser Electric 72V TI TI 62V 64V
CI No.2 T/G
TI PI Heater PI TI
L.O Cooler
PI PS
(F) (F)
51V 47V TI TI
TI 14V TI Unit Cooler
No.1 Main Air-Con.
for Workshop 78V TI TI 79V
Condenser 73V No.1 T/G Bearing
D/G Engine L.O Cooler
PI PS (Hyundai-B&W:9L32/40) From
L.O System
TI 28V TI TX TIAH
H.T Charge 70V TI TI 58V 60V
IAS
No.2 Aux. Air-Con. 59V 77V No.2 T/G
Condenser W Air Cooler
Engine L.O Cooler
(F) (F)
Jacket
PI PS ORI-1
No.2 Turbine TIAH
TI 27V TI PIAH PX L.T Charge 75V TI Generator IAS TX TI 53V 57V
IAS
No.1 Aux. Air-Con. 30V 50V Air Cooler 29V
Condenser (F) (F)
No.1 Turbine TIAH
PI PS
L.O Cooler 74V TI Generator IAS TX TI 52V 56V
TI TI TIAH
IAS
TX (F) (F)
No.2 Provision 18V 26V TI Diesel Alternator TI
Refrigerant Condenser To F.W.P.T L.O Cooler,
Unit Cooler for Boiler
PI PS TIAH TX D/G Bearing 16V 31V TI TI 32V Test RM, S/T L.O Cooler
IAS 17V TI L.O Cooler TI 25V
TI TI Drain Cooler
No.1 Provision For Engine Room
Refrigerant Condenser
To Air From F.W.P.T
Compressor 9V TI PI
L.O Cooler,
No.2 S/T L.O Cooler
41V TI TI 39V TX TIAH
(F) Main
No.2 N2 Compressor No.2 N2 Generator PI IAS Unit Cooler for
No.2 IAS 11V TI PI Central
(Oil Cooler) (After Cooler) TI 68V TX Boiler Test Room
PI Main TI F.W
L.O Sett. 36°C Cooler
40V TI TI 38V 67V TI
(F) I (F)
Cooler P
No.1 N2 Compressor No.1 N2 Generator
(Oil Cooler) (After Cooler) (F)
Control 12V 8V TI PI
From W/H PI Air No.1
PI
Unit Cooler 65V TI No.1 To Aux. Cent. 37V (F) Main
TI 66V 46V
Main Cool. F.W PIAL 10V TI PI Central
PX
22V TI TI 21V (F) L.O Boost Pump 13V
IAS
F.W
I.G.G Dryer Cooler (F) Cooler
PS PS 2V PI (F)
Cooler
49V 6V 4V

1SF
20V TI 4127 TI 19V
I.G.G Water Chiller
Unit Condenser

42V
To Bilge Well PI PI

43V
PI PS
Main Central Cooling
No.2 No.1 Fresh Water Pump
Chemical
TI 36V TI (1,200 m3/h x 30 MTH)

7V
No.2 Main Air-Con.
CI Dosing CI
Unit for MSBD/ECR Tank

(F)

(F)
3V

1V
(20 L)
Temporary Filter to be

45V
PI PS

44V
Removed After Flushing
From Air
TI 35V TI
Compressors
No.1 Main Air-Con.
Unit for MSBD/ECR From Auxiliary
Central F.W Cooler

Final Draft / 2007.12.28 2 - 25 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.4 Centralised Fresh Water Cooling System
1. General Description
The fresh water cooling pumps supplies fresh cooling water throughout the
engine room and cargo machinery area. There are three pairs of pumps set up
identically as duty / standby pairs, and these are Main Central Cooling Fresh
Water, Auxiliary Central Cooling FW Boost pumps and Auxiliary Cooling FW
pumps.
The pumps are set up as a duty standby pair. Two pressure switches on the
pumps common discharge line is used to start the standby and the duty pump
will be stopped after a predetermined time. A standby start can also be triggered
by duty pump failure. Duty pump failure includes unexpected loss of running
and starter failure. Any standby start will call for an alarm.
From a mimic panel, operators can start / stop the pumps as well as switching
duty and standby. Pressing the “ON” button will automatically set both pumps
to auto mode and the duty pump will be started. Pressing the “OFF” button will
stop the running pump and switch both pumps to manual mode. When
switching duty pumps, the standby will first start. When confirmed running, the
duty will be stopped and the duty standby indication will be switched.
2. Capacities and Ratings
Main Central C.F.W. Pumps: Shinko
No. of sets: 2 room.
Model: SVA400M
Capacity: 1,200 m3/h X 30MTH
(5) Open the suction and discharge valves on the CFW pumps and cargo Sea water is used as cooling medium for the closed fresh water loop that supplies
machinery cooling fresh water boost pumps, venting off casings to fresh cooling water throughout the engine room and cargo machinery area. There
ensure that the units are flooded. are three fresh water cooling system; Main central Fresh Water Cooling, Auxiliary
Central Fresh Water Booster system and Auxiliary Central Fresh water.
(6) Start one of the pump CFW pump and check that it is operating
normally. Two auxiliary central pumps supply cooling water via two seawater cooled main
central coolers to various coolers, like lube and air coolers.
(7) Start the cooling fresh water boost pumps and check that it is Two auxiliary central booster pumps supply cooling water to cargo machinery
operating normally. fresh water coolers installed in cargo motor room.
Two auxiliary central pumps supply cooling water to cargo machinery to various
(8) Place each second pump in stand-by mode. cargo equipment coolers.
Fresh water temperature control is achieved by regulating a three way valve
(9) Stop each of the pumps in turn to prove that the auto cut-in operates allowing water to pass or bypass the coolers. If temperature is higher than the 36°C
correctly. set point, the valve will reduce the bypass flow thus increasing the flow through the
cooler.
(10) Check all systems for leaks, and that the operating temperature is A PID controller is used to control the three way valve. Set point can be adjusted
normal. by operator while operating in auto mode. For direct valve control, the controller
must be set to manual mode.
2) Remotely:
5. Control and Alarm Settings
(1) Ensure the pump discharge pressure is correct and that the
temperature is being maintained and observe that the temperature IAS
control valve is operating satisfactorily. Description Setting
Tag No.
FC022 M/CENT CFW PP DISCH PRESS L 1.0 bar
(2) Start and stop the pumps at the remote position in the engine control
FC021 M/CENT FW CLR OUT TEMP H 40℃
4. Central Cooling Fresh Water Temperature Control FC027 AUX FW CLR OUT TEMP H 40℃

FC028 AUX CFW PP DISCH PRESS L 1.5 bar

Central F.W. Coolers: Alfa-Laval Main Central
Fresh Water Cooler DG005
No. of sets: 2 G/E HT CFW IN PRESS L 2.0 bar
Type : Plate type No.1 No.2
SP Operator DG008 G/E HT CFW OUT TEMP H 95°C
Heat Dissipation: 5,400,000 kcal/h PID
Auto/Man PV DG009 G/E CFW TEMP HH 98 °C
3. Operating Procedures Operation Main Central Fresh
Water Cooler FC032 D/G FW CLR OUT TEMP H 40 °C
Temperature Control
Ensure the main sea water service system is in use, with cooling sea water being Temp. DG010 D/G ALT AIR CLR FW OUT TEMP H 38 °C
provided to the fresh water coolers and both inlet and outlet valves to the cooler Control
Valve
to be placed in use are open. DG007 D/G ALT AIR CLR OUT TEMP H 120 °C
TIC
TG040 G/T 1 AIR CLR AIR TEMP H 120 °C
l) Locally: A&B Sensor
TIAH
Selector TG045 G/T 1 AIR CLR WTR TEMP H 38 °C
(1) Ensure that all the vent air valves on the fresh water cooling system TIAH TG102 G/T 2 AIR CLR AIR TEMP H 120 °C
for return to the fresh water header expansion tank are open.
To Other Coolers TG107 G/T 2 AIR CLR WTR TEMP H 38 °C
Main Central Fresh
(2) Ensure that all system drain valves are closed. Water Cooling Pumps
DG060 G/G BRG LO CLR FW OUT TEMP H 45℃
(3) Open the inlet and outlet valves on the units to be cooled.

(4) Open the inlet and outlet valves on the cooler to be used.

Final Draft / 2007.12.28 2 - 26 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.5a Boiler Water Sampling and Treatment System

M-114V From Auxiliary Condensate Auto. Control

BV219 BV203 Blowdown Valve
Water System Blow
Steam Drum Orifice S
9 bar
TI BV218 Air
From Central Fresh Water

Blow-off Line
Cooling System BV204

Surface
No.2 Main Boiler

Deaerator

313V
(30 m3) BV210 BV205 902V
Bottom
Water Drum
BV206 Blow-off Line
BV209 BV209
(Sampling Line)

W-116V
(Sampling Line)
BV209
TX Boiler Water Quality 315V
Management System 306V
No.2 H.P Cooler BV209
C.D P.H
SIAH W-126V
SX 30 W-130V BV209 BV209
IAS 1V C.D : Conductivity Probe

312V
P.H : PH Probe (Sampling Line)
314V BV210 BV205 901V
304V
(Sampling Line) Bottom
No.2 H.P Cooler Water Drum
Sampling Block BV206 Blow-off Line

(Sampling Line)

(Sampling Line)

(Sampling Line)
W-122V

No.1 Main Boiler

Blow-off Line
Surface
Rotameter S Cooler
Sample Drain
with Plug Fail Safe 308V 309V
BV219 BV203

310V
Valve Blow
Steam Drum Orifice S
9 bar
9 bar BV218 Air
Control
Air
Wash Basin BV204
Dosing Dosing Dosing Dosing
Tank Tank Tank Tank (For Boiler
Auto. Control
Water Test)

Cooling System

Cooling System

Cooling System
From Central
Fresh Water

To Central
Fresh Water

To Central
Fresh Water
Blowdown
A-238V

S Valve
S

S Condensate No.1 Boiler No.2 Boiler

Product Product Product
S Pump Pump Pump

Oxygen (No.2 Boiler Chemical Dosing)

Scavenger
Product Pump (No.1 Boiler Chemical Dosing)

Key
(For Flushing Line)

(Common Relief)
2V (Oxygen Scavenger Dosing To Boiler Feed Water Pump Suction) Condensate /
30
Flushing Lines to be Insulated where Chemical Feed Line
Necessary Against Personal Damage. Fresh Water Line
To Boiler Feed Pump Air Line
From Boiler Feed Pump To Atmospheric From Boiler Feed Water Drain Line
Recirculating Line Drain Tank Pump Discharge

Final Draft / 2007.12.28 2 - 27 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.5 Boiler Water Sampling and Treatment Systems recommended and system levels should be reduced into the range. 9) Flat Screen Monitor: 1
Increase in hardness and/or sodium results from sea water contamination, and
1. General Description should be rectified as soon as possible. Iron contamination is a result of too low a 10) Printer: 1
pH and/or excess dissolved oxygen. If the oxygen level increases, the source of
Chemical analysis and treatment of feed water is undertaken to prevent corrosion contamination is to be located and rectified as soon as possible and hydrazine The management unit takes samples of the boiler and feed water systems
sequentially. The samples pass through a cooler and manifold before flowing
and scale formation in the main boilers and degradation of the steam quality. dosage increased until the feed water content returns within limits.
through the measurement module and are discharged to the F.D.W drain tank.
Inadequate or incorrect treatment can result in severe damage to the boilers, and
Each sample is allowed to flow for a period that ensures full flushing of the
constant monitoring is necessary to give an early indication of possible Contamination by organic matter cannot be rigorously defined, as potential previous sample. The module contains probes which measure the pH and
contamination of the feed water. contaminants are diverse. Any source of oil contamination must be identified and conductivity of the sample.
isolated as soon as possible, with the use of the scum valves on the drain
Chemical treatment and analytical tests must be undertaken in accordance with inspection tank used to clear any accumulation found in the tank. The controller interprets the analysis of each sample.
the detailed instructions given by the chemical supplier and the water
characteristics maintained within the ranges specified. Test results are to be 1) Boiler Water Characteristics Normal Max The unit operates automatically unless the following conditions apply:
recorded in a form that enables trends and the effect of treatment to be monitored. pH @ 25°C 9.6~10.2 10.3 ppm
Conductivity ≤ 120 US/CM - Manual Blowdown Required
The dissolved solids in the boiler water are controlled by use of scum lines in the - Contaminated water alarm requiring system check
steam drum and/or water drum blow down valves in the water drum, through Total dissolved solids - Chemical tank level low
Chlorides ≤ 10 max 10
which these impurities are discharged overboard. These systems are an integral
Phosphates 5~25 25 ppm The sample temperature is monitored and the Fail Safe valve will close if the
part of the boiler water treatment.
Alkalinity temperature exceeds 50~55°C. The valve will remain closed until the
Silica ≤ 0.5 5 temperature remains at below 50°C for a period of 10minutes.
The main water analyser unit has permanent sample lines, which are led through Ammonia ≤ 1.0
coolers to permanent test meters. These are fitted for the following:
2) Feed Water Characteristics
y No.1 main boiler -water drum sample-test for pH and conductivity pH @ 25°C 8.6~9.0 9 ppm
y No.2 main boiler -water drum sample-test for pH and conductivity Total hardness
y Deaerator outlet-water sample-test for pH, conductivity and oxygen Oxygen 0.007 ppm
Hydrazine reserve 0.01~0.03 max 0.03
All the above permanent test points can be bypassed to enable samples to be
taken and manual testing to be done. 3. Boiler Water Quality Management System

All the coolers use the fresh water cooling system as their supply. 1) Model No. AQ 300 3S/4P

2) Manufacturer AQUA net International Limited

2. Water Specification: (boiler manufacturer’s figures)
3) AQ300 System
Note
The following information is given for general guidance only. Reference
- Ultrasonic Flowmeter: 1
must be made to the specific instructions from the boiler chemical - HP Blowdown Valve: 2
supplier regarding final data for chemical treatment of the boilers and - Temperature Probe (0~110℃): 1
feed water. - Cooling Water Ball Valve: 2
- Chemical Injection Valve: 3
Low boiler water pH may be the result of pollution by sea water or lack of - Stainless Steel High Pressure Coolers: 2
adequate phosphate treatment. A return to the normal state is required at the
earliest opportunity. A tendency for a rise in the boiler water analysis figures 4) Computer Cable: 1
towards the maximum range, with the exception of hydrazine, may also be the
result of contamination by sea water or insufficient blow down of the boilers. 5) Data and boiler select cable: 1

Low or inadequate dosage of ammonia or neutralizing amine may cause a feed- 6) Test and maintenance kit for pH and conductivity probes: 7
water pH of 8.5 or less. This should be rectified at the earliest opportunity. Too
7) Spare Kit for AQ300HP: 1
high a dosage of ammonia or neutralizing amine, resulting in a pH in excess of
10, may not be detrimental to the steelwork in the system, though it is not
8) AQUA net Computer: 1

Final Draft / 2007.12.28 2 - 28 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

4. Operating Instructions Non-return

Ballstop Valve Note :
Solenoid Valve
1) Check, Boiler and Feed Line Manual Valves are open, where appropriate. Valve Cooler pipework, valve and
2) Check product pump discharge lines are open to systems as required. thermal Sensor layout may vary
3) Check product drums are full, with correct products. dependant on specific requirements,
but principal of operation remains the same.
4) Ensure suction lances are fully immersed in the product.
5) Check HP Cooler Inlet and Outlet Valves are open and any ship’s system
that provides the coolant.
6) Open Sample Inlet stop Valves for each Inlet in the unit and on the system. Sample
7) Open Sample Drain/Test Cock's alternately. Manifold
8) Switch unit on. [Sampling will commence after 1minute.]
9) Set Mode Switch to 'MANUAL'.
10) Operate each inlet valve manual switch to test Solenoid Valves.
11) Check flow indicator rotation from each valve individually and Sample
Cock to drain, then close. Flow should be towards the probe block.

Note Coolant Inlet

If there is a back pressure in the sample return line due to the pipe Coolant Outlet
Orifice Plate
layout, the sample can back flow giving the impression that there is a Thermal Sensor
sample flow when there isn’t - If you are not sure, check this by
Failsafe Valve
disconnecting the sample return outlet pipe at the first coupling until the
Sample Outlet
test is complete

12) Switch ALL manual Valve Switches OFF.

13) Set Mode Switch to 'AUTO'.
14) Turn Pump Mode Switches ON. Green LED on. Centre position is for Plate Cooler Flow Indicator
manual operation and enables pumps to be operated locally. - Green is for
Auto and is NORMAL position. - Do NOT leave pumps in manual mode,
except when values are low after first full cycle, in which case, operate in
manual until ALL Boiler readings are within range, remembering that the
Feed Sample may alarm during this period due to the relatively high initial
dosage.
1.
2.
Flow
FlowIndicator
Indicator
1pH 10.7 3.
15) Unit is now operational and will cycle as programmed. SITE IDLE 4.
5.
HRSG1 Blowdown request
HRSG2 Blowdown request
16) Use 'DISPLAY HOLD' button to stop Display at desired read-out. DISPLAY HOLD
6.
7.
Temp fall safe(on=ok)
HRSG1 selected
8. HRSG2 selected PUMP

POWER HEALTHY LINK 1 2 3 4 5 6 7 8 STATUS

1 pH Feed 9 pH Second Boiler
PULSES
2 Cond Conductivity (uMho) 10 Cond Conductivity (uMho)
3 DO2 Dissolved Oxygen ppm 11 DO2 Dissolved Oxygen ppm MAN OFF
MAN
OFF
MAN
OFF
MAN
4 Temp Feed Temperature 12 Not Displayed AUTO ON ON ON AUTO AUTO AUTO

5 pH First Boiler 13 pH Condensate FEED HRSG1 HRSG2 HRSG1 BWT HRSG2 BWT Condensate
6 Cond Conductivity (uMho) 14 Cond Conductivity (uMho)
7 DO2 Dissolved Oxygen ppm 15 DO2 Dissolved Oxygen ppm
8 Not Displayed 16 Not Displayed
1.
2.
3 Temp 86.9 3.
Note SITE IDLE 4.
5. Pump Low Level/Fault
Display readings group 1-4, 5-8, 9-12 and 13-16 are only “Live” when the 6.
7.
corresponding automatic sample is operating. At other times display 8. PUMP

POWER HEALTHY LINK 1 2 3 4 5 6 7 8 STATUS

shows the last reading taken at the end of previous sampling period.
PULSES

17) Only one Sample Valve LED will be ON. - The Cooler Sample ‘Fail-Safe OFF
MAN
Valve will be ON at any time a Sample Valve is open. (Note: If a cooler AUTO

outlet Solenoid Valve is fitted, it operates in Tandem with the ‘Fail-Safe’

OXY SCAV
valve so is only open when a sample is running to minimise water loss if ON
operated to bilge)

Final Draft / 2007.12.28 2 - 29 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

5. Control Method Carry-over

Boiler Scale, Corrosion Inhibitor and Sludge Conditioners
In most cases, the pH of the boiler water determines the dosage rate of the
Boiler chemical, to maintain the required P. Alkalinity, which is related to pH.
If traditional Phosphate and Sodium Hydroxide are used, control is achieved
with a combination of Feed rates and pH, maintaining the correct phosphate
reserve and P. Alkalinity. (Traditional Phosphate/Alkali programs are not
preferred in Low to Medium pressure Boilers as they have no ability to
maintain clean surfaces and are out performed by modern Polymer based multi-
functional products.)
Oxygen Scavengers
Controlled by Feed pH in the case of volatile products that elevate the
Condensate pH if there is a reserve, or modulated in relationship to feed rate
and temperature or dissolved oxygen reading.
Condensate pH Control
Controlled directly by the pH of the returns, by measurement of the Feed pH
which contains over 90% condensate and is therefore unaffected by the Make-
up.
Carry-over is the passage of solids bearing water droplets in the steam, which
cause physical damage to valves, valve glands, joints and turbine blades. -
Consequently, the measurement of uMho in the boiler ensures that none of the
harmful solids reach maximum safe levels.
Conductivity (uMho)
Conductivity is NOT used for pump control, only as an indicator of Water
Quality and for control of the Automatic Blowdown.
Bottom Blowdown
Bottom blowdown should be minimal as it wastes water and removes relatively
few dissolved solids, only serving to remove heavy particles which have
already fallen out of circulation, due to poor manual treatment control. (Read
specific Instructions on Top and Bottom Blowdown under AQUANET in the
"User Guide".
Feed and Condensate uMho
Feed and Condensate uMho is an accurate method of measuring the TDS, umho
and Chlorides of the water and if kept within the limits, no harm will be caused.
Remember, if they are high, it can only be a malfunction in the ship’s system,
such as seawater in leakage, due to heat exchanger failure, contaminated tanks
and malfunction of the Distilling Plant. Water Treatment cannot compensate for
major seawater in leakage and automation can only show you the trend, alarm
and inform you to take action.

Boiler TDS - Conductivity - Chlorides - uMho 6. IAS Display

Most solids in a boiler are derived from the chemicals, especially the Sodium or
Potassium Hydroxide which provides P. Alkalinity (pH) - The TDS rises as the
chemical concentrates in the boiling water and as small amounts of
contamination enter the feed from minor seawater leaks or poor quality make-
up.
Chlorides are circa 30% of all solids in water distilled from sea water and are
present in all of them.

The Chloride test is purely a simple method of determining the presence of salts
and Sodium Chloride in itself is not harmful to boilers so long as the TOTAL
SOLIDS are not excessive. - The most accurate measurement for the Total
Dissolved Solids is uMho, which is approximately 30% higher than TDS in
ppm. (1,000uMho = 700ppm TDS = 150-250ppm as Chloride)

As the majority of the dissolved solids are harmless to the boiler (less than
7.5% form scale and the rest only increase the density of the Boiler water), the
continuous refreshing of the chemical at very low dosage rates ensures that any
hardness is treated to avoid scale and the resultant microscopic, fluid, light
sludge is removed by surface blowdown, when the Total Dissolved Solids
reaches the upper limits. - This is to avoid excessive foaming in the boiler that
gives a false water level and can cause carry-over. - It also ensures removal of
the microscopic sludges formed as the Water Treatment reacts with Hardness
salts. - This in turn avoids these sludges combining, forming heavier
compounds which can eventually drop out of circulation and Bake onto hot
surfaces or require more wasteful Bottom blowdown (See Para Below ‘Bottom
Blowdown)

Final Draft / 2007.12.28 2 - 30 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.6.1a Fuel Oil Bunkering and Transfer System

From/To Em'cy G/E From/To G.O IAS

Gas Oil Tank Bunker Station
LS
LS LAHH
Em'cy G/E Upper Deck 72V IAS

Air vent/Overflow
IAS 42V
Room 3V AFT H.F.O.
From I.G.G G.O Pump LIAH
Bunker Tank (P) LX
IAS
Overflow

From Incinerator G.O Service Tank 4V 17V (164 m3) TIAH

TX
Overflow IAS
To Main Boiler
IAS H
IAS Sett. 5 bar LS For H.F.O Transfer
Pump Auto Stop
44V LS
LS
For M.D.O Transfer LS H
Pump Auto Stop 19V 74V 31V

F-204V
78V H.F.O

77V
IAS LS
67V I.G.G G.O 15V G/E M.D.O Settling Tank (P) LX LIAHL
Service Tank Service Tank F-203V IAS

2SG
LIAHL LIAL
IAS
LX
IAS
LX (518.1 m3) TIAH
(100.7 m3) (134.2 m3) TX
IAS
35V Near 28V
L
1SG I.G.G. G.O IAS LS For H.F.O Transfer

13V
Pump Auto Start
Service Tank LS
M.D.O Storage
5V
G.O Service Tank

LAHH

4SG
Tank 76V
LS
IAS
29V

36V

LIAHL
To Incinerator

LX (211 m3) 61V

Air vent/Overflow
IAS
69V 46V Low Sulphur
68V
26V F.O Tank (P) LX LIAH
IAS

Air vent/Overflow
(288.7 m3)
52V TX TIAH
IAS
To I.G.G

27V
G.O Pump

G.O Transfer Pump From L.O Bunker 12V

34V

33V
(2 m3/h x 2.5 bar)

(A)

(A)
Station (P) Drain
PI CI 11V

M.D.O Transfer Pump

IAS
Near
48V

39V

(30 m3/h x 4.5 bar)

3S 37V

3SG
3rd LS
Deck LS LAHH
PI PI IAS
H.F.O Transfer 75V
(32 Mesh) Low Sulphur 60V
Pump 53V F.O Tank (S) LIAH
LX
(50 m3/h x 4 bar)

Air vent/Overflow
66V 43V
IAS
70V (282.6 m3)
CI CI 49V TX TIAH
From G/E M.D.O Service DPI-I IAS
Pump Coaming Drain 2S 1S Duplex H

14V
50V DPI Pressure LS For H.F.O Transfer
(32 Mesh) (32 Mesh) F-201V Pump Auto Stop
Gauge
10V

F-202V
From G/E Leaked Oil Drain & Coaming Drain H.F.O 30V
Settling Tank (S) LX LIAHL
32V

From I.G.G F.O Pump Coaming Drain

(A)

(A)
IAS

9V
21V IAS
(537.8 m3)
To M.D.O LS TX TIAH
From M.D.O Purifier Purifier IAS
L
73V LS For H.F.O Transfer
From Purifier Work Bench Drain Pump Auto Start

65V
From Boiler F.O Heater Coaming Drain IAS
23V LAHH
1V LS
IAS
AFT H.F.O. 41V
6V

From Boiler F.O Burner 8V 2V Bunker Tank (S) LX LIAH

IAS IAS
Coaming Drain (252.7 m3)
Key LAH LS
LS TIAH
IAS TX
Fuel Oil Line LAH IAS
LS H.F.O Overflow 71V
IAS
Diesel Oil Line 7V F.O Drain Tank (87.6 m3) 51V
Tank (1.0 m3)
Air Line
Drain Line To/From H.F.O
To Oily Bilge Tank Bunker Station (S)

Final Draft / 2007.12.28 2 - 31 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.6 Fuel Oil and Fuel Gas Service Systems
2.6.1 Fuel Oil Bunkering and Transfer Systems
1. General Description
1) Boiler Fuel Oil System
The Aft HFO tank(P) (capacity 164m3) , Aft HFO tank(S) (capacity
252.7m3), Low sulphur FO Tank(P) (capacity 288.7m3 ), Low sulphur
FO Tank(S) (capacity 282.6m3 ), are situated on either side of the engine
room. The two settling tanks are located above their respective bunker
tanks, HFO settling tank(P) (Capacity 518.1m3 ), HFO settling tank(S)
(Capacity 537.8m3 ).
Normally, fuel oil is supplied to the boilers from the settling tanks, in
which the fuel oil is allowed to stand for 24 hours. Any entrained water
is allowed to settle out and is drained from the tanks to the fuel oil drain
tank through a spring loaded self-closing valve.
The settling tanks are kept filled as necessary by transferring oil from
the bunker tanks, using the engine room fuel oil transfer pump. The
transfer pumps can take suction from any of the fuel oil tanks, and
discharge to any of them as well as to the main deck.
diesel are led to the fuel oil drains tank, where a level alarm will sound Gas oil Transfer Pump Naniwa
to indicate a leak in the system. No. of sets: 1
Model: ALGP-25
The suction valves from the bunker and settling tanks are fitted with Capacity: 2m3/h
remotely operated quick closing valves. These can be closed from a Discharge Pressure: 2.5bar
remote fire station. After being operated they have to be reset manually.
3. Operating Procedure
All storage tanks, both heavy fuel oil and diesel oil, are fitted with a
float type air vent pipe with flame screens to prevent tank pressurisation. 1) To Transfer Fuel Oil from HFO Settling Tank
The engine room fuel oil transfer pump can be used in auto mode, where (1) Put steam heating on the aft fuel tank and ensure the temperature is
a low level switch in the fuel oil settling tank will initiate the pump to raised for easy pumping.
run and a high level switch will cause the pump to auto-stop.
(2) Ensure blanks are fitted to manifold valves and that valves are closed.
Auto start of the fuel oil transfer pump from Stbd or Port tanks can be Open the deck line valves and inlet valves on tanks to be filled.
selected from the group starter panel..
(3) Ensure the aft tank filling valves are closed and open the pump
2) Diesel & Gas Oil System discharge valve.
(1) Marine Gas oil system supplies fuel to: (4) Open the suction, discharge valves of the pump, ensuring that the line is
filled by testing the vent valve on the suction filter.
- Emergency diesel generator
(5) Start the pump with the relief/bypass valve partly open and, once oil is
- Inert gas generator flowing, set the valve to give optimum discharge pressure.

The marine diesel oil transfer pump can also be used to transfer diesel (2) Marine diesel oil system supplies fuel to: (6) Have personnel inspecting the line throughout the transferring, ensuring
oil to the main deck and D.O service tank, and in case of emergency it that there is no leakage and that they are able to stop the transfer
can be used to transfer heavy fuel oil after changing over spectacle - Incinerator immediately should any problems occur.
blanks. However, great care should be taken if doing so to prevent
contamination of the diesel oil system by heavy fuel oil. - Boiler when in cold condition (7) As the transfer continues, continuously monitor the levels in the forward
fuel tank as well as the tanks being filled.
The GO transfer pump can take suction from the I.G.G.G.O service tank - Diesel generator engine
and discharge to the main deck line and emergency G/E GO tank. (8) When the receiving tank is at the required level, stop the transfer and
Both the G.O and the D.O storage tanks are fitted with high level alarms, close all valves on the pump and tanks. Check all tank levels, and record
All the fuel oil pumps (transfer and service) are gear and screw type with any overflow going to the fuel oil overflow tank. amounts transferred and received.
driven by electric motors.
2. Capacities and Ratings 2) Diesel Oil Transfer
The two Aft bunker tanks and settling tanks are steam heated, . The
bunker tanks have three coils with a control valve to isolate the steam at H.F.O Transfer Pump: Naniwa (1) Open the following valves:
tank low level. No. of sets: 1
Model: ALGV-100BSJ - Service tank filling valve 34V
The settling tanks each have three coils, with a control valve to maintain Capacity: 50 m3/h - Quick closing valves from the storage tank 27V
a fuel oil temperature. All the lines to and from the tanks have steam Discharge Pressure: 4.0 bar - Pump suction and discharge valves 32V, 34V
tracing to maintain line temperature.
MDO Transfer Pump: Naniwa (2) Vent off any air at the pump suction filter.
Overflows from settling tanks are led to the overflow tanks. When the No. of sets: 1
each bunker tanks level high limit switch activated the bunker tanks MODEL: ALGP-80 (3) Start the pump and monitor the service tank filling.
filling valves are automatically closed. Capacity: 30 m3/h
Discharge Pressure: 4.5 bar (4) On completion, stop the pump and close all valves. Note and record the
Drains from save-alls around equipment using either heavy fuel oil or quantities transferred with current tank levels.

Final Draft / 2007.12.28 2 - 32 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.6.1a Fuel Oil Bunkering and Transfer System

From/To Em'cy G/E From/To G.O IAS

Gas Oil Tank Bunker Station
LS
LS LAHH
Em'cy G/E Upper Deck 72V IAS

Air vent/Overflow
IAS 42V
Room 3V AFT H.F.O.
From I.G.G G.O Pump LIAH
Bunker Tank (P) LX
IAS
Overflow

From Incinerator G.O Service Tank 4V 17V (164 m3) TIAH

TX
Overflow IAS
To Main Boiler
IAS H
IAS Sett. 5 bar LS For H.F.O Transfer
Pump Auto Stop
44V LS
LS
For M.D.O Transfer LS H
Pump Auto Stop 19V 74V 31V

F-204V
78V H.F.O

77V
IAS LS
67V I.G.G G.O 15V G/E M.D.O Settling Tank (P) LX LIAHL
Service Tank Service Tank F-203V IAS

2SG
LIAHL LIAL
IAS
LX
IAS
LX (518.1 m3) TIAH
(100.7 m3) (134.2 m3) TX
IAS
35V Near 28V
L
1SG
I.G.G. G.O IAS LS For H.F.O Transfer

13V
Pump Auto Start
Service Tank LS
M.D.O Storage
5V
G.O Service Tank

LAHH

4SG
Tank 76V
LS
IAS
29V

36V

LIAHL
To Incinerator

LX (211 m3) 61V

Air vent/Overflow
IAS
69V 46V Low Sulphur
68V
26V F.O Tank (P) LX LIAH
IAS

Air vent/Overflow
(288.7 m3)
52V TX TIAH
IAS
To I.G.G

27V
G.O Pump

G.O Transfer Pump From L.O Bunker 12V

34V

33V
(2 m3/h x 2.5 bar)

(A)

(A)
Station (P) Drain
PI CI 11V
M.D.O Transfer Pump
IAS
Near
48V

39V

3S 37V (30 m3/h x 4.5 bar)

3SG
3rd LS
Deck LS LAHH
PI PI IAS
H.F.O Transfer 75V
(32 Mesh) Low Sulphur 60V
Pump 53V F.O Tank (S) LIAH
LX
(50 m3/h x 4 bar)

Air vent/Overflow
66V 43V
IAS
70V (282.6 m3)
CI CI 49V TX TIAH
From G/E M.D.O Service DPI-I IAS
Pump Coaming Drain 2S 1S Duplex H

14V
50V DPI Pressure LS For H.F.O Transfer
(32 Mesh) (32 Mesh) F-201V Pump Auto Stop
Gauge
10V

F-202V
From G/E Leaked Oil Drain & Coaming Drain H.F.O 30V
Settling Tank (S) LX LIAHL
32V

From I.G.G F.O Pump Coaming Drain

(A)

(A)
IAS

9V
21V IAS
(537.8 m3)
To M.D.O LS TX TIAH
From M.D.O Purifier Purifier IAS
L
73V LS For H.F.O Transfer
From Purifier Work Bench Drain Pump Auto Start

65V
From Boiler F.O Heater Coaming Drain IAS
23V LAHH
1V LS
IAS
AFT H.F.O. 41V
6V

From Boiler F.O Burner 8V 2V Bunker Tank (S) LX LIAH

IAS IAS
Coaming Drain (252.7 m3)
Key LAH LS
LS TIAH
IAS TX
Fuel Oil Line LAH IAS
LS H.F.O Overflow 71V
IAS
Diesel Oil Line 7V F.O Drain Tank (87.6 m3) 51V
Tank (1.0 m3)
Air Line
Drain Line To/From H.F.O
To Oily Bilge Tank Bunker Station (S)

Final Draft / 2007.12.28 2 - 33 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

4. Control and Alarm Settings

IAS
Description Setting
Tag No.
FO002 HFO SETT TK S LEVEL H/L 15.97/0.5m

FO003 HFO SETT TK S TEMP 80℃

FO006 AFT HFO TK S LEVEL H 15.77m

FO007 AFT HFO TK S TEMP H 80℃

FO012 LOW SULF TK S LEVEL H 10.88m

FO013 LOW SULF TK S TEMP 80℃

FO017 FWD HFO TK S LEVEL H/L 9.91/2m

FO018 FWD HFO TK S TEMP H 80 °C

FO024 HFO SETT TK P LEVEL H/L 16/0.5m

FO025 HFO SETT TK P TEMP H 80 °C

FO028 AFT HFO TK P LEVEL H 15.77m

FO029 AFT HFO TK P TEMP H 80 °C

FO032 LOW SULF TK P LEVEL H 15.8m

FO037 FWD HFO TK P LEVEL H/L 9.91/2.0 m

FO038 FWD HFO TK P TEMP H 80℃

DO001 MDO STORAGE TK LEVEL H/L 11.16/0.45m

DO004 GE MDO SERV TK LEVEL L 0.45m

DO007 IGG GO SERV TK LEVEL H/L 4.69/0.45m

5. IAS Display

Final Draft / 2007.12.28 2 - 34 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.6.2a Diesel Oil Purifying and G/E Fuel Oil System

Near G/E G.O

Service Tank Top
G/E M.D.O
Service Tank
(134.2 m3)
Finned Tube
Pipe (100A)

101V

126V
127V 128V
From M.D.O
Near 2nd Storage Tank

102V
Deck
To Boiler F.O
11S Pump Suction
(60 Mesh) V4
PI

S
RV4
115V

103V 9 bar Air

MT

S
105V

FI
FI IAS
104V

PX

PI
PX

V1
M.D.O Supply Line for
G/E Back-out Starting

M.D.O
PI
G/E M.D.O Service Pump L.O Purifier
Loose Supply
(2.95 m3/h x 4 bar) (3,000 L/H)
PX V5
PI CI
CI PI TX
ST
124V

122V
120V 119V 129V 12S

130V
Generator Engine
(Hyundai-B&W Model : 9L32/40) IAS (32 Mesh)

131V
No.2 M.D.O Purifier Supply Pump LS
PS PI CI
PIAL PX (3 m3/h x 3 bar)
MC
116V

109V

123V

121V

112V 118V 117V

No.1 Sludge Tank

(14 m3)

Key
Diesel Oil Line
Air Line
To F.O Drain Line
To F.O Drain Tank Drain Tank To F.O Drain Tank

Final Draft / 2007.12.28 2 - 35 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.6.2 DO Purifying and G/E Fuel Oil System 4. Diesel Generator Fuel Oil System

1. General Description
The diesel oil storage tank is on the port side of the engine room. The purifier
feed pump takes suction from the storage tank, which, after the purification
process, discharges to the diesel oil service tank.
Waste oil from the purifier flows into the fuel oil sludge tank, under the base of
the purifier. The sludge pump can pump this tank out.
Excess line pressure in the system is protected by a spring-loaded regulating
valve, which re-circulates the oil back to the return chamber.
Both service and storage tank suction valves are of the spring-loaded, quick
closing type, and can be operated remotely should an emergency situation arise.
The operation of the diesel generator should be done in conjunction
with the manufacturer’s instruction manual. The following outlines the
use of the fuel system.
1) Open the quick closing valve (101V) on the service tank to the
generator engine.
2) Check the line suction filters and vent off any air at the cock,
ensuring they are closed on completion.
3) Open the inlet (103V) and outlet (104V) valves to the counter/flow
meter.
4) Open the following valves:

2. Capacities and Ratings - Service pump suction and discharge valves

MDO Storage Tank: 211.0m3

- Duplex strainer in use inlet and outlet valves
G/E M.D.O. Service Tank: 134.2m3
Sludge Tank: 14.0m3
- D/G inlet and return line valves
MDO Purifier Supply Pump: Naniwa
No. of sets: 1 5) Start the generator engine and monitor the differential pressure
Model: ALGP-32 across the suction filters, as well as the spill line pressure.
Capacity: 3m3/h x 3bar
6) Check the flow meter and counter is operating correctly.
MDO Purifier: Alfa-Laval
No. of sets: 1
Capacity: 3000L/h

3. Operating Procedure of Purifier System

The operation and running of the diesel oil purifier should be undertaken
with reference to the manufacturer’s instruction manual.

1) Open and set the storage tank suction line quick closing valve
(27V) to the purifier inlet.

2) Open the inlet line suction valve to the filter and vent off to ensure
that the line is flooder DO open the purifier discharge valve to the
service tank.

3) Run up the purifier as per manufacturer’s instructions and ensure

that the service tank level is rising.

4) Monitor the purification process. Set up the cut-out process of the

purifier on the service tank level and check that the unit stops
when the required level is reached. Test the purifier alarms to
prove that all are operational.

Final Draft / 2007.12.28 2 - 36 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.6.3a Boiler Fuel Oil & Fuel Gas Service System

F-4V F-3V
LS
ABC To H.F.O Transfer Pump
E Control
AFT H.F.O.
281V P Air AFT Bunker
230V 231V Side Wall Tank (P)

280V
BV405-1

249V
248V
279V 278V 277V (164 m3)
LS
FI Extraction Fan
(A) No.2 No.1 (60 m3/min. x 40 mmAq) 252V
CV231 250V

SF-2

SF-1

Pipe (250A)
F.O Return
DPX
ACC
H.F.O
For Temp. TI
No.2 Main Boiler Boiler Hood Room Settling

204V
TX
H/L Alarm IAS ACC E
BV423 BV422 Control Air
F.O Boiler No.3 Burner BV424
P Tank (P)
TS LS LS LS 203V
Trip (518.1 m3)
BV405-2 BV404-1 BV404-2
BV401 LS LS LS A440 CV221 BV420
Control Air
BV425 275V

Furnace
TI From Seal BV425
F-46V

206V
Air Fan DFX PIL

218V CV031 219V

PX

Gas Header (250A)

BMS
BV423 BV422 TX ACC For F.G. Trip From G/E M.D.O
Base Burner BV424 LS LS
TX IAS
PIH
BMS
ABC Service Tank Low Sulphur

220V
BV405-2 BV404-1 BV404-2 For F.G. Trip
F.O Tank (P)

211V
BV401

F-68V
LS LS LS A440 Control Air
BV425 276V
(288.7 m3)

Control Air
For Pressure DPX For

212V
PS P
Performance

Furnace
Low Trip (F.O) PI From Seal E FI
For Pressure Air Fan Monitor
PS BV406 F-13V

210V
Low Trip (Dual) To Coaming BV425 239V
BV415

214V

213V
LS
Inside No.2 Burner BV423 BV422
For Dual PIAL PX BV424 LS LS
Burning IAS
Control Air
To No.4
BV431

F-69V
DPX
For F.O PAL BV405-2 BV404-1 BV404-2 Vent Riser
BV401 LS LS LS A440 LS
CI CI
Burning IAS
PI PI PAH PAL
21S
PI BV402 BGB IAS IAS IAS (60 Mesh)

No.2

No.1

207V
IAS From Seal BV430 LS

N2 Purge Header (50A)

On. PI BV403 Air Fan LS
TI 205V
B.G.B BGB LS
(F.O Recirc. Line)

(Burner Coaming) PI PI
BV428

209V

208V
ACC PX BV402
LS To H.F.O
BV427
TX Transfer Pump
From N2 Buffer
LS Tank In E/R 216V 125V For Performance DPI
282V

283V BV428 Monitor

Duplex
BV426 Pressure Gauge
246V For Master LS Boiler F.O
Gas Valve Trip A447 217V Service Pump
LS ACC PX

F-70V
TS (13 m3/h x 29.4 bar)
To F.O BV428 Boil-off PS
Drain Tank TX
BV428 Gas
244V

253V
TX F-14V
LS
270V

222V

221V
IAS PX
269V

BV428
N2 Purge Header (50A)

TI TI
(F.O Recirc. Line)

PI
LS BGB
BV402 BV427

F-66V
LS BV430 PI PI

No.2 Boiler F.O

No.1 Boiler F.O

Heater (A421)

Heater (A421)
LS BV434 BV434
ACC PX BV403 BV428
(Burner Coaming) LS Low Sulphur
On. PI
B.G.B BGB BV405-2 BV404-1 BV404-2 From Seal BV433 BV433 F.O Tank (S)

225V
BV402 BV431
BV401 Air Fan
PI
LS LS LS
LS PI PI PAH PAL F-43V (282.6 m3)
IAS BV423 BV422 BGB IAS IAS IAS BV435 BV435
For F.O PAL PI BV424 LS LS
Burning IAS
BV406 To Coaming BV425
DPX
238V Control Air 201V
For Dual PIAL PX
BV415 LS A440
Burning IAS Inside No.2 Burner
TI TI
Furnace

224V

223V
For Pressure
PS BV405-2 BV404-1 BV404-2 From Seal

202V
Low Trip (Dual)
BV401 LS LS LS Air Fan BV425 262V H.F.O
For Pressure
Gas Header (250A)

Low Trip (F.O)

PS
BV423 BV422
DPX Settling
BV424 Viscosity Control 251V
LS LS Control Air Tank (S)
IAS
TX IAS PIH For F.G. Trip Temperature Control (537.8 m3)
A440 ABC
Base Burner TX ACC
BMS 232V
BV425 For F.G. Trip
PIL

Viscorator
PX To F.O Heater
Furnace

XFD BMS
BV405-2 BV404-1 BV404-2 From Seal

234V
TI BV401 Air Fan
BV425 261V Temperature 233V F-2V F-1V
LS LS LS LS
Control Valve To H.F.O
BV423 BV422 Control Air Drain Valve & Transfer Pump AFT H.F.O.
BV424 LS LS LS Press. Gauge to
Bunker

ORI-21
be Provided on PI
F.O Boiler 226V 229V
TS
Trip
No.3 Burner A440 CV121 BV420 Each Strainer Tank (S)
For Temp. TI
TX
No.1 Main Boiler ACC 237V
TIALH
IAS 22S DPX DPAH To F.O Key
(252.7 m3)
H/L Alarm IAS E Control Air IAS
ABC DPX
P (60 Mesh) Drain Tank Fuel Oil Line
TX 228V
E Control ACC
Methane Vapour Line
P Air
BV405-1 227V
F.O Chamber
265V CV131 264V 263V Nitrogen Line

236V
FI Air Line
266V

(A) PIAL
267V PX IAS Drain Line

Final Draft / 2007.12.28 2 - 37 Part 2 Machinery System

CLEAN FORCE
2.6.3 Boiler Fuel Oil Service Systems
1. General Description
Fuel oil is normally supplied to the three burners of each boiler from either of
the two fuel oil settling tanks, by one of the two fuel oil service pumps.
Diesel oil may be used for flushing through lines or for flashing the boilers
from cold when no heating steam is available.
The fuel oil service pump takes suction from the in-use settling tank, through a
manually cleaned suction strainer. The strainer has a differential pressure alarm
fitted and care should be maintained to have a positive suction pressure at all
times. One pump will be running with the other on auto-start stand-by, in case
the discharge pressure from the using pump is fallen.
The fuel oil passes through a flow meter and counter, from which the
consumption can be calculated, and then to the pump suctions and each boiler
suction. The pumps are electrically driven horizontal rotary type, with auto-start
change-over.
The system pressure is controlled by a recirculation valve 237V, which allows
oil to re-circulate to air separator, and maintains a constant set pressure. The
pressure is set as part of the automatic combustion control system.
The oil then passes through the fuel oil heaters, normally one of which is in use,
with the other clean and ready for use.
Temperature control is by means of a viscometer, which measures the viscosity
of the oil and, from its signal, opens or closes the steam valve to the heaters to
alter the temperature. The viscosity value is set at the control station, with
temperature and viscosity signals from after the FO heater being compared with
the set point.
On the fuel inlet rail, both boilers have the same arrangements after passing
through a flow meter. There are three valves placed in parallel to each other,
and the oil is able to pass through a choice of them as follows:
- At all steam loads except minimum fuel demand from the boilers, the oil
will pass through the fuel oil flow control valve (CV131, CV231) to the
rail.
- The minimum fuel pressure keeping valve (267V, 281V) will be open to
maintain the boiler flame even when the steam load is in an extremely
low condition.
- A bypass valve (280V, 266V), which allows fuel oil to bypass the other
valves. It can also be used for emergency boiler operations, for instance,
when the flow control valve is out of order.
Final Draft / 2007.12.28
Machinery Operating Manual
Each boiler burner system has a recirculating valve(BV405-2) opened when all (3) Commence supplying steam to the in-use fuel oil heater. As above, open
the burners are extinguished and closed when the burner operation is initiated, the drains to the bilge until it is certain they are uncontaminated, and
to stop fuel from passing through the recirculation line to the pump suctions. then open them to the engine room drains cooler. Use the steam
temperature control bypass valve to allow steam through the system
When total (No.1 and No.2) FO flow is less than 900kg/h or either boiler is gas slowly.
mode, the viscoratror outlet valve (233V) is opened.
(4) As diesel fuel will be in the system, with the fuel oil pump taking
At each burner, there are two solenoid-operated valves (BV404-1, BV404-2). suction from the diesel oil service tank and diesel oil storage tank,
These form a double shut off when the burner is not in use. Also fitted to the ensure that the temperature in the heater does not rise above 50°C.
line is another solenoid operated valve which opens for a set time when the
burner is first taken out of use, and allows steam to pass through the burner, (5) When the line temperature rises to approximately 80°C, close the valve
preventing any fuel in the line from turning to carbon and blocking the burner. 207V, and open the valve of the heavy fuel oil system 205V
The boilers are tripped in an emergency by valves (BV405-1). (6) As the heavier fuel oil purges the system of diesel oil, the system
pressure will rise. Care should be taken to manually control the pump
2. Capacities and Ratings back pressure, and maintain it at a suitable level. The fuel oil heater
inlet steam valve should be opened further to bring the line temperature
FO Service Pump: KHI to over 100°C, for good combustion.
No. of sets: 2
Type: Horizontal Screw (7) As the boiler was flashed using diesel oil, air will have been supplied as
Flow: 13.0m3/h x 29.4bar the atomising medium at the burner. Continue to use the air for this
purpose until the system has been cleared of diesel oil.
FO Heater: KHI
No. of sets: 2 Caution
Type: Shell & Tube At no time should atomising steam be used in conjunction with diesel oil
Capacity: 50/150℃ when flashing the boiler. Explosions with resultant injuries and damage
could occur.
FO Viscosity Controller: VAF Instrument B.V
No. of sets: 1 (8) Open the atomising steam valves on the 16 bar line from the boiler
Type: Diff. Press. & Pneumatic desuperheater steam system. Open manually the atomising steam valves
on the burners not in use, and allow any condensation in the lines to be
3. Operating Procedures blown through. When it is certainly that water not remains any more in
the lines, slowly open manually the valves to the base burner, and shut
1) Supplying fuel oil to boiler off the atomising air supply.
It is assumed steam has been raised using diesel oil, with all inlet and
outlet valves to pumps and heaters open. (9) With the base burner now being supplied by fuel oil with atomising
steam, the boiler pressure can continue to be raised as the fuel pressure
(1) When sufficient steam pressure is raised on a boiler to supply the is increased.
desuperheater system, commence supplying steam to the heating
coil of the settling tank to be used. Open the heating coil drains (10) Start the viscorator unit, and shut the unit bypass valve. As the
valve to the bilge and the steam inlet valve. Check the drains for viscosity reading rises to coincide with the fuel oil line temperature, set
contamination and, if they are satisfactory, open the outlet valve to the control value, place the unit on automatic, and allow the
the drains cooler and close the valve to the bilge. temperature to be on auto-control.
(2) As the temperature rises, check the tank for water. The temperature (11) Check and inspect all systems for leaks. Ensure all bypass valves are
would normally need to be around 50°C for good pumping closed, and that flow meters at the suction filter, and at the boiler fuel
conditions. rail for the automatic combustion control system are operating.
2 - 38 Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.6.3a Boiler Fuel Oil & Fuel Gas Service System

F-4V F-3V
LS
ABC To H.F.O Transfer Pump
E Control
AFT H.F.O.
281V P Air AFT Bunker
230V 231V Side Wall Tank (P)

280V
BV405-1

249V
248V
279V 278V 277V (164 m3)
LS
FI Extraction Fan
(A) No.2 No.1 (60 m3/min. x 40 mmAq) 252V
CV231 250V

SF-2

SF-1

Pipe (250A)
F.O Return
DPX
ACC
H.F.O
For Temp. TI
No.2 Main Boiler Boiler Hood Room Settling

204V
TX
H/L Alarm IAS ACC E
BV423 BV422 Control Air
F.O Boiler No.3 Burner BV424
P Tank (P)
TS LS LS LS 203V
Trip (518.1 m3)
BV405-2 BV404-1 BV404-2
BV401 LS LS LS A440 CV221 BV420
Control Air
BV425 275V

Furnace
TI From Seal BV425
F-46V

206V
Air Fan DFX PIL

218V CV031 219V

PX

Gas Header (250A)

BMS
BV423 BV422 TX ACC For F.G. Trip From G/E M.D.O
Base Burner BV424 LS LS
TX IAS
PIH
BMS
ABC Service Tank Low Sulphur

220V
BV405-2 BV404-1 BV404-2 For F.G. Trip
F.O Tank (P)

211V
BV401

F-68V
LS LS LS A440 Control Air
BV425 276V
(288.7 m3)

Control Air
For Pressure DPX For

212V
PS P
Performance

Furnace
Low Trip (F.O) PI From Seal E FI
For Pressure Air Fan Monitor
PS BV406 F-13V

210V
Low Trip (Dual) To Coaming BV425 239V
BV415

214V

213V
LS
Inside No.2 Burner BV423 BV422
For Dual PIAL PX BV424 LS LS
Burning IAS
Control Air
To No.4
BV431

F-69V
DPX
For F.O PAL BV405-2 BV404-1 BV404-2 Vent Riser
BV401 LS LS LS A440 LS
CI CI
Burning IAS
PI PI PAH PAL
21S
PI BV402 BGB IAS IAS IAS (60 Mesh)

No.2

No.1

207V
IAS From Seal BV430 LS

N2 Purge Header (50A)

On. PI BV403 Air Fan LS
TI 205V
B.G.B BGB LS
(F.O Recirc. Line)

(Burner Coaming) PI PI
BV428

209V

208V
ACC PX BV402
LS To H.F.O
BV427
TX Transfer Pump
From N2 Buffer
LS Tank In E/R 216V 125V For Performance DPI
282V

283V BV428 Monitor

Duplex
BV426 Pressure Gauge
246V For Master LS Boiler F.O
Gas Valve Trip A447 217V Service Pump
LS ACC PX

F-70V
TS (13 m3/h x 29.4 bar)
To F.O BV428 Boil-off PS
Drain Tank TX
BV428 Gas
244V

253V
TX F-14V
LS
270V

222V

221V
IAS PX
269V

BV428
N2 Purge Header (50A)

TI TI
(F.O Recirc. Line)

PI
LS BGB
BV402 BV427

F-66V
LS BV430 PI PI

No.2 Boiler F.O

No.1 Boiler F.O

Heater (A421)

Heater (A421)
LS BV434 BV434
ACC PX BV403 BV428
(Burner Coaming) LS Low Sulphur
On. PI
B.G.B BGB BV405-2 BV404-1 BV404-2 From Seal BV433 BV433 F.O Tank (S)

225V
BV402 BV431
BV401 Air Fan
PI
LS LS LS
LS PI PI PAH PAL F-43V (282.6 m3)
IAS BV423 BV422 BGB IAS IAS IAS BV435 BV435
For F.O PAL PI BV424 LS LS
Burning IAS
BV406 To Coaming BV425
DPX
238V Control Air 201V
For Dual PIAL PX
BV415 LS A440
Burning IAS Inside No.2 Burner
TI TI
Furnace

224V

223V
For Pressure
PS BV405-2 BV404-1 BV404-2 From Seal

202V
Low Trip (Dual)
BV401 LS LS LS Air Fan BV425 262V H.F.O
For Pressure
Gas Header (250A)

Low Trip (F.O)

PS
BV423 BV422
DPX Settling
BV424 Viscosity Control 251V
LS LS Control Air Tank (S)
IAS
TX IAS PIH For F.G. Trip Temperature Control (537.8 m3)
A440 ABC
Base Burner TX ACC
BMS 232V
BV425 For F.G. Trip
PIL

Viscorator
PX To F.O Heater
Furnace

XFD BMS
BV405-2 BV404-1 BV404-2 From Seal

234V
TI BV401 Air Fan
BV425 261V Temperature 233V F-2V F-1V
LS LS LS LS
Control Valve To H.F.O
BV423 BV422 Control Air Drain Valve & Transfer Pump AFT H.F.O.
BV424 LS LS LS Press. Gauge to
Bunker

ORI-21
be Provided on PI
F.O Boiler 226V 229V
TS
Trip
No.3 Burner A440 CV121 BV420 Each Strainer Tank (S)
For Temp. TI
TX
No.1 Main Boiler ACC 237V
TIALH
IAS 22S DPX DPAH To F.O Key
(252.7 m3)
H/L Alarm IAS E Control Air IAS
ABC DPX
P (60 Mesh) Drain Tank Fuel Oil Line
TX 228V
E Control ACC
Methane Vapour Line
P Air
BV405-1 227V
F.O Chamber
265V CV131 264V 263V Nitrogen Line

236V
FI Air Line
266V

(A) PIAL
267V PX IAS Drain Line

Final Draft / 2007.12.28 2 - 39 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

(12) Open all master valves on fuel and steam lines to other burners. These (7) Change to the second fuel oil heater to ensure that this is also flushed
can now be operated from the control panel as required. through.

2) To Circulate Fuel to Second Boiler
It is assumed that one boiler is already on line, using fuel oil and
atomising steam.
(1) Open slowly the fuel rail recirculation isolation valve for the second
boiler. This allows fuel oil to flow along the inlet rail to the three
burners, and back to the pump suction.
(2) Open the instrument air supply to the fuel flow control valve.
(8) Stop the in use pump, allowing the stand-by unit to be in use, and
flushed through.
(9) After a few minutes, shut down one boiler. After stopping the boiler,
each burner rail recirculation valve is opened, and allowed it to
recirculate for a short time. After a few moments close the main fuel
oil shut off valve to the fuel oil rail. Do not leave the diesel oil
recirculating to the boiler for longer than necessary, as the diesel oil
will be recirculating to the fuel oil settling tank.

(3) Open the inlet and outlet valves to the rail flow meter, and reset the (10) Repeat operation for the second boiler, when steam supply is no
emergency shut off valve, allowing fuel oil to the control valves. longer required.

(4) With boiler ACC control on manual mode, slowly open the fuel oil (11) Stop the pumps and close all fuel oil valves on the system.
control valve until pressure is noted in the rail. Ensure that the fuel oil
pressure on the in-use boiler is not affected by this operation. 4. Control and Alarm Settings

(5) Check pressure gauges and thermometers for ongoing readings, and IAS
bring the fuel temperature up to approximately 100°C to enable a Description Setting
Tag No.
satisfactory flashing process.
BC741 MB FO HTR OUT VISCO H/L 35 / 8.75 cSt
3) To Change to Diesel Oil Firing Prior to Shut Down BC742 MB FO HTR OUT TEMP CONT H/L 170 / 110℃
It is assumed both boilers are firing. This operation should be undertaken
approximately 15minutes before total plant shut down. BC725 BOILER FO HEAT OUT PRESS L 0.0bar

BC726 BOILER FO HEAT STRAINER DP H 1.0bar

(1) Shut off steam lines and steam tracing line to the fuel oil settling
tanks and fuel oil heaters.
5. IAS Display
(2) Maintain a close watch of the fuel oil temperature, and when this has
dropped to approximately 95°C, open the diesel oil tank outlet to fuel
oil pump suction line valve.

(3) Open diesel oil supply valves and close the fuel oil valves to pump
suction from settling tanks.

(4) Change over from atomising steam supply to the boiler burners,
closing the steam valves, and replace with the atomising air supply.

(5) With the ACC system on manual control, ensure the pressure drop in
the fuel line with diesel oil now in use is compensated for by opening
the fuel oil valves further.

(6) Change to the spare bank of both the fuel oil pump suction and
discharge strainers, to ensure both banks are flushed through with
diesel.

Final Draft / 2007.12.28 2 - 40 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.6.3a Boiler Fuel Oil & Fuel Gas Service System

F-4V F-3V
LS
ABC To H.F.O Transfer Pump
E Control
AFT H.F.O.
281V P Air AFT Bunker
230V 231V Side Wall Tank (P)

280V
BV405-1

249V
248V
279V 278V 277V (164 m3)
LS
FI Extraction Fan
(A) No.2 No.1 (60 m3/min. x 40 mmAq) 252V
CV231 250V

SF-2

SF-1

Pipe (250A)
F.O Return
DPX
ACC
H.F.O
For Temp. TI
No.2 Main Boiler Boiler Hood Room Settling

204V
TX
H/L Alarm IAS ACC E
BV423 BV422 Control Air
F.O Boiler No.3 Burner BV424
P Tank (P)
TS LS LS LS 203V
Trip (518.1 m3)
BV405-2 BV404-1 BV404-2
BV401 LS LS LS A440 CV221 BV420
Control Air
BV425 275V

Furnace
TI From Seal BV425
F-46V

206V
Air Fan DFX PIL

218V CV031 219V

PX

Gas Header (250A)

BMS
BV423 BV422 TX ACC For F.G. Trip From G/E M.D.O
Base Burner BV424 LS LS
TX IAS
PIH
BMS
ABC Service Tank Low Sulphur

220V
BV405-2 BV404-1 BV404-2 For F.G. Trip
F.O Tank (P)

211V
BV401

F-68V
LS LS LS A440 Control Air
BV425 276V
(288.7 m3)

Control Air
For Pressure DPX For

212V
PS P
Performance

Furnace
Low Trip (F.O) PI From Seal E FI
For Pressure Air Fan Monitor
PS BV406 F-13V

210V
Low Trip (Dual) To Coaming BV425 239V
BV415

214V

213V
LS
Inside No.2 Burner BV423 BV422
For Dual PIAL PX BV424 LS LS
Burning IAS
Control Air
To No.4
BV431

F-69V
DPX
For F.O PAL BV405-2 BV404-1 BV404-2 Vent Riser
BV401 LS LS LS A440 LS
CI CI
Burning IAS
PI PI PAH PAL
21S
PI BV402 BGB IAS IAS IAS (60 Mesh)

No.2

No.1

207V
IAS From Seal BV430 LS

N2 Purge Header (50A)

On. PI BV403 Air Fan LS
TI 205V
B.G.B BGB LS
(F.O Recirc. Line)

(Burner Coaming) PI PI
BV428

209V

208V
ACC PX BV402
LS To H.F.O
BV427
TX Transfer Pump
From N2 Buffer
LS Tank In E/R 216V 125V For Performance DPI
282V

283V BV428 Monitor

Duplex
BV426 Pressure Gauge
246V For Master LS Boiler F.O
Gas Valve Trip A447 217V Service Pump
LS ACC PX

F-70V
TS (13 m3/h x 29.4 bar)
To F.O BV428 Boil-off PS
Drain Tank TX
BV428 Gas
244V

253V
TX F-14V
LS
270V

222V

221V
IAS PX
269V

BV428
N2 Purge Header (50A)

TI TI
(F.O Recirc. Line)

PI
LS BGB
BV402 BV427

F-66V
LS BV430 PI PI

No.2 Boiler F.O

No.1 Boiler F.O

Heater (A421)

Heater (A421)
LS BV434 BV434
ACC PX BV403 BV428
(Burner Coaming) LS Low Sulphur
On. PI
B.G.B BGB BV405-2 BV404-1 BV404-2 From Seal BV433 BV433 F.O Tank (S)

225V
BV402 BV431
BV401 Air Fan
PI
LS LS LS
LS PI PI PAH PAL F-43V (282.6 m3)
IAS BV423 BV422 BGB IAS IAS IAS BV435 BV435
For F.O PAL PI BV424 LS LS
Burning IAS
BV406 To Coaming BV425
DPX
238V Control Air 201V
For Dual PIAL PX
BV415 LS A440
Burning IAS Inside No.2 Burner
TI TI
Furnace

224V

223V
For Pressure
PS BV405-2 BV404-1 BV404-2 From Seal

202V
Low Trip (Dual)
BV401 LS LS LS Air Fan BV425 262V H.F.O
For Pressure
Gas Header (250A)

Low Trip (F.O)

PS
BV423 BV422
DPX Settling
BV424 Viscosity Control 251V
LS LS Control Air Tank (S)
IAS
TX IAS PIH For F.G. Trip Temperature Control (537.8 m3)
A440 ABC
Base Burner TX ACC
BMS 232V
BV425 For F.G. Trip
PIL

Viscorator
PX To F.O Heater
Furnace

XFD BMS
BV405-2 BV404-1 BV404-2 From Seal

234V
TI BV401 Air Fan
BV425 261V Temperature 233V F-2V F-1V
LS LS LS LS
Control Valve To H.F.O
BV423 BV422 Control Air Drain Valve & Transfer Pump AFT H.F.O.
BV424 LS LS LS Press. Gauge to
Bunker

ORI-21
be Provided on PI
F.O Boiler 226V 229V
TS
Trip
No.3 Burner A440 CV121 BV420 Each Strainer Tank (S)
For Temp. TI
TX
No.1 Main Boiler ACC 237V
TIALH
IAS 22S DPX DPAH To F.O Key
(252.7 m3)
H/L Alarm IAS E Control Air IAS
ABC DPX
P (60 Mesh) Drain Tank Fuel Oil Line
TX 228V
E Control ACC
Methane Vapour Line
P Air
BV405-1 227V
F.O Chamber
265V CV131 264V 263V Nitrogen Line

236V
FI Air Line
266V

(A) PIAL
267V PX IAS Drain Line

Final Draft / 2007.12.28 2 - 41 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.6.4 Boiler Fuel Gas Service System 2. System Capacities and Ratings Note
If the gas master valve and the boiler gas valve stay in the shut-off
1. General Description LD. Compressor condition (“Close” button lamp flashes) and the valve will not open even
Type: Centrifugal though the “Open” button is pressed, the interlock is engaged and must be
The fuel gas is normally supplied to the three burners of each boiler from the Capacity: 8,500m3/h x 1.96bar reset to the normal condition in accordance with the boiler gas shut-off
cargo tanks via the L/D gas heater and L/D compressor. The combination No. of sets: 2 routine.
burner burns the fuel-oil/gas inside the furnace and its burning mode is changed
through fuel-oil only, gas only , dual mode etc according to the boiler operating Forcing Vaporiser 4. Control and Alarm Settings
condition. Type: Shell & Tube type
Mass Flow: 7,100 kg/h IAS
Pressurised N2 is provided for eliminating remaining fuel gas from the fuel gas No. of sets: 1 Description Setting
Tag No.
pipeline when fuel gas burning is automatically stopped. The gases mixed with
BC701 MB BOG COMMOM PRESS H/L 0.7 / 0.1bar
N2 and fuel gas are released via the vent master of No.3 cargo tank and the Boil-off/Warm-up Heater
purging function sequence is as follows; Type: Shell & Tube type
No. of sets: 2
- Master N2 purge
- Gas header N2 purge 3. Gas Burner Operation
- Burner N2 purge
1) Open the instrument air supplies to the control valves and piston valves
To enable the gas to be supplied to the boilers from cargo tanks, the following and confirm its operating condition.
equipment is provided:
2) Operate one of the boil-off leak gas extraction fan and the other one on
- Two Low duty (LD) compressors stand-by condition.
- Two Boil-off/Warm-up heaters
- One steam-heated forcing vaporiser 3) Open Master Gas Valve
Pressing the master gas valve “Open” pushbutton causes the valve to
The L/D compressor discharges fuel gas through the gas heater where the open, when the master gas valve opens, the master N2 vent valve closes
temperature is regulated with two flow control valves, allowing the gas to pass 10 seconds afterwards.
through or by-pass the heater.
4) Open Boiler Gas Valve
The master gas valve is provided to isolate the engine room gas burning system Pressing the boiler gas valve “Open” PB causes the valve to open. When
from cargo part in case emergency operations such as the emergency Shut the boiler gas valve opens, the header N2 vent valve closes after 5
Down System (ESDS) activate. The fuel gas from the master gas valve is led to seconds. This is to replace existing N2 gas in the boiler gas header
the boiler gas header via each boiler gas valve (BV420) and the burner gas piping by boil-off gas and to fill the line with boil-off gas. Thereafter,
valves (BV422, BV423); these two valves on each burner form a double shut- the boiler will be in the gas burning stand-by state.
off between gas header and furnace. Gas flow control valve (CV121, CV221)
controls gas flow by fuel demand signal from the boiler ACC. 5) Open the burner gas valve (214B) for the base burner
Before starting gas burning, prepare the LD gas compressor, High &
In the master N2 purge to vent sequence, the piping from the master gas valve Low duty heaters and related systems. Initial gas burner starting should
outlet to each boiler gas valve (BV420) inlet is internally N2 purged for 60 be done under free-flow conditions without the LD compressor running.
seconds. The start of the gas burner may be conducted at the BGB and manually
or automatically at the ECR.
In the gas header N2 purge to vent sequence, the piping from the boiler gas
valve (BV420) outlet to the gas burner valve (BV422, BV423) inlet is internally 6) Check & confirm temperature control function of gas heater.
N2 purged for 35 seconds.
7) Increasing the number of gas burners as required.
In the gas burner N2 purge to vent sequence, the piping from the burner gas
valve (BV422, BV423) outlet to the gas burner nozzle is internally purged for 8) Checked the L/D compressor and run it if required.
15 seconds.
9) Checked and confirm burning condition and gas leakage etc.

Final Draft / 2007.12.28 2 - 42 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.6.5a IGG and Incinerator Fuel Oil System

From/To Em'cy G/E From/To G.O

Bunker Station From Waste Oil Key
Gas Oil Tank
Transfer Pump
Waste Oil Line

302V

B-82V
Em'cy G/E Upper Deck
Diesel Oil Line
Room
(Overflow) Sea Water Line
(Overflow)
Fresh Water Line

31SG
LAH
LS TS
IAS L
Inert Gas Line
Overflow

Incinerator G.O LAL TS

H
Service Tank LS
IAS Incinerator Waste Oil Air Line

32SG
LS
(2.0 m3) Service Tank H
Drain Line
IAS 309V 315V LS
(3.0 m3) L
LS
314V
78V
67V
LIAHL
I.G.G G.O
LX Service Tank
IAS

308V
304V
(100.7 m3)
35V Near

1SG
I.G.G. G.O
301V
Service Tank
CI
To M.D.O
29V

36V

Storage Tank
Mill Pump
(26 m3/h x 0.4 bar)
G.O Transfer Pump
(2 m3/h x 2.5 bar)
303V
PI CI To H.F.O PI
48V

39V

3S 37V Overflow Tank

To F.O
(32 Mesh) Drain Tank

To F.O
Drain Tank Incinerator
(700,000 kcal/h) To Bilge
1003 I.G.G D.O Pump From 9 bar Holding Tank

305V
1013
M PI (1,460 l/h x 25 bar) Service Air
1004

1001 1002 1005 1051 1052 S 313V

306V

1012 2105 MS PS
1061 S 316V
From Control
1060

4V S S
1062 Air System MS
1507 S
2032 1509

PS
PI
317V
1506
2103

S To F.O 307V
TC S S
2037 2038 Drain Tank
To F.O PI
From L.O
2041 Primary Bunkering From Oil Mist
Drain Tank S
2042

Control Blower Station (S) Chamber/

2040 Washing Panel Drain Header Drain
rner

Cooling
Pilot Bu

Tower
Main B
urner

Blower 2 Inert Gas

Combu Cooler
Blower 1 s tion Ch
amber
318V
0V
From 9.8 bar 32
Steam System
9V
(Burner Atomizing Steam) 31

From S.W Supply

(For Ballast System)
To Oily
From F.W Supply
Bilge Tank
(For Rinsing)

Final Draft / 2007.12.28 2 - 43 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.6.5 IGG and Incinerator Fuel Oil System 5) Ensure that the service tank gauge glass valves are open, and monitor
them as the level rises. Stop the pump when the required level is reached.
1. General Description
4. IAS Display
The IGG system use gas oil as its operating fuel supply.

The incinerator use gas oil as its operating fuel supply.

The GO is bunkered to the IGG GO service tank via a line running from the
manifold, which can be supplied from either barge or shore installation.

The emergency diesel generator service tank is supplied gas oil by GO transfer
pump and IGG GO service tank supplies the IGG system by direct suction from
the tank through a remote operating quick closing valve.

The GO transfer pump takes suction from the IGG GO service tank and
supplies to incinerator GO service tank. The gas oil can also be mixed with the
waste oil to the incinerator (306V), both to flush through the suction line to the
unit and to lower the viscosity of the oil to be incinerated.

The incinerator waste oil tank is fitted with gauge cocks to monitor the level,
remote operated quick closing valve on the suction and overflows to the oily
bilge tank. The incinerator waste oil tank is also fitted with high and low level
alarms.

2. System Capacities

- IGG GO service tank 100.7m3

- Incinerator GO service tank 2.0m3

- Incinerator waste oil Tank: 3.0m3

3. Operating Procedures

To Supply GO to Emergency Generator Service Tank

1) Check the IGG GO service tank for water through the spring self-
closing valve and open the remotely operated quick closing valve 29V.

2) Open the GO transfer pump inlet and outlet valve 37V, 48V and close
39V, and vent off any air in the suction strainer.

3) Set the transfer pump relief / by-pass valve to approximately half open
and start the pump.

4) When the pump is operating satisfactorily, adjust the relief valve to the
correct discharge pressure.

Final Draft / 2007.12.28 2 - 44 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.7.1a Main Turbine Lubrication Oil System

232V V-4V
LX LIAL To be Located Far Away
Main L.O IAS From React. Air Outlet
Reactivation To ECR
Gravity Tank 229V
Reactivation Air Inlet
Monitor
(28.1 m3) 225V For Initial Filling
Air Outlet
(Nor. Close)
Dehumidifier
223V

(In E/R) XT XT
224V ORI-21 173V 173A
Dry Air Supply
Manifold
226V LP Turbine
To L.O
Drain Tank

No.2 L.O Cooler No.1 L.O Cooler PIAL

IAS
IAS T-82A
PI PI PI PI
TI TI TI TI
Main L.O Filter PX
(200 Mesh W/Magnet)
T-143
Sett. Control
213V

214V

215V

216V
Air 21S
45℃ TX
T-82A O-51
P
E
PI
On ECP
217V

234V
212V

211V

ORI-23
23S PI PI
Control L.O Filter DPX PX
(200 Mesh W/Magnet)
DPIAH
219V

210V

IAS

PI PI ORI-22
DPX
To ECR
220V

218V
Monitor
DPIAH
209V

209V

IAS PI PI
LS TIAH TIAH PI
TX TX
IAS IAS
XT XT
O-40

LS
T-85
Em'cy Turn'g CI 173V 173A
Intermediate
PI
Cut-off Gear
Maneouv. No.2 No.1
S

Pilot Vale
MV-1
Valve (Ast. & T-86A
Bearings
Valve Block PIAL
HP

Turning
Ahead PX
T-86 IAS

Gear
Valve) Over
Operating
PS
T-86B Speed
Governor
TI TI Turbine
Mechanism
PI
(L.P T/B
Rotor)
TI TI
T-141

T-83
204V

203V
206V

205V

PS
208V 209V

PS PS PS ORI-24 Low Press.

T-144 Trip
Drain Tank
To L.O

IAS T-145
Sett.
230V

E
P
4 bar
202V 201V
207V

22S 227V

Control
Air To Main L.O
Sump Tank PI PI
233V

Auxiliary L.O Pump 228V

(180 m3/h x 4.5 bar)
No.2 No.1
Key
231V Lubricating Oil Line
LIAHL
Main L.O Sump Tank LX
IAS Air Line
(66.6 m3) LAL Drain Line
LS
IAS

Final Draft / 2007.12.28 2 - 45 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.7 Lubricating Oil Systems
2.7.1 Main Turbine Lubricating Oil System
1. General Description
Lubricating oil is delivered to the main turbine bearings and double reduction
gearing through a system which ensures the continuity of supply of high quality
oil. Two electrically driven pumps, arranged in main and stand-by configuration
and one shaft driven pump, draw oil from the main turbine sump tank and
discharge into a common line. The shaft driven pump has a filter in its suction
line.
In the event of the failure of pressure supplies to the main turbine lube oil
system, the flow of oil from the bottom of the gravity tank reverses and the
positive head of oil in the tank (minimum 5m above the shaft), is supplied
through a non-return valve to the bearings and gears.
The oil passes through another orifice plate and flows to the turbine and gearing
bearings and the reduction gear oil sprays. A separate line leads the oil to the
two shaft bearings. All the oil from the bearing and gearing supplies is returned
to the sump.
To maintain system purity, in addition to the in-line filtration provided, the oil
in the sump is circulated through the lube oil purifier system.
6) If the gravity tank level is low, open the valve 225V(NC) and fill the tank
until oil is seen at the overflow line sight glass. Shut the valve, and ensure
that overflow continues.
7) Line up the stand-by auxiliary lube oil pump and, when operational
conditions permit, check the auto changeover of the unit.
8) With the system in operation, visually check all sight glasses on gearing and
bearings. Check that local and remote thermometers and pressure gauges
are reading correctly.
4. Normal Operation

During normal full-away operations, at over 90% full ahead revolutions, the 2. Capacities and Ratings 1) With the lube oil system in use, the turbine itself can be brought back into
discharge pressure from the shaft driven pump is sufficient to supply the system. operation and the turning gear operated.
At this rev/min, a signal from the main turbine control unit stops the running Auxiliary Lube Oil Pumps Shinko
auxiliary lube oil pump, without starting the stand-by pump, and places the No. of sets: 2 2) With the engine at over 90% of its full sea rev/min, ensure the in use
stopped pump as first start stand-by. Reducing the turbine speed below the 90% Type: Vertical centrifugal auxiliary lube oil pump stops and the pressure in the system is maintained
full rev/min or pressure drops below 2.9bar initiates the start of the first standby Capacity: 180m3/h by the shaft driven pump.
auxiliary electrically driven pump with sounding failure alarm. If, for any Pressure: 4.5 bar
reason, there should be a further reduction in lube oil pressure, the other 3) Similarly, when speed is reduced, ensure the auxiliary pump cuts-in and
electrically driven auxiliary pump will cut in. Lube Oil Coolers: Alfa Laval provides the system oil pressure.
No. of sets: 2
To ensure the shaft driven pump picks up suction as the engine revolutions rise, Type: Plate type 4) When operational requirements permit, test the system alarms to prove all is
oil from the auxiliary pump discharge line passes through an orifice to keep a Capacity: 850,000kcal/h satisfactory.
continuous oil pressure to the shaft driven pump suction.
3. Operating Procedures 5) Monitor the system filter units and the operation of the auto back-flush unit.
The system pressure is maintained constantly at around 4.0bar by a pneumatic
control valve fitted behind the main LO filter. This allows excess oil pressure to To place the main turbine Lubricating oil system into service
be vented back to the sump tank.
1) Verify the system’s integrity. Check the level of oil in the main turbine
Oil from the main line is used as a control medium for the main turbine sump and top up as required.
manoeuvring block operating mechanism. Oil from this line is also fed through
an orifice plate to the emergency trip valve, which will allow the oil to return to 2) Under cold operating conditions, it may be necessary to increase the
the sump, thereby closing the manoeuvring valve and stopping the turbine. sump oil temperature by use of heating steam.

Two lube oil coolers (main and stand-by), and the associated control system,
regulate the temperature of the oil under normal operating conditions. A three
way control valve allows oil to pass through or bypass the in-use cooler to
maintain a cooler outlet temperature of approximately 45°C. The coolers are of
the plate type and are cooled by water from the fresh water cooling system.
The oil then passes through an orifice plate, which reduces its pressure, and a
line is led to the bottom of the gravity tank, which is constantly fed to overflow
back to the sump. A visual check of this overflow can be observed through a
sight glass in the line.
Note
Depending upon service requirements, a certain degree of heating can
be achieved by the circulation of the sump through the lube oil purifier
system.
3) Select and line up the duty auxiliary lube oil pump. Ensure cooling
water is operating through the lube oil cooler to be used.
4) Supply instrument air to the pressure control valve and the cooler three-
way bypass valve. Check the operation of both units on manual control
and, when satisfied, return to automatic.

5) Start the pump; vent off the system at the filters and selected lube oil
cooler.

Final Draft / 2007.12.28 2 - 46 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.7.1a Main Turbine Lubrication Oil System

232V V-4V
LX LIAL To be Located Far Away
Main L.O IAS From React. Air Outlet
Reactivation To ECR
Gravity Tank 229V
Reactivation Air Inlet
Monitor
(28.1 m3) 225V For Initial Filling
Air Outlet
(Nor. Close)
Dehumidifier
223V

(In E/R) XT XT
224V ORI-21 173V 173A
Dry Air Supply
Manifold
226V LP Turbine
To L.O
Drain Tank

No.2 L.O Cooler No.1 L.O Cooler PIAL

IAS
IAS T-82A
PI PI PI PI
TI TI TI TI
Main L.O Filter PX
(200 Mesh W/Magnet)
T-143
Sett. Control
213V

214V

215V

216V
Air 21S
45℃ TX
T-82A O-51
P
E
PI
On ECP
217V

234V
212V

211V

ORI-23
23S PI PI
Control L.O Filter DPX PX
(200 Mesh W/Magnet)
DPIAH
219V

210V

IAS

PI PI ORI-22
DPX
To ECR
220V

218V
Monitor
DPIAH
209V

209V

IAS PI PI
LS TIAH TIAH PI
TX TX
IAS IAS
XT XT
O-40

LS
T-85
Em'cy Turn'g CI 173V 173A
Intermediate
PI
Cut-off Gear
Maneouv. No.2 No.1
S

Pilot Vale
MV-1
Valve (Ast. & T-86A
Bearings
Valve Block PIAL
HP

Turning
Ahead PX
T-86 IAS

Gear
Valve) Over
Operating
PS
T-86B Speed
Governor
TI TI Turbine
Mechanism
PI
(L.P T/B
Rotor)
TI TI
T-141

T-83
204V

203V
206V

205V

PS
208V 209V

PS PS PS ORI-24 Low Press.

T-144 Trip
Drain Tank
To L.O

IAS T-145
Sett.
230V

E
P
4 bar
202V 201V
207V

22S 227V

Control
Air To Main L.O
Sump Tank PI PI
233V

Auxiliary L.O Pump 228V

(180 m3/h x 4.5 bar)
No.2 No.1
Key
231V Lubricating Oil Line
LIAHL
Main L.O Sump Tank LX
IAS Air Line
(66.6 m3) LAL Drain Line
LS
IAS

Final Draft / 2007.12.28 2 - 47 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

5. Main Turbine Lube Oil Temperature Control In case of a failure in the LO supply system, the flow from the LO gravity tank MT167 MT HPT AFT BRG TEMP H 80℃
will reverse, thus providing a positive head to bearings and gears.
MT169 MT LPT INLET STM PRESSURE L 0.7bar
SP Operator
L.O Coolers PID
PID controllers operated in “Auto” mode, are used in separate control loops to MT176 MT MANEOUVRING TRIP OIL PRESSURE L 10.0bar
Auto/Man PV
No.1 No.2
Operation
A&B Sensor
maintain pressure and temperature for the lube oil system. For direct operator MT180 MT MAIN WHEEL FWD BRG TEMP H 60℃
Selector intervention, the controllers must be set to “Manual” mode.
MT181 MT MAIN WHEEL AFT BRG TEMP 60℃
TIC TIC
To Main Turbine
6. Control and Alarm Settings MT182 MT MAIN THRUST PAD TEMP 80℃
Bearing and
Temp. Reduction Gear
MT183 MT AST TURBINE STM CHEST TEMP 350℃
Control
Valve IAS
PIC PIC Description Setting MT186 INT SHFT FWD BRG TEMP 65℃
Tag No.
L.O Filter MT187 INT SHFT FWD BRG TEMP 65℃
A&B Sensor MT121
Shaft Driven Selector
MT BRG LO IN TEMP H/L 54.0/34.0℃
Auxiliary Main L.O Pump PV MT123
L.O Pump Pressure
SP Operator MT MAIN LO PRESS L 0.7bar
2 1
Control
Valve
PID 7. IAS Display
Man/Auto MT141 MT LPT FWD BRG TEMP H 80℃
Operation
Main L.O Sump Tank
MT142 MT LPT AFT BRG TEMP H 80℃
MT143 MT LPT THR BRG TEMP H 80℃
MT144 MT RG HPT P1 FWD BRG TEMP H 80℃
Lubricating oil is delivered to the main turbine bearings and double reduction
gearing through a system which ensures the continuity of supply of high quality MT145 MT RG LPT P1 FWD BRG TEMP H 80℃
oil. Two electrically driven pumps, arranged in main and stand-by configuration MT146 MT RG HPT P1 AFT BRG TEMP H 80℃
and one shaft driven pump, draw oil from the main turbine sump tank and
MT147 MT RG LPT P1 AFT BRG TEMP H 80℃
discharge into a common line. The shaft driven pump has a filter in its suction
line. MT148 MT RG HPT W1 FWD BRG T H 70℃
MT149 MT RG LPT W1 FWD BRG T H 70℃
During normal full-away operations, at over 90% full ahead revolutions, the
MT150 MT RG HPT W1 AFT BRG T H 70℃
discharge pressure from the shaft driven pump is sufficient to supply the system.
At this rev/min, a signal from the main turbine control unit stops the running MT151 MT RG LPT W1 AFT BRG T H 70℃
auxiliary lube oil pump, without starting the stand-by pump, and places the MT152 MT RG HPT W1 L FWD BRG T H 70℃
stopped pump as first start stand-by. Reducing the turbine speed below the 90%
MT153 MT RG LPT W1 L FWD BRG T H 70℃
full rev/min or pressure drops below 2.9bar initiates the start of the first standby
auxiliary electrically driven pump with sounding failure alarm. If, for any reason, MT154 MT RG HPT W1 L AFT BRG T H 70℃
there should be a further reduction in lube oil pressure, the other electrically MT155 70℃
MT RG LPT W1 L AFT BRG T H
driven auxiliary pump will cut in.
MT156 MT RG HPT P2 FWD BRG T H 70℃
To ensure the shaft driven pump picks up suction as the engine revolutions rise, MT157 MT RG LPT P2 FWD BRG T H 80℃
oil from the auxiliary pump discharge line passes through an orifice to keep a MT158 MT RG HPT P2 AFT BRG T H 80℃
continuous oil pressure to the shaft driven pump suction.
MT159 MT RG LPT P2 U AFT BRG T H 80℃
Main turbine bearings and reduction gear lubrication is provided by two MT160 MT RG HPT P2 L FWD BRG T H 80℃
electrically driven auxiliary pumps and one shaft driven pump. Auxiliary pumps
MT161 MT RG LPT P2 L FWD BRG T H 80℃
are set up as a duty standby pair. As the pipes from the electrical and shaft driven
pump is joined, the lube oil is fed through a filter and a cooler before fed back to MT162 MT RG HPT P2 L AFT BRG T H 80℃
bearings and reduction gear. MT163 MT RG LPT P2 L AFT BRG T H 80℃
MT164 MT MAIN THRUST BRG TEMP H 60℃
A PID controller is used to maintain the LO temperature at 45°C, at the cooler
outlet. When the temperature is higher than the set point (45°C), IAS will open MT165 MT HPT THR BRG TEMP H 80℃
the control valve to reduce bypass flow and thereby increasing flow through MT166 MT HPT FWD BRG TEMP H 80℃
cooler, and vice versa.

Final Draft / 2007.12.28 2 - 48 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.7.2a Stern Tube Lubricating Oil System

LAL
IAS
LS 9 bar Control
S/T L.O Off : 0.1 bar PAL PS
Air Service
334V On : 0.2 bar IAS Air Control Unit 328V
Gravity

335V
From F.W Hyd. Unit
Tank Out 1 Out 2 (For Cleaning)
(0.1 m3)
Full Load W. Level
(12.35 m A/B)

AFT To #2/3 Seal

B.H. LAHL 332V Sett.
Chamber MC
2.1 bar

312V

331V
LS
12.3~14.6 m

(For Em'cy Circ.)

326V Stern Tube
L.O Tank 333V

1-2 m From AFT

(0.1 m3)

Shaft Center
Below the Oil Level
7.95 m

Level of S/T L.O Tank

317V

306V
B.W.L
31SG

315V
(9.18 m A/B)

330V
321V
318V

314V
323V
320V

PI
PI
S/T TI 309V
S/T For M/T L.O FWD
4.78 m

Stern Tube
Seal Tk

L.O Cooler
Bearing Slowdown
(A)
TIAH TIAH (20L) PI

310V
IAS IAS 308V
322V

324V

325V

TX TX
TI
Temp. Filter
To be Removed PS 305V
#1 #2 #3 #3S #4 #5 After Seal Trial PS

DPI
304V 302V

PI PI
336V

337V

Stern Tube L.O Pump

No.2

No.1

307V
(1.0 m3/h x 2.5 KDP)
311V
CI CI
(L.O Supply)
To #3/3S Seal 32S 303V 31S 301V

316V
327V
(For Seal L.O Drain)

PI

338V
313V

339V
From #2/3 Seal
Air Drain PI
Flow
319V

Key
Controller
AFT Shaft

Lubricating Oil Line

Drain
Below

Air Line LS LAH Stern Tube

Collecting IAS LAL L.O Sump
Drain Line Unit (10 L) IAS
LS
Tank (5.4 m3) To Oily
Bilge Tank

Final Draft / 2007.12.28 2 - 49 Part 2 Machinery System

CLEAN FORCE
2.7.2 Stern Tube Lubricating Oil System 2. FWD / AFT stern tube seal
1. General Description Maker: KOBELCO EAGLE MARINE ENGINEERING CO., LTD
The stern tube lubrication oil (ST LO) system is provided to lubricate the stern Type: Forward stern tube seal -
tube and the stern tube seal system. The stern tube lube oil enters the stern tube
at the bottom of the shaft through ST LO cooler by ST LO pumps and is
discharged to ST LO tank. Then the oil flows back to ST LO pump.
Two ST LO pumps are designed for duty standby operation. Two differential
pressure switches on the pump common discharge line is used to start the
standby pump. One pump is selected as duty and the other one is standby. If the
discharge pressure falls under set point value, the standby pump will start and
duty pump runs until discharge pressure establishes.
When auto change over function is activated by motor failure and differential
pressure switch, manual stop from IAS or stop at local side, the standby pump
will start and the duty pump will stop. A standby start alarm is announced in
IAS.
The stern tube lube oil system is provided to lubricate the stern tube and the
stern tube seal system.
A stern tube lube oil tank (100L capacity), supplies the stern tube lube oil
system. The tank is fitted with a sight glass to observe the level and also has a
low level alarm fitted. The stern tube LO gravity tank (100L capacity)
overflows via a sight glass in the overflow line return to the stern tube lube oil
sump tank.
The lube oil is fed to the stern tube bearing through stern tube LO pump and the
oil circulates between the shaft and aft bearings.
The oil enters the stern tube at the bottom of the shaft and discharged at the top.
The oil can flow either through the stern tube LO tank and then back to the LO 2) FWD SEAL ( To be added illustration)
pumps or through an overflow sight glass via the S/T LO gravity tank in an
emergency case and can return to the LO sump tank.
There is a lube oil cooler in the line to the stern tube LO tank, which is cooled
from the fresh water cooling system. A by pass valve is fitted to the cooler, to
both regulate the temperature and allow work to be carried out on the unit, if
required.
3. Operating Procedures
Final Draft / 2007.12.28
Machinery Operating Manual
5) Fill the aft /fwd stern tube seal tank to the normal level and open inlet and
outlet valve of the aft stern tube system.
AIR SEAL 3A-850 6) Confirm the stand-by pump selection on the IAS.
Aft stern tube seal - AIR SEAL 3A-850
7) When operations allow, check all alarms on the unit to prove that they are
operating satisfactorily.
1) AFT SEAL ( To be added illustration)
Note
The AFT SEAL can be broadly divided into the casing, which is fixed
After the inspection of the seals in dry-dock, the stern tube must be filled
to the hull, and the chrome steel liner, which is fixed to the propeller at least 12 hours prior to flooding the dry-dock. A visual inspection of the
boss and rotates with the propeller shaft. The casing is composed of
seals is to be made to verify that they are oil tight. During the period, the
three kinds of metal rings; flange ring, intermediate ring and cover ring, shaft is to be turned periodically with the turning gear in order to change
which are tightened to each other with bolts. Three or four sealing the position of the shaft in relation to the seal.
rings are chrome steel liner. The lips are pressed hard against the
rotating liner and maintain a sealing effect through water pressure, oil 4. Control and Alarm Settings
pressure, elasticity of the sealing ring and tightening force of the
springs. IAS
Description Setting
Tag No.
The sealing rings are numbered 1, 2, 3 The #1 and #2 sealing rings
SN001 ST AFT No.1 BRG TEMP H 60℃
close out seawater, while the #1 sealing ring also has the function of
protecting the inside of the stern tube from foreign matter in the SN002 ST AFT No.2 BRG TEMP H 60℃
seawater. Lubricant oil in the stern tube is sealed in with the #3 sealing
SN003 ST FWD BRG TEMP H 60℃
ring.
SN016 ST AIR CONT UNIT PRESS L 0.1bar
The Double Security type has an additional construction of the #3S
sealing ring and the #3 intermediate ring on the standard type. If the #3 5. IAS Display
sealing ring is damaged, the #3S sealing ring can be immediately
brought into service by closing the valves on the oil lines to the oil
chamber between the #3 and #3S sealing rings.
The FORWARD SEAL is of similar construction to the AFT SEAL
except that it is composed of two sealing rings. The sealing rings are
numbered 4 and 5 in order from the stern tube. The #4 sealing ring
seals the lubricant oil in the stern tube. The forward chrome steel liner
is tightened with bolts to the split clamp ring mounted to the propeller
shaft.
1) All oil tank levels should be checked.
2) Open the pumps’ suction and discharge valves, and the inlet and outlet
valves on the cooler. Have fresh water cooling medium circulating
through the cooler.
3) Start up one of the pump, ensuring air is vented at the suction strainer.
4) Confirm the condition of the flow indicator and pressure gauge.
2 - 50 Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.7.3a Lubricating Oil Transfer System

Surface Valve
(Port) (STBD) (Port) (STBD) with Handle (Port) (STBD) Oil Coaming
Upper Deck

To I.G.G G.O Service To Incinerator Waste Oil

Tank Drain Line Service Tank Overflow Line

29V

30V

33V
15V
10V

14V
1V

4V LAH
IAS
LAH
IAS
LS LS Main L.O
Generator Engine Generator Engine LAH Generator Turbine Generator Turbine LAH Main L.O Key
LS
IAS
LS
IAS Settling Tank
L.O Storage Tank L.O Settling Tank L.O Storage Tank L.O Settling Tank Storage Tank
2V 5V 12V 16V 31V (96.6 m3) 34V Lubricating Oil Line
(16.7 m3) (16.9 m3) (16.7 m3) (16.9 m3) (96.6 m3)
Air Line
Drain Line

13V

35V
3V

17V
From Deaeration
6V

32V
28V
Tank Vent
7V 39V
41V
From No.1 Main To Bilge Shore
From Hyd. Oil L.O Purifier Connection

42V
Power Unit
Drain

25V 26V

From No.2 Main

27V

40V
L.O Purifier From No.2 Main
L.O Purifier 38V PI

L.O Transfer Pump

20V

18V

(5 m3/h x 4 bar)
CI No.2 L.O No.3 L.O
LAL LS LAL LS 1S No.1 L.O Daily Tank Daily Tank Clean Oil
IAS No.2 G/T 36V IAS No.1 G/T 37V (32 Mesh) Daily Tank (0.2 m3) (0.2 m3) Tank
L.O Sump Tank L.O Sump Tank 46V (0.2 m3) 45V 44V (0.6 m3) 43V
22V 23V 24V 50V

52V
To Oily
LAL From L.O
IAS
Bilge Tank Deaeration Tank
54V
LS
19V 21V From Main L.O Purifier To No.2 Main
G/E L.O From L.O Deaeration Tank To No.1 Main L.O
Heater and Coaming Drain L.O Purifier 51V
Sump Tank Purifier Supply Pump
Supply Pump

47V
From Main L.O Gravity

(A)
To No.1 Main L.O 53V (A) Stern Tube
Tank Coaming Drain L.O Sump
49V Purifier Supply Pump 48V Tank
From Main Turbine L.O Cooler (A)
(5.4 m3)
Coaming Drain
LS LAH
L.O Drain IAS To No.2 Main L.O Main L.O Sump
To F.O Tank (0.5 m3) Purifier Supply Pump Tank (65 m3) From Auxiliary L.O Pump
Drain Tank Discharge Line Drain

Final Draft / 2007.12.28 2 - 51 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.7.3 Lubricating Oil Transfer and Purifying System They discharge to the following: 3. Storage Capacity

1. LO Transfer System - Main lube oil settling tank - Main lube oil storage tank: 96.6m3
- Main turbine sump tank - Main lube oil settling tank: 96.6m3
The Lube oil transfer system consists of as Follows: - Turbine generator lube oil settling tank - Main lube oil sump: 65.0m3
- Turbine generator sump tanks - Turbine generator lube oil storage tank: 16.7m3
The purifying and transfer system supplies bulk oil to the main machinery - Diesel generator lube oil settling tank - Turbine generator lube oil settling tank: 16.9m3
systems within the engine room, and facilitates the circulation of lube oil - Diesel generator sump tank - Diesel generator engine lube oil storage tank: 16.7m3
through purifiers. - Diesel generator engine lube oil settling tank: 16.9m3
The main lube oil purifiers are supplied through two electrically driven rotary - S/T lube oil sump tank: 5.4m3
Main storage and settling tanks are provided as follows: feed pumps. The pump discharges can be crossed over so that either purifier can
4. Operating Procedures
be supplied from either pump. The lube oil is passed through a steam heater.
- Main lube oil storage tanks Automatic operation of all the self-cleaning purifiers is program controlled, and
1) To Fill Lubricating Oil
- Main lube oil settling tank a supply of fresh water provides seal, flushing and bowl operating water.
- Turbo generator lube oil storage tank The three-way solenoid operated inlet/bypass valves are operated under the
(1) Check and record the level in the tank to receive the oil.
- Turbo generator lube oil settling tank same program. The drain/sludge from the purifiers is led to a sludge tank under
Check the specification of oil being supplied.
- Diesel generator lube oil storage tank the unit, which is emptied by the engine room sludge pump.
- Diesel generator lube oil settling tank (2) Inspect the bunker connections, ensure that the area is clean and the
Apart from the above mentioned main lube oil tanks, which may be filled
save-alls are secure to receive any leakage. Remove the blanks and
The main storage tanks have facilities for direct filling from deck, and drop through transfer systems, daily using other tanks are provided, and have to be
connect the hose at the manifold. Commence filling, checking for
lines to the main consumer sump tanks. The settling tanks are located adjacent filled by hand. These are as follows:
leakage and monitoring tank levels.
to their main storage tanks and, though it is possible to drop lube oil from these
tanks to the consumers, the valves joining them to the storage tank drop lines - One (1) Clean Oil Tank: 0.6m3
(3) On completion, re-check tank levels and record. Disconnect the hose
are normally locked shut. If it is required to transfer lube oil from the settling - Three (3) LO Daily Tanks: Each 0.2m3
and refit the blank. Contain and clear any spillage. Record the amounts
tanks, this is normally done through the lines after the oil has passed through received and that are now on board.
the purifiers. For safety, the drop valves from the storage and settling tanks are 2. Capacities and Ratings
fitted with remotely operated quick closing valves. 2) To Drop Lube oil from Storage Tanks to Sumps and Services
Main Lube oil Purifiers: Alfa-Laval
The lube oil transfer pump is able to take suction from all the main storage and No. of sets: 2
(1) Check oil in the storage tank for water contamination, draining as
settling tanks, either turbine lube oil or oil for the diesel engine. Other suctions Type: Automatic, Self-cleaning,
Partial Discharge necessary.
available are as follows:
Capacity/Viscosity: 3,000 L/h SAE#30 at 40°C
(2) Check levels in both the storage tank and the receiving tank. Check all
- Turbine generator sump tanks Main Lube oil Purifier supply Pump: Naniwa branch valves from the drop line are closed, then line up the valves
- Main turbine lube oil sump tank No. of sets: 2 between the tanks, leaving the local receiving tank valve closed until
- Diesel generator engine sump tank Model: ALG-32N ready to commence the drop.
Capacity: 3.0m3/h
The pump is able to transfer the oil to any of the main storage and settling tanks Pressure: 3.0bar (3) Monitor the tank levels, stopping the drop at the required level.
and to deck through the tank filling lines. Record the amount of oil transferred.
Lube oil Transfer Pump: Naniwa
2. LO Purifying System No. of sets: 1
Model: ALG-40N
There are two lube oil purifiers for the turbine oil systems; they are used Capacity: 5.0m3/h
primarily to circulate and purify the main turbine sump. They have options to Pressure: 4.0bar
purify the following:
Main Lube oil Purifier Heaters: Dong-Hwa Entec
- Main turbine oil sump and settling tanks No. of sets: 2
- Turbine generator sump and settling tanks Type: Shell & tube
Capacity: 3.0m3/h x 40/85°C
- Diesel generator sump and settling tanks

Final Draft / 2007.12.28 2 - 52 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.7.3b Lubricating Oil Purifying System

To G/E L.O Settling Tank To G/T L.O Settling Tank To Main L.O Settling Tank
or Main L.O Settling Tank Top Side

L-41V
To G/E L.O Sump Tank
L-42V

120V

119V
118V To G/T L.O Sump Tank
L.O
116V Deaeration
Loose Supply Loose Supply Tank
TX PX TX PX (0.2 m3)

117V

PI PI PI PI

S
S S

S
No.2 L.O Purifier No.1 L.O Purifier
Heater Heater
9 bar Air 9 bar Air
TI TI TI TI
113V

112V

109V

108V

To Main L.O Sump Tank

or S/T L.O Sump Tank

To L.O Drain Tank

PX PI
PX PI PX
PX
MT
MT

No.1 Main
115V No.2 Main 111V L.O Purifier PI
L.O Purifier PI
(3,000 L/H)
(3,000 L/H)

Purifier
TS
TS Work Bench

124V
121V
LS
122V

123V LS
To Waste Oil
Transfer Pump

107V 106V
TI Sludge Tank
PI (14 m3) PI

No.2 Main L.O Purifier No.1 Main L.O Purifier To F.O

Supply Pump Supply Pump Drain Tank
(3 m3/h x 3 bar)
(3 m3/h x 3 bar) To L.O
CI CI
12S Drain Tank 11S
(32 Mesh) (32 Mesh)

104V 103V 118V 102V 101V Key

Lubricating Oil Line

From L.O Drain Tank From G/T L.O Sump or G/T L.O Settling Tank Air Line
To Oily
From G/E L.O Sump Tank From Main L.O Sump Tank or Main L.O Settling Tank Drain Line
Bilge Tank
or G/E L.O Settling Tank or Main L.O Storage Tank or S/T L.O Sump Tank

Final Draft / 2007.12.28 2 - 53 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

3) To Use the Lube oil Transfer Pump 5. Control and Alarm Settings

As the transfer pump can be used to pump oil from many tanks and IAS
systems, great care must be taken to ensure the valves are open only on Description Setting
Tag No.
the lines required to be used, and that all other valves are closed.
LO019 MAIN LO SUMP TK LEVEL H 2.635m
(1) Ensure that all inlet and outlet valves on the pump are closed. Check LO020 MAIN LO GRAV TK LEVEL L 0.45m
lines through which the oil is to be transferred and that all valves on
branch lines are closed, both on the suction and discharge side of the
pump. 6. IAS Display

(2) Line up the suction side of the pump, ensuring that only the valves
on the line from which the pump is to take suction are open.

(3) Line up the discharge side of the pump, ensuring that only the valves
on the line to which the pump is to discharge are open. If to be
discharged ashore, check that the line blank is removed and that the
connection of the hose is satisfactory.

(4) Monitor the tank level before, during and after the transfer. When
given authority, start the pump, check the discharge pressure and
inspect lines for leakage.

(5) On completion of transfer, stop the pump and shut down the system,
ensuring that all valves are closed. Return all blanks removed or
spectacle pieces turned back to their normal positions.

(6) Contain and clear any spillage. Record all tank levels and amounts
transferred.

4) To Purify the Lube oil

(1) Open the shut-off valve in the product feed line.

(2) Switch on the motor.

(3) Open the stop valve in the product discharge.

(4) Switch on the control unit.

(5) Check that the operating mode selected on the control unit
corresponds.

(6) Start the program.

(7) After the feed valves have automatically opened.

- Set the backpressure in the product discharge to approx. 1.5bar.
- Adjust the desired throughput.
- When necessary, correct the backpressure in the product discharge.

(8) Check the discharges for solids and dirty water.

Final Draft / 2007.12.28 2 - 54 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.8a Engine Room Bilge System

From A-215V Shore Connection

Upper Deck (P)
0.9 bar
Control (P) (S)
Surface Valve BF-95

BF-94
Air with Handle
Oily Bilge Separator ORI-9 BF-73
Casing

S
(5 m3/h) Oil Coaming (STBD) ORI-8
BF-72

14V

(F)
ORI-7 2nd Deck
2nd Deck
(PORT) Low
S

Power
Electric Heater (STBD) ORI-6 BF-71
Control
Panel
BF-70 3rd Deck Sea Chest
PI ORI-5 (PORT)
Sep. Floating PI ORI-4 BF-69
3rd Deck
Tank Tank 4th Deck

105V
42V (STBD)

(F)
(PORT) LS
BF-68

M
To I.G.G G.O To Incinerator ORI-3 BF-67 From
Bilge
4th Deck IAS
Service Tank Coaming Drain (STBD)
Alarm
ORI-2
40V

0.8 ppm
Drain Line BF-66 ORI-1 Floor
For Floor (PORT)
Sampling To Incinerator
82V (STBD)
LAH

157V
LS IAS

(F)
Waster Oil 64V
LAH
Service Tank PI LS Middle Bilge FWD Bilge
27V

PX IAS LS
IAS Well (P) Well (P)
From L.O PI LS
Transfer Pump PS Pump Start : 9.5 bar For E/R Bilge P/P Control Direct
Auto Start/Stop 18V S Air
PS Pump Stop : 10.5 bar LS Bilge
3M
S

Mach. Emulsion 5M
(20 L) Breaker
(20L)
11V 5V 16V
PI CI
46V No.2 4V 2M
To Distilled Plant
9V

26V 28V 41V S.W Feed Pump

81V

7V
2V

49V

37V
Bilge, Fire & G/S Pump
Auto Auto Auto
Stop PS Stop PS Stop PS (245/150 m3/h x 30/115MTH)
10V
PI PI PI
Oily Bilge E/R Bilge PI CI 3V Sea Water Hyd.
From F.W Waste Oil No.1
Fire Control
Hyd. Unit Pump Pump Unit (1,500 L) Station
Transfer Pump
(5 m3/h (10 m3/h PIAHL
(5 m3/h x 4 bar) 1V On:9.8 bar
CI x 4 bar) CI x 4 bar) CI 6V IAS
Sett. Off : 11.3 bar
12.4 bar PS PX
3S 2S 1S 45V

25V 70V 33V 34V 44V 54V

T/B Recess (FWD) PI

43V
65V PI CI
To Ballast
BA-52 BA-51

77V
From L.O Stripping
Sludge Tank Eductor
From Distilled
22V

Water Tank (S)

Steering Gear Room Water Spray Pump
32V

SF-3 80V
(850 m3/h x 110 MTH)
Fire Line Pressure Pump
62V (Rinsing Water for From I.G.G From M/T L.O 58V (2 m3/h x 115 MTH)
Water Spray Line) Cool. Tower Mist Box Drain CI PI
OVBD Line Drain

57V
(F) 47V
AFT Peak Tank 21V 72V 20V
61V 69V
6M
LAH LAH LAH LAH LAH
S/T Cooling IAS 24V IAS IAS IAS IAS
60V

F.W Tank 23V SF-2 5R 2R 3R 15V

38V

1M
68V

LS LS LS LS LS
T/B Recess T/B Recess

156V
Near Scoop Inlet

(F)
AFT (AFT) (FWD) LAH
Valve(S-13V)
Bilge Well Oily Bilge From Boiler To Ballast From Main IAS
Key Bilge Holding Tank Drain Tank 19V 73V Stripping Condenser
Tank S FWD Bilge
LAH (119.2 m3) Eductor Drain Control LS
Bilge Water Line LS
IAS (49.4 m3) Well (S)
Air 17V From
Lubricating Oil Line 4M LS IAS

BA-53

101V
1R 4R
71V
51V

78V

79V

(F)
LAH LS
76

M
Sea Water Line Cofferdam IAS
From Deoiler
From E/R Toiler Drain From F.O Drain Tank
Fresh Water Line 3-way Valve Upper Deck LS
Middle Bilge
From Incin. W.O Service Soot Blower From Boiler Sprayer From S/T L.O Pump & For E/R Bilge P/P Well (S) High
Air Line Tank Drain Steam Drain Cleaning & Purge Drain Tank LS
Sea Chest
Auto Start/Stop
Drain Line From Aux. From Incin. W.O Service From Main L.O Purifier Pump &
From Drain Tank To Water Spray
Cond. Drain Tank Overflow L.O Trans. Pump Coaming Drain

Final Draft / 2007.12.28 2 - 55 Part 2 Machinery System

CLEAN FORCE
2.8 Bilge System
Discharge of Oil Prohibited
The Federal Water Pollution Control Act prohibits the discharge of oil or oily
waste into or upon the navigable waters of the United States or the waters of the
contiguous zone if such discharge causes a film or sheen upon or a
discolouration of the surface of the water or causes a sludge or emulsion
beneath the surface of the water. Violators are subject to a penalty.(USCG Rule
# 155.445)
1. General description
There are five main bilge wells in the engine room. These can be pumped out
by one or more of the engine room bilge pumps, namely the bilge pump & bilge,
fire & G/S pump (for emergency flood clearance only) and the oily bilge pump.
Note that normally the bilge wells would be pumped by the E/R bilge pump to
the holding tank
The bilge holding tanks are as follows:
- Oily bilge tank (49.4m3)
- Bilge water holding tank (119.2m3)
The oily bilge tank is filled with drains and/or oily residues from the oily water
separator, as well as any oily water which may be directed from incinerator
waste oil tank, M/T LO pump coaming, burner cleaning device and sludge
pump coaming. This tank is normally emptied by the waste oil transfer pump
and can be transferred to shore installations through the deck shore connection,
or to the waste oil tank for use in the incinerator. A limit switch is fitted to the
tank for high level alarm at incinerator waste oil service/settling tank high level.
The bilge water holding tank accepts drains from the soot collecting tank, de-
oiler, IGG generator drain, sewage & STP drain, bilge water separator,
deaerator tank, incinerator coaming and E/R bilge pump coaming. This tank is
pumped out using the bilge water separator pump and transferred through the
bilge water separator unit, before passing overboard. A limit switch is fitted for
the auto stop of the bilge water separator pump as the level drops.
All other scupper drains from the various flats and from around various
machinery save-alls, are drained down to the oily bilge tank for disposal.
All the tanks are fitted with high level alarms.
There are five main bilge wells in the engine room as follows:
- Port and starboard forward
- Port and starboard middle
- Aft well
Final Draft / 2007.12.28
Machinery Operating Manual
All of the above are linked to a suction ring main and can be pumped out using
the bilge pumps, the E/R bilge pump or bilge line suction on the bilge pumps.
Attached to this suction ring main are suctions from the bilge hat under the
main condensate water pump, the cofferdam, M/T recess area and recess port &
starboard.
The port and starboard forward bilge wells are fitted with high level alarms, and
the port well can be pumped out by direct suction through No.2 bilge, fire &
G/S pump. The port and starboard mid bilge wells are fitted with a high level
alarm and level switch, which will automatically start and stop the engine room
bilge pump.
The aft bilge well collects drains from the save-alls in the steering gear room,
FW tank (P & S) and Dist. water tank (P & S) which can be emptied into the
well through spring loaded valves. The aft well has a high level alarm fitted.
The oily bilge pump is an electrically driven horizontal piston unit and can take
suction from the bilge holding tank and the main bilge line. Normally it pumps
the bilge water through the bilge water separator unit to discharge overboard.
The engine room bilge pump is an electrically driven reciprocating pump,
which takes suction from the bilge main and bilge water holding tank. The
pump can transfer the bilge water to the bilge holding tank or to shore facilities.
A limit switch on the middle bilge wells enables this pump to start and stop
automatically, as the bilge levels rise and fall.
The waste oil transfer pump is an electrically driven horizontal piston pump,
which can take suction from the oily bilge tank, fuel oil drain tank, lube oil
drain tank and lube oil sludge tank. It normally transfers the sludge to the
incinerator waste oil tank, or to the deck main for shore disposal.
No.1 ballast pump has the engine room emergency bilge suction valve fitted to
its suction lines. This can be used in an emergency for direct suction of bilge
water and pumped overboard.
2 - 56
2. Bilge Water Separator
Technical data
- Model (Double stage): HYN05000
- Design / Hydro pressure: 4.4/6.6bar
- Capacity: 5.0m3/h
- Operation Temp.: 20~60℃
Principal of separation
The HANYOUNG oily separator HYN-5.0 is combination of a gravity separator
with built-in coalesce.
The system works with a completely new principle of hydrodynamics. Latest
physical trends concerning oil-in-water dispersion, homogeneous fluid mechanics
and coalescence effects are incorporated in the HYN-system.
Not to cause of emulsion when pump run, it is advantageous to use a pump of low
revolutions and less emulsification. Such as MONO, PISTON instead of high one
such as Centrifugal Pump.
Separator has CPI (Corrugate Plate Interceptor). The oil and water mixtures
introduced into square chambers where enhance buoyancy effects from small oil
droplets to larger one.
In 1st Filter cartridge and Upper tank, after going through CPI oil coalesced will be
accumulated on upper tank and water will be down to the level of oil. But very
small disperse oil and oil droplets which is too small to buoyancy will be lowered
down to the bottom tank where located 1 filter cartridge. When liquid pass through
filter cartridge, oils absorbed by filters.
The oil separated out collets in the upper settling zone of the own. An efficient
heating system warms this area to support the separation process, make the oil
pumpable and protect the electrodes against clogging. It is recommended to set the
temperature approximately 50 degrees.
Oil level detector detects oil level and if detected send signal to solenoid valve
open to discharge oil to oil collecting tank. Oil can be discharged by existing tank
inside pressure to oil collection (sludge) tank.
Oil content meter monitor works on the light scatter principle and can be relied on
to give warning when free oil particles or oil-in-water emulsions cause the 15ppm
limit to exceeded. When the alarm is triggered, the pneumatic 3-way valve is
switched via a dead contact to re-circulation mode after the set time interval has
elapsed to prevent possible outboard oil contamination.
Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.8b Oily Bilge Separator

Floating Tank
Separator Tank
S
Electric Heater To Oily Bilge Tank
S
EH OLS OLS

Mixing Tank

Pressure Control
15 ppm
N.P. Bilge
Gauge Panel Alarm

Air Supply Inlet Point

Bilge In

Automatic
Stopping
Device Recirculation
S Valve Over
S Board

F.W. Inlet
P.G Dosage Dosage
Pump Pump To Holding Tank
Motor & Emulsion
Mixing
Pump Pump NAOH

S
Breaker To Holding Tank
(20L) (20L)
S
Strainer Back Washing

Bilge Tank

Final Draft / 2007.12.28 2 - 57 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Water for backwashing
- Water for back washing
Approximately 1~2 bar pressure are required for backwash water from sea
or fresh water hydrophor are sed. Backwash are controlled by oil detector
and it run until oil purge out of oil collecting tank.
- Backwashing :
Solenoid actuated 2-way valve is operated fully automatically. Separation,
backwash are sequenced by controller and valves are controlled by
solenoid actuator.
Immediately after discharging the oil the backwashing is started. Clean water is
used for backwashing. The coalescer is cleaned from oil and dirt by automatic
backwashing. The mixture of oil sludge and water is drained off to the bilge.
In case of malfunction the “System” LED will indicate any type of
internal fault of the unit. This LED is flashing green in normal
conditions and is red in alarm conditions. Also this alarm is related
to an relay output.
Additional to the alarm LED’s each alarm circuit is equipped with a
relay with potential free alarm contacts. These contacts can be used
for external processing of the signal or for control of further
functions.
If a malfunction or failure of the power supply occurs, all 3 relays
will switch to alarm condition.
2) Operating procedure

a) Switch on the power supply.

2. 15ppm Bilge Alarm
b) Allow a period of time for water entering the sample tube.
1) Principle of operation
c) Flow oil free water through the system for a few minutes
a) Measuring principle
An optical sensor array measure a combination of light scattered and d) Switch the instrument sample supply from the clean water supply to
absorbed by oil droplets in the sample stream. The sensor signals are the separator sampling point connection.
then processed by a microprocessor to produce linearized output.
e) The instrument is now ready for use.
If an alarm (work set point 15ppm) occurs, the two oil alarm relays
are activated after the adjusted time delay. NOTE
1. When oily water flow through the instrument the display will show the
The microprocessor continuously monitors the condition of the actual value of oil content.
2. If the oil concentration exceeds the adjusted threshold (works
sensor components and associated electronics to ensure that
adjustment 15 ppm), the alarm indicator 1 will be illuminated in intervals
calibration accuracy is maintained over time and extremes of
during the selected time delay before it change to steady light and the
environmental conditions. associated alarm relay will operate. Accordingly also the alarm indicator
2 will be illuminated and its associated alarm relay will take the
b) Displays and Alarms appropriate shut down action.
In the unit are two independent oil alarm circuits available. Both can
be set separately from 1 to 15 ppm. From the manufacturing both
alarms are set to 15 ppm (according IMO). The set points can be
changed to 10 ppm or 5 ppm. An alarm point setting above 15 ppm
is not possible. The adjustment can be done in the programming
mode

In the mode also the individual adjustment of the time delays for the
alarms and the possible changing between 0 ~ 20mA or 4 ~ 20 mA
output can be done

Both alarm circuits are also related to an alarm LED on the front
panel.

Final Draft / 2007.12.28 2 - 58 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.9.1a Control Air System

234V

128V

205V

104V

120V

105V

238V

129V

204V
206V

207V
153V 178V 184V 110V 198V 174V No.1 Boiler Soot Blower PS PS 103V 166V
No.1 F.D Fan No.2 F.D Fan No.2 Boiler F.O No.1 Boiler F.O No.1 Boiler Auto. Cont. No.1 Boiler F.G Flow Air Purge Type
Upper Deck (P) (40A)
Steam Vent Position

Low Trip

Low Trip
No.1 Boiler Press.

No.2 Boiler Press.

Drive Unit Drive Unit Cont. V/V (CV131) Cont. V/V (CV231) Blowdown Valve Cont. V/V (CV121) Level Gauge for E/R
109V 130V 185V 172V 199V 195V Valve (BV332) 191V 189V

2nd Deck (PORT) (40A)

No.2 Boiler Soot Blower No.2 Boiler F.G Flow
3rd Stage Feed Stand-by F.D Fan Spare 60.3/9.8 bar Steam Aux. Steam Exter. Air Dryer Unit
Steam Vent Position V/V Cont. V/V (CV221)
W. Heater L.C.V. 111V 152V Driven Unit 186V 108V P.R.V. (T-715V) 200V 196V Desuperheater T.C.V. 182V 151V For Elec. Equip. RM
No.2 Boiler Atomiz. (BV332)
86.5/30 bar P.R.V. for 60.3/15.7 bar Steam No.1 G/T Sealing

Boiler Upper Part (40A)

No.1 Boiler Atomiz.

3rd Deck (40A)

Spare Spare Steam Position Spare
V/V (CV212) 187V 181V Steam Position V/V (CV112) Exter. Desuperheater 201V 197V P.R.V. (T-707V) 180V 156V Steam Controller

3rd Deck (PORT) (40A)

Boot Blower Supply
154V

No.2 G/T Sealing

No.1 Boiler F.O Bunker

No.2 Boiler F.O Bunker

No.2 Boiler Feed W. No.1 Boiler Feed W. No.1 Boiler Main

Solenoid V/V Rack for

Solenoid V/V Rack for

Solenoid V/V Rack for

Steam Piston Spare

No.1 &2 Boiler F.G

Control V/V (CV201) Control V/V (CV101) Steam T.C.V. (CV111) Steam Controller
190V 192V 160V

Bunker (A-406)
188V Valve (BV331) 193V No.1 Distlled Plant

183V
No.1 Boiler Exh. Gas No.2 Boiler Auto. Cont. 9.8/6 bar Steam Spare Heating Steam

(A-406)

(A-406)
O2 Meter Control Unit 173V Blowdown Valve P.R.V. (T-402V) 202V Contro. Valve
137V 203V 168V
No.2 Boiler Exh. Gas No.2 Distlled Plant
Spare Spare Spare
O2 Meter Control Unit Heating Steam
163V 169V
Contro. Valve

219V
Spare Spare
194V
To Boiler Feed Water

218V
Spare
Treatment system

217V
To Oily Bilge To Air Control Unit
Separator for S/T L.O System

215V

125V
113V

127V

123V

236V
MV2 164V 133V 161V 157V 228V
S To Main Condenser Boiler Feed W. P/P Recir. 60.3/3.2 bar Steam Mid Bilge Well (S) M/T L.O T.C.V.
To M/T Astern Plasma Equipment
L.C.V. (T-42, T-43) W. Shut-off V/V (M-824V) 177V 158V P.R.V. (T-719V) Shut-off V/V (B-17V) 135V 131V (L-217V) 136V
Guardian V/V (T-3)
To M/T Nozzle MV9 To M/T Packing Steam No.2 Boiler Main 5.7/1.8 bar Steam M/T L.O T.C.V.

4th Deck (STBD) (40A)

Valve Operation S De-oiler 3-way V/V L.O Purifier
MV8 To Water Spray V/V L.C.V. (T-302, T-303) Steam T.C.V. (CV211) P.R.V. (X-52V) (L-208V)
179V 144V 138V 134V 155V

Purifier Room (40A)

To Water Spray S for Ast. Operation (T-57) 2.1 bar/722 mmHg V/V Excess Dump Steam Central F.W 16.3/10.3 bar Steam
MV4 M.D.O Purifier

3rd Deck (Mid) (40A)

Valve (T-56) Dump Steam P.R.V. (X-28V) Shut-off V/V (T-730V) T.C.V. (W-12V) P.R.V. (T-162V)
S Floor, STBD 149V 145V 143V 240V Boiler F.O Heater 175V

124V
for Dumping Steam MV3 To M/T Packing Steam No.2 Excess Steam No.1 Excess Steam Spare Bilge Holding Tank Heating Steam
S L.C.V. (T-302, T-303) Dump Valve Dump Valve T.C.V. (T-480V)
To Drain Valve for MV7 150V 148V 146V 140V T.C.V. (BV432) 167V
Maneu. V/V (T-51) S Deaerator Make-up Boiler F.O Service
No.1 Exter. Desuper- 1st Stage Feed W.
107V

MV6 To M/T Packing Steam Cont. V/V (M-120V) Spare

heater Temp. Cont. V/V Heater L.C.V. 147V Pump P.C.V (CV031)
S L.C.V. (T-302, T-303) 142V 126V 176V
To H.P T/B Casing MV5 Deaerator Make-up

141V
60.3/4.5 bar Steam No.2 Exter. Desuper- Spare
Drain V/V (T-54) S To Air Vent Cont. V/V (M-116V)
P.R.V. (T0711V) heater Temp. Cont. V/V 132V

4th Deck (PORT) (40A)

To M/T Packing Steam 159V 165V
Manifold Atomos. Drain Tank
L.C.V. (T-302, T-303) Sett.

237V
9.9 bar Spare Spare L.C.V. (M-108V)
162V
Mid Bilge Well (P)

214V
Floor, STBD
114V

Shut-off Valve (B-18V)

139V
Spare PIAL
Control Air Reservoir

PIAL PX IAS
(7.5 m3 x 9 bar)

Control Air Compressors IAS

213V
(500 m3/h F.A.D. x 9 bar) PI
Oil Removal Filter Oil Removal Filter PX PI
PS (1 Micron) (0.01 Micron)

229V
220V 221V 112V
No.2

170V

171V
(Auto Drain) No.2 Air Dryer
(Manual Drain) (3 Micron) (1 Micron) (250 Nm3/h F.A.) PIAL To I.G.G System
222V 223V Desiccant Type IAS
(For I.G.G.)
Air Dryer 101V

121V
PX PI
(250 Nm3/h F.A.) To I.G.G System
PS Refrig. Type 118V 119V
(For I.G. Dryer)

122V
232V
115V
To Cargo Control
No.1 System

116V

117V
(Auto Drain) From Working
(Manual Drain) Air System
Key
No.1 Air Dryer Control Air Line
(250 Nm3/h F.A.)
To Air Reservoir Desiccant Type Drain Line
To Bilge Well for Quick Closing

Final Draft / 2007.12.28 2 - 59 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.9 Compressed Air System
2.9.1 Control Air Systems
1. General Description
The control or instrument air system provides dry, clean air at 9.0bar pressure, to
operate control valves (both pneumatic and electro-pneumatic) and dampers
throughout the vessel.
Two electrically driven compressors supply air to the control air receiver. From
here the air flows through the oil/water separator. If the air is for the cargo
operating systems it will then pass through a desiccant type dryer and if for the
engine room control systems, it will pass through a refrigerant type air dryer.
1) Air Compressors
The first unit will now have its desiccant heated and air circulated over it.
The moisture created is separated out in a cyclone type separator, where
the moisture droplets will fall and be drained off, and the dry air allowed
to purge the unit. At the end of the regeneration cycle, the desiccant bed
will again be in a satisfactory condition to dry the moisture of the
incoming control air supply, repeating the process as necessary.
3) Refrigerated Type Dryer
There is one refrigerant type air dryer is provided. These types of units
consist of a sealed refrigeration compressor, which flows through an
evaporation coil. The control air from the receiver passes around the coil
and cooling it, so that moisture droplets in the air become heavy and
separate out. An automatic drain in the unit allows the accumulated
moisture to flow to the bilge.
4) )Start the compressor and check the air pressures and lube oil pressure are
satisfactory.
5) )Switch the compressor to auto control, and allow the reservoir to reach its
full pressure. Check that the compressor stops.
6) )Open the reservoir discharge valve.
7) )Open the inlet and outlet valves to one set of oil filters.
8) )Open the inlet and outlet valves to the desiccant, ensuring that all drain
valves are closed.
9) )Switch on the power supply. Start up the driers in conjunction with the
manufacturer’s operating instructions.

The compressors can be started locally, they are normally on remote An after filter is fitted in the line, to further remove any remaining 10))Once the driers are in operation, maintain checks on the line pressure and
control, one unit on auto start, the other on standby. The in-use entrained water droplets. dew point in the system.
compressor will cut in with the receiver pressure at approximately 8bar
and stop when the bottle pressure is raised to approximately 9bar, when 2. System Capacities and Ratings 11) When operations permit, check and test all cut-ins and alarms.
the receiver pressure continue to fall to approximately 7bar, the second
compressor will start and assist in pumping up the receiver. Control air compressor: Atlas Copco MFG. Korea Co., Ltd 4. Control and Alarm Settings
No. of sets: 2
If, for any reason, the air pressure in the receiver should fall 7bar below Type: M.D., Rotary Screw
Capacity: 500m3/h x 9.0bar IAS
the No.2 compressor’s cut-in pressure, an emergency cross over valve Description Setting
Tag No.
(19V, Illustration 2.9.3a) from the working service air system will open,
allowing air to flow from the working air compressors to the control air Control air reservoir: Kang Rim CA009 CONTROL AIR RSVR PRESS L 7.0bar
system. No. of sets: 1
Capacity: 7.5m3 x 9.0bar CA015 E/R CONT AIR PRESS 7.0bar
The receiver is fitted with relief valve set at 9.9bar. After the receiver, the
air passes firstly through a dust filter, which is a cartridge type filter, to Air drier: Kyung-Nam
No. of sets: 2 5. IAS Display
remove small solids trapped in the air.
Type: Desiccant
Secondly, the air passes through an oil free filter, to remove any Flow: abt. 250m3/h
entrained oil droplets.
Air drier: Kyung-Nam
The air then flows to dryer units: No. of sets: 1
For the cargo control air system-desiccant type units Type: Refrigerated
For the engine room machinery control system-refrigerant type units Flow: abt. 250m3/h

2) Desiccant Type Dryer 3. Operating Procedures

There are two units provided, to work in automatic mode, where one unit 1) )Ensure that the air compressor is ready for use, that the sump oil level is
is operating and drying the air passing through it and the second is having satisfactory, cooling water to inter-coolers is in use and the discharge
its desiccant regenerated. valve from the compressor is open.

The control air passes into the unit and over a desiccant bed, where the 2) )Open the inlet valve to the reservoir, closing the drain valve.
moisture in the air is drawn out by the desiccant. The dry air then flows Ensure that the valve to the auto drain is open and the bypass valve is
out to the control system, leaving the moisture in the desiccant. closed.

When the desiccant has become saturated, the units will automatically 3) )Check that all valves and lines to the pressure switches for starting and
change over, allowing the standby unit to become the dryer. stopping the compressor are open.

Final Draft / 2007.12.28 2 - 60 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.9.2a Starting Air System

13V Key

9V
To Sea Water
Starting Air Line
Hydrophore Tank
Drain Line
Generator Engine 25/12 bar Pressure To Funnel
Reducing Valve
(Sett. 12 bar)
48V

6V
PX

PIAL
IAS

Sett.
From N2 System 27.5 bar

From Working
Air Reservoir
From Control
Air Reservoir

44V

Generator Engine

(1.0 m3 x 25 bar)
Air Reservoir
Oil/Water
Separator
2V Oil/Water
Separator PIAL PX
IAS
PI
H.P Magnetic Valve
PS
L.P Magnetic Valve
PS
S

No.2 Generator Engine

Starting Air Compressor
(25 m3/h F.A.D. x 25 bar)

1V

H.P Magnetic Valve

L.P Magnetic Valve

No.1 Generator Engine

Starting Air Compressor
(25 m3/h F.A.D. x 25 bar)
Separately Lead
To Bilge Well

Final Draft / 2007.12.28 2 - 61 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.9.2 Starting Air System 3. Operating Procedures 4. Control and Alarm Settings

1. General Description 1) Diesel Generator Engine Air Starting System IAS

Description Setting
Tag No.
Two air compressors supply the G/E start air reservoir. At the compressors, the (1) Check the compressor to be used. Ensure that the oil sump level is
auto drain valve will open for short periods for short periods to allow any correct. Check that the fresh water cooling system valves are open CA025 G/E START AIR RSVR PRESS L 7.0bar
accumulated moisture to be discharged to the bilge. A software generated “Long and there is a flow through the inter and after coolers. DG053 G/E START AIR PRESS 15bar
run” alarm will be implemented for the compressors.
(2) Open the discharge valve from the compressor and the inlet valve
The G/E air compressors are set up in a lead follow/configuration. The lead to the air reservoir. 5. IAS Display
compressor will start at 20bar receiver pressure, and stop at 25bar. If the
pressure should fall to 18bar, the follow compressor will cut in, assisting (3) Line up the drain valves from the reservoir for the auto drain valve
charging up the reservoir to 25bar. Start and stop limits are parameter settings to be in use.
that can be changed by operators.
(4) Ensure that all valves are open to the pressure switches for the cut-
Pressing the “ON” button on the operator panel, both compressors will be in and cut-out of the compressor.
switched to auto mode and follow compressor can be switched by operating
software buttons. Pressing the “OFF” button on the operator panel, both (5) Start the compressor in manual mode and commence to raise the
compressors are switched to manual mode. The diesel generator has air-starting pressure in the reservoir. Inspect the pressures of the compressor
systems and unit is provided with air at 25bar local gauges and, when all is satisfactory, change to auto mode.

The generator engine starting air compressors for the system are two electrically (6) Ensure that the compressor stops when the reservoir pressure
driven reciprocating units, which supply air to the diesel generator air start reaches approximately 25bar, and restarts when the pressure drops
reservoir. to approximately 20bar.

At each start of the compressor, the auto drain will open for a short period to (7) As the compressor starts, check the operation of the magnetic
allow any accumulated moisture in the unit to be discharged to the bilge before unloader, so that the unit drains to the bilge in order to exclude any
allowing the compressed air into the reservoir. moisture already in the compressor, before pumping to the
reservoir.
Although the compressors can be started locally, they are normally on remote
control, one unit on auto start, the other on stand-by. The in-use compressor will (8) When the operation of the compressor is satisfactory, open the
cut in with the reservoir pressure at approximately 20bar and stop when the reservoir outlet valve to the diesel generator engine air start system.
pressure is raised to approximately 25bar. Should the reservoir pressure .
continue to fall to approximately 18bar, the second compressor will start and Note
assist in pumping up the reservoir. At the lowest point along the line from reservoir to the
generator engine, a double shut off valve is fitted. Periodic
opening of these valves will ensure that no moisture stays in
Both air reservoirs are fitted with relief valves set to lift at approximately 30bar.
this line and is unable to enter the engine air start system.
2. System Capacities and Ratings (9) Periodically open the generator engine starting reservoir manual
drain valves and the generator engine starting reservoir to ensure
G/E Starting Air Compressor: Jong Hap
all moisture is drained from them and to ensure the auto drain
No. of sets: 2
valve is operating correctly.
Type: M.D., 2 Stage, Reciprocating,
Air cooled
(10) When the system is operating satisfactorily, place the second
Capacity: 25m3/h x 25bar
compressor on stand-by mode and when operating procedures
allow, check that all alarms and changeovers operate satisfactorily.
G/E Starting Air Reservoir: Kang Rim
No. of sets: 1
Capacity: 1.0m3 x 25bar

Final Draft / 2007.12.28 2 - 62 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.9.3a Working Air System

To Emergency To Accommodation
Diesel Generator To Passage To Passage To Air To To CO2 Pneumatic
Room Way (P) Way (S) Horn Accommodation Room Fire Damper

To Incinerator Purge Air

37V

36V

20V
27V
34V 35V
To Incinerator Room

(2nd Deck, AFT)

Fire/Gen. Alarm
26V
32V Near Feed Fan

Horn
To 2nd Deck (P) 25V
(A) To Engineer's Store Door
(Outside)
To N2 Air Compressor Discharge Line 61V
31V To Steering Gear Room
To Near Auxiliary Condenser

S
38V
30V
To Fresh Water/Drinking Water To Electric Work Shop
Hydrophore Unit 24V
29V To Work Shop
To Near Boiler Burner 47V
23V
To L.O Purifier
Work Bench
To Boiler Atomizing
50V
28V Floor, AFT
To Funnel
To Near Generator Engine
49V
Sett. To Pipe Duct Bilge Pump
9.9 bar
51V 22V
To Cofferdam Bilge Pump Near Bilge Fire & G/S Pump

43V
(7.5 m3 x 9 bar)

PIAL S Fire/Gen. Alarm

Air Reservoir

PX
IAS Horn
39V 40V
Working

18V
PI (Floor, FWD)
63V To Air Reservoir for
Quick Closing Valve
in Fire Control Station

62V
Auto Drain 41V 42V

19V
Manual Drain
Oil Removal Oil Removal Filter
Filter (0.01 Micron)
(1 Micron)
Working Air Compressor
(500 m3/h F.A.D. x 9 bar)
To Control From Control
From Control From Starting Air Air System Air System
Air System Compressors
Key
Working Air Line

Separately Lead Drain Line

To Bilge Well

Final Draft / 2007.12.28 2 - 63 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.9.3 Working Air System 3. Operating Procedures 5. IAS Display

1. General Description 1) To Distribute working Air

The working air service provides service air at 9bar to the following auxiliaries (1) Check the compressor to be used. Ensure that the oil sump level is
and locations: correct. Have the fresh water cooling system valves open and check
the flow through the inter and after cooler units.
On deck:
(2) Open the discharge valve from the compressor and the inlet valve to
- CO2 room the air receiver.
- Air horn
- Deck air service line (3) Line up the drain valves from the receiver for the auto drain valve to
- Accommodation air lines be in use and the by pass valve closed.
- Passage way (P&S)
- To accommodation pneumatic vent damper (4) Ensure that all valves are open to the pressure switches for cut-in and
- Em’cy D/G room cut-out of the compressor.
- Incinerator room
- To incinerator purge air (5) Start the compressor in manual mode and raise the pressure in the
Engine room: receiver. Inspect the pressures of the compressor on local gauges and
when all is satisfactory, change to auto mode.
- To 2nd deck (P)
- To near aux. condenser (6) Ensure that the compressor stops when the receiver pressure reaches
- Near FD fan approximately 9bar, and restarts when the pressure drops to
- To near G/E approximately 8bar
- To main boiler atomising air
- Near main boiler burner (7) As the compressor starts, check the operation of the magnetic
- To electric work shop unloader that the unit drain to the bilge in order to exclude any
- To work shop moisture already in the compressor, before pumping to the receiver.
- To steering gear room
- To FW / DW hyd. unit (8) When the operation of the compressor is satisfactory, open the
- Near bilge fire & G/S pump receiver outlet and open the valves on the air main as required.
- Floor deck aft
- To engineer’s store door (outside) (9) As the compressors have no air dryer units in the system, great care
- Fire/Gen. alarm horn should be taken to ensure the receiver is drained of any moisture. The
auto drain valve operation should be checked and the by pass valve
Control air system is also provided, should the pressure in the control system opened occasionally to ensure this.
become too low. A solenoid valve is operated if this occurs, allowing the W/A
compressor to supply air control system. (10)For similar reasons as in item 9), whenever working air is to be used
in a system, always blow through the line and ensure no moisture has
Similarly, the control air compressors are able to supply the working air system been allowed to accumulate, especially if the system has not been
by opening the auto solenoid valve. used for some time.

One electrically driven compressor supplies air to the working air receiver. (11)If a piece of machinery is to be operated by the supplied air, always
From here the air is discharged to the various lines and connections as detailed ensure there is a lubricator unit attached.
above.
(12)When the system is operating satisfactorily, place the second
2. Specification compressor on stand by mode, and when operating procedures allow,
check all alarms and changeovers operate satisfactorily.
Working air compressor: Atlas Copco MFG. Korea Co., Ltd
No. of sets: 1 4. Control and Alarm Settings
Type: M.D., Rotary Screw
Capacity: 500m3/h x 9bar IAS
Description Setting
Tag No.
Working air reservoir: Kang Rim
No. of sets: 1 CA018 WORKING AIR RSVR PRESS L 7bar
Capacity: 7.5m3 x 9bar

Final Draft / 2007.12.28 2 - 64 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.9.4a Emergency Shut-Off Air System

Fire Control Station These Cocks/Valves

To be Located To be Installed Near
Sett. Outside Engine Room
9.9 bar Fire Damper
To Funnel Ventilation Damper (S)
PX PIAL
IAS
PI
Air To Funnel Ventilation Damper (P)
To Fire Damper air Cylinder for E/R Ventilation
Reservoir
for
Quick
Closing To No.1 Engine Room Supply Fan
Valve Fire Damper

To No.2 Engine Room Supply Fan

To STBD Side Tank Group

Fire Damper

To Port Side Tank Group

To No.3 Engine Room Supply Fan

F-304V

F-315V
Fire Damper

To No.4 Engine Room Supply Fan

Incinerator Incinerator Fire Damper
From G/S
Air System W.O Service G.O Service
Tank (3.0 m3) Tank (2.0 m3) Casing To No.1 Engine Room Exhaust Fan
Fire Damper

To No.2 Engine Room Exhaust Fan

F-101V

F-126V
F-36V

F-29V

L-17V

L-6V
Fire Damper

To Purifier Room Exhaust Fan

I.G.G G.O G/T L.O G/E L.O G/E M.D.O Fire Damper
Service Tank Settling Tank Setting Tank Service Tank
2nd Deck (100.7 m3) (16.9 m3) (16.9 m3) (134.2 m3) 2nd Deck
To Diesel Generator Exhaust Fan
Damper

L-223V

L-32V
To L.O & Grease Store Exhaust Fan
Damper
F-27V

Main L.O Main L.O To Chemical Store Exhaust Fan

Gravity Tank Settling Tank
Damper
M.D.O (28.1 m3) 3rd Deck (96.6 m3)
Storage Tank
(211 m3) 4th Deck
F-203V

F-201V
F-46V

F-43V

Key
F-3V

F-1V

Air Line To Welding Space Exhaust Fan

F-6V

Damper
Diesel Oil/ Gas Oil Line
Low Sulphur H.F.O AFT H.F.O Low Sulphur H.F.O AFT H.F.O Fuel Oil Line
F.O Tank (P) Settling Tank (P) Bunker Tank (P) F.O Tank (S) Settling Tank (S) Bunker Tank (S)
(288.7 m3) (518.1 m3) (164 m3) H.F.O Overflow (282.6 m3) (537.8 m3) (252.7 m3) Lubrication Oil Line
4th Deck Tank Drain Line
(87.6 m3)
Floor Deck

Final Draft / 2007.12.28 2 - 65 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.9.4 Emergency Shut Off Air System 2. Control and Alarm Settings

1. Operation of Emergency Shut-off System

IAS
Description Setting
1) Ensure that the air supply to the receiver through engine room control air Tag No.
drier and inlet valve to the receiver is open. CA020 QUICK CL V/V AIR RSVR PRESS L -
2) Check that the receiver pressure is at 9bar.

3) The air from the receiver can be used to operate the quick closing valves
by operating the two way lever valve for four systems:

To STBD Group:

HFO overflow tank

Low Sulphur tank (S)
HFO settling tank (S)
Aft HFO bunker tank (S)
MDO storage tank
Main LO settling tank
G/E LO settling tank
G/E MDO service tank
Incinerator WO service tank
Incinerator GO service tank

To PORT Group

Low Sulphur tank (P)

Aft HFO bunker tank (P)
HFO settling tank (P)
IGG GO service tank
G/T LO settling tank

To Main LO Gravity Tank

Main LO gravity tank

To Vent Damper Air Cylinder

To funnel ventilation damper(S)

To funnel ventilation damper(P)
To No.1 engine room supply fan fire damper
To No.2 engine room supply fan fire damper
To No.3 engine room supply fan fire damper
To No.4 engine room supply fan fire damper
To No.1 engine room exhaust fan fire damper
To No.2 engine room exhaust fan fire damper
To purifier room exhaust fan fire damper
To diesel generator exhaust fan damper
To LO & grease store exhaust fan damper
To chemical store exhaust fan damper
To welding space exhaust fan damper

Note
The emergency generator diesel oil service tank quick closing valve is
operated by a wire, situated outside the emergency generator room.

Final Draft / 2007.12.28 2 - 66 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.10a Steering Gear Hydraulic Diagram

No.2 Cylinder No.1 Cylinder

Key
Hydraulic Oil Line
B A

Limit Switches for

Rudder Angle Limiter

No.4 Cylinder No.3 Cylinder

D C

"E" Position
Isolating Valve "N" Position
(IV-2)

C4 C5 C6 C3 C1 C5 C6 C2
T P T P

G4 B A G3 G1 B A G2

AC BC AC BC

T T

X X

AV BV AV BV
Y

A B A B
Unloading Unloading
Device Device
LAL LAL
P T P T
LS11.2 LS11.1

LS LS

No.2 Oil Tank No.1 Oil Tank

No.2 Power Unit Torque No.1 Power Unit Torque
HS004

Strainer

Strainer
Motor Motor
HS005
T LVDT T LVDT
PI Electric Heater Electric Heater
Hyd. Oil
Storage
HS001 Tank
(770 L) HS003 CP
Servo Pump Servo Pump
HS002 No.2 Pump No.1 Pump

Final Draft / 2007.12.28 2 - 67 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.10 Steering Gear Rudder turning speed by one power unit: 65deg / 28sec (2) Failure mode operational sequence in both power units running :
Normal radius of tiller arm: 850mm If oil level in No.1 or No.2 oil tank goes down “LOW-LOW” position, the
1. General Description Ram diameter: 315mm isolating valve will be operated suitably and No.1 or No.2 power unit will
be automatically stopped.
Tong Myung – Kawasaki Electrical Pump Control (Continuous Control) Steering Note
Gear is of the “Rapson Slide Type” construction and consists mainly of tiller, Steering over 35 degrees on both side, ship speed is to be reduced (3) In case one power unit is running, if the low alarm in oil tank of stand-by
ram and ram pin, Hydraulic cylinder, valves and piping, Kawasaki axial piston under 12knots. power unit is activated, stand-by power unit is automatically started.
pump and pump control unit. Then both power units are running.
3. Automatic Isolation System
The hydraulic pump is tilted and discharges the oil, through the control box and 4. Em’cy local steering operation
the pump control unit according to the order rudder angle from the steering stand. This steering gear is so arranged that in the event of loss of hydraulic fluid from
The ram thrust produced by the pressure oil is transmitted to the tiller arm one system, the loss can be detected and the defective system is automatically In failure of the control system in the wheel house (bridge) or during the
through the ram pin and the roller bearings and converted to the torque of the isolated within 45 seconds so that the other actuating system shall remain fully adjustment operation of the steering gear, the steering gear can be operated by
tiller keyed to the rudder stock and then the rudder is moved. operational (50% torque remained) the pump control knob of pump control unit mounted on the oil tank in the
steering gear room.
The signal of the actual rudder angle is directly feed – backed to the steering 1) Operation
stand by means of the repeat back unit, and when it coincides with the signal of 1) Preparation
the order rudder angle, the rudder stops. Two identical power actuating systems with either one or two units act
simultaneously in normal operation. (1) Disconnect the control box from electric power.
Thus, in the control system of the Electrical Pump control (Continuous Control) (2) Push the manual button of the solenoid control valve and lock it by
Steering Gear, the actual rudder angle is directly compared with the order rudder (1) Failure mode operational sequence in one power unit running : means of lock nut.
angle and the deviation signal between order and actual rudder angles controls
directly the tilting angle of the hydraulic pump. With No.1 power unit running and No.2 power unit stopped if loss of oil 2) Operate the steering gear by turning the pump control knob by watching the
occurs, the following sequence will take place. pump tilting angle indicator plate and rudder angle indicator plate.
Therefore the steering gear can obtain the very fast response and the accurate
rudder angle, and the ship can keep her heading correctly with a less steering a) The oil level in No.1 oil tank goes down to “LOW” position and 3) When the steering gear reaches the desired angle, release the pump control
order. This improves the propulsion efficiency remarkably and consequently can audible and visual alarms are given on the navigating bridge and in knob.
save fuel consumption of the main engine highly. the machinery space. The knob and the hydraulic pump will return to the neutral position and
steering gear will stop automatically.
One or two sets of the hydraulic pump and electric motor are provided and have b) And No.1 isolating valve is automatically energized and the
enough capacity to operate the rudder within the time required by the hydraulic system associated with No.2 power unit is isolated. Caution
classification society. 1. Correctly operate the hydraulic pump and the valves in accordance
c) If the oil loss is in the hydraulic system associated with No.2 power with the instruction plate.
For the specifications of the steering gear, refer to the PARTICULARS of the unit, steering is being carried out by No.1 power unit and the speed
separate volume. of vessel should be half of full speed because its two related 2. Don’t operate the steering gear over max. working angle (35degrees)
cylinders (No.1 & No.2) giving 50% torque. because the rudder angle limiter is not actuated in local steering.
For the general arrangement and the hydraulic circuit, refer to the drawings of
ARRANGEMENT and HYDRAULIC CIRCUIT of the separate volume. d) On the other hand, if the oil loss is in the hydraulic system associated 3. Reduce the ship’s speed to half of the max. service speed or 7 knots
with No.1 power unit, the oil level in No.1 oil tank goes down to (or 8knots) whichever is greater in case of the failure of pipings, and
2. Specification “LOW-LOW” position and No.1 isolating valve is automatically de- so on .
energized. And also No.1 power unit is automatically stopped, No.2
Maker: Tongmyung-Kawasaki isolating valve is automatically energized and No.2 power unit is
Model: FE21-400-T050 / 350Ton-M automatically started, then the hydraulic system associated with No.1
Torque at max. working press. at 35deg 3,432 kN.m (350Ton-m) power unit is isolated. Steering is now being carried out by No.2
Rudder turning angle Ship speed : at normal Starboard: 35deg. power unit and the speed of vessel should be half of full speed
Port: 35deg. because its two related cylinders (No.3 & No.4) giving 50% torque.
Ship speed : below 12Knots Starboard: 45deg
Port: 45deg If No.2 power unit running and No.1 power unit stopped. No.1 and No.2
Mechanical limit rudder angle Starboard: 47deg of power unit, No.1 and No.2 of isolating valve are replaced in above
Port: 47deg sequence.

Final Draft / 2007.12.28 2 - 68 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.11.1a Turbine Generators Control Oil System

Main Steam
Inlet
Main Stop Valve

Limit Switch
for ESV Close SHUT
(ACB Trip)

OPEN

Starting
Governor Lever
Valver
M
Trip To Nozzle
Lever
Trip UG10D
Cylinder Limit Switch for
GOV. Valve Full Open Woodward
Governor
Hydraulic
Limit Switch for Servo Motor
Overspeed Indication

Solenoid
Valve Reset
Knob
To L.O. Tank

Orifice

Control oil
To L.O. Tank Strainer

Press. Adjust. Valve

For Lub. Oil To Bearings
Press. Adjusting Valve
For Control Oil

To L.O.
Check Tank
Valve
Duplex L.O.
Stariner
Main
L.O. Pump Priming
L.O. Pump
Check
M Valve

Cooling
Water

L.O. Cooler

Final Draft / 2007.12.28 2 - 69 Part 2 Machinery System

CLEAN FORCE
2.11 Electrical Power Generators
2.11.1 Turbine Generator
1. General Description
The two turbine generators are supplied with superheated steam at boiler
conditions (60bar, 510°C) and normally exhaust to the main condenser.
The turbines drive the generators through a single helical reduction single
gearbox with forced lubrication. The turbine speed is maintained at a constant
10,000 rev/min (pinion), corresponding to a generator speed of 1,800 rev/min
by a mechanical hydraulic type Woodward governor.
The turbine and gearing bearings are force lubricated by a shaft driven pump,
when the unit is at full speed, which takes suction from the built-in sump and
discharges to the bearings, gears and control oil circuits. The steam valve is
maintained in the open position by the control oil and is tripped by venting the
control oil to the sump, thereby closing the steam supply valve.
Prior to starting, and during the turbine run down period after the steam supply
is shut off, an electrically driven lube oil pump operates to supply oil to the
systems. When starting, the oil supplied to the control system opens the steam
supply valve as well as supplying the bearings and, when stopping, supplying
oil to the turbine and generator bearings as the turbine runs down. The
electrically driven lube oil pump can be operated in the manual or automatic
modes, according to circumstances and requirements.
1) Lubricating Oil System
The generator turbine is equipped with a lubricating oil system. The oil
piping arrangement is made up of a high pressure line foe the control oil
and of a low pressure line for the bearing and the reduction gear
lubrication. Oil is sucked from the oil tank in the common bed and
pressurized by the main oil pump and adjusted its pressure by the oil
pressure adjusting valve and supplied to the high pressure line for the
control oil and of the low pressure line for the lubrication.
(1) Main oil pump
The main oil pump is of the gear type. The pump is driven by the
turbine reduction gear wheel shaft through the gear. A valve
serving as the safety valve is fitted on the pump casing.
The valve is composed of the spindle and spring, and regulates the
pump delivery pressure directly.
(2) Priming oil pump
The priming oil pump is of the gear type and driven by the motor.
The pump is used for the turbine start and stop. The pump is started
Final Draft / 2007.12.28
Machinery Operating Manual
and stopped automatically. In case the switch of the starter is In the case of excessively high pressure in packing steam reservoir piping,
“AUTO”, the pump is started automatically at abt. 0.4bar of the the steam from the gland packing of high pressure side is bled into the
bearing oil pressure and stopped automatically at 0.9~1.5bar packing steam reservoir piping, surplus steam can be sent to the condenser
through the packing steam spill valve.
(3) Hand pump
In case of excessively high pressure in packing steam reservoir piping, the
A hand oil pump is provided in the lubrication system and used for steam from the gland packing of high pressure side is bled into the packing
the turbine starting and stopping, when the priming oil pump is not steam reservoir piping, surplus steam can be sent to the condenser through
available. the packing steam spill valve.
(4) Lube oil cooler The steam leak from the 1st stage gland of the governing valve is led after
the 2nd stage of the turbine. The steam leak from the 1st stage gland of the
The lube oil cooler is of the surface cooling shell and tube type. high press parts of the turbine is led after the 6th stage of the turbine. The
The cooling is by fresh water or sea water. The cooling tubes are steam leak from the 2nd stage gland of the high press parts and the 1st stage
expanded at both ends into the tube sheets. of the low pressure parts of the turbine and 2nd stage glands of main trip
valve and the governing valve is sent to the gland condenser.
(5) Oil strainer
The steam leak from 1st stage glands of the main trip valve is sent to the
The oil strainer is fitted on the L.O. line and control oil line. This packing steam line.
oil strainer is duplex change-over type, therefore, it is possible to
clean the strainer basket during operation.
The oil strainer consists of the body and strainer basket having
gauge screen and magnet.
The strainer can be changed over with cock handle by setting the
mark on handle root.
When the strainer is changed over, it is so arranged as to fill the
strainer to be used with oil by giving a few turns to the strainer up-
handle and thus raising the change-over cock to a small extent and
reduce the moment at the time of change-over by hydraulic balance.
(6) Oil pressure adjusting valve
A part of oil sent from the oil pump is adjusted by the control oil
pressure adjusting valve to the 6.5~9.5bar and acts as control oil,
and the remaining oil is adjusted by the LO pressure adjusting valve
to 1.0~1.5bar and acts as lubricating oil. For adjusting valve the oil
pressure, remove the cap and turn the adjusting screw.
Clockwise turning of the adjusting screw makes the actuating oil
pressure up and vice versa.
2) Steam System
The main steam from the boiler through the main trip valve and
governing valves, then, passes through the turbine stages to drive the
turbine. The exhaust steam from the generator turbines is led to the
condenser through the exhaust valve.
The pressure in the packing steam is to the turbine gland packings of
high and low pressure sides. The pressure in the packing steam reservoir
piping is controlled 0.01~0.2bar automatically.
2 - 70 Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.11.1b Turbine Exhaust Steam System

From 9.8 bar To Safety Manifold

Steam System Vent Line
Control Sett. Control Sett.
Air PC Air PC
To Dump Piston 0.7 bar 0.7 bar
Control Control

35V
Valve (T-730V) Air Air
Inter-clocking 36V 39V
From Excess Steam Steam Header PIAHL Steam Header PIAHL
PX IAS PX IAS
Dump Valve Make-up Make-up Spill
Control Spill Control Control Sett. TI
Valve Control Valve Valve 2.5 bar 33V

5T 69V
From Main Valve

73V
Condensate

71V

72V
43V 70V 34V
Water System LS To Auxiliary 37V 40V
LS No.1 Generator No.2 Generator
Condenser Turbine Turbine
42V

Main Cond. IAS

Vacuum Low Trip PS Deaerator
T-41B

21V
From Main
47V From Main
49V
Dump Valve LS To Atmos. LS (30 m3)
T-41A
T-68B

PS Interlock
Condensate Condensate
Drain Tank
Water System Water System

48V

50V

41V
38V
CI

M
VIAL
IAS
M-60V T-56 From 3rd Stage
T-68A Main Condenser M-59V O-27 M-58V LS LS
From Main Feed Water Heater
ESLD Water Spray for
IAS VX
Dumping Steam Cond. Pump
2.1 bar/
T-68D CI T-57 722mmHg V. IAS
M-64V

Dump Valve
Open/Close PS
Astern Turbine M-62V O-26 M-61V
Water Spray From Gland Dump Valve I P Control
Start of T-68C Cond. Out Air
Stand-by PS Silence 28V
31V Piece 29V 27V
Vacuum P/P L.P
T-68 Turbine
On ECP

20V
(Nanometer) VI

32V
26V
To Auxiliary Condensate
TI PX PI
IAS TX
75V
From Main
Gland Leak Off Reservoir
Condensate
No.2 Distilling Plant PI Water System
From Cross Gland
17V

61V
TI
Over Bleed On Body Exhaust Fan
Sett. Sett. VG
120°C 100°C S
Control
TI PI TS TS Air
To B.W
H.P Turbine Gland
19V

11V

59V
Condenser

67V 2T 66V
23V PI
From Main PIAHL PIAL S
PX PX PX Control
IAS DCS

68V
Steam Supply Air
Control M-51V
51V

Air CI
5V 10V 62V

IAS I No.1 Distilling Plant

P PI
53V 52V

To Atmospheric
ORI-1 46V

5.7/1.8 bar Pressure 22V 44V

58V
TI
No.1 Main Feed No.2 Main Feed Reducing Valve From L.P Drain Tank
Water Pump 3T 54V Water Pump 4T 55V Sett. Sett. Turbine Bleeding
Turbine Turbine 120°C 100°C S
Control
PI TI PI TS TS Air
4V 9V 25V Key
TI TI PIC
PI PI PX
IAS
15V
24V Superheated Steam Line

56V

18V
64V 1T 63V
To Atoms. Drain Tank

To Atoms. Drain Tank

PI
To Steam Drain Line

To Steam Drain Line

To Main Turbine 12V 6T 13V Desuperheated Steam Line

PIAL S
for Packing Steam PX PX
DCS Control
1V

6V

Exhaust Steam Line

65V

Air
14V
3V

8V

M-50V Condensate Line

2V

7V

LS LS
Air Line
From Main To Atmos. Drain Line
Condensate Pump Drain Tank

Final Draft / 2007.12.28 2 - 71 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2. Operating Procedures drive at about 400rpm and keep it for about 25minute for warming. 3. Control and Alarm Settings
Afterwards, increase the turbine speed till the rated speed in
1) Starting 20~30minute IAS
Description Setting
Tag No.
(1) Confirm the steam source and electric source are ready for operation. Confirm delivery pressure of the main oil pump and bearing oil
TG008 G/T 1 STM IN PRESS LL 54bar
pressure increase as the turbine speed increase.
(2) Check all gauges indicating zero point. TG009 G/T 1 MAIN STM IN TEMP L/LL 300/280℃
(19) Fully open the main stop valve after confirming the governing
(3) Check the oil level in oil tank at “NORMAL”. operation of turbine. TG011 G/T 1 STM IN PRESS L 55bar

TG013 G/T 1 EXH STM PRESS H 0.7bar

(4) Check the circuit breaker is open. (20) Close the drain valves on main steam line.
TG014 G/T 1 EXH STM PRESS HH 1.0bar
(5) Confirm the main stop valve, exhaust valve and packing steam valve (21) Close the drain valve on the main stop valve.
TG016 G/T 1 VACCUM L 300mmHg
are closed.
(22) Adjust the voltage and frequency. Put the turbine speed in parallel TG068 G/T 2 STM IN PRESS LL 54bar
(6) Confirm the bearing oil pressure reaches approx 0.25~0.3bar. with the other generator with the synchronizer on the electric panel.
TG069 G/T 2 MAIN STM IN TEMP L/LL 300/280℃
(7) Start the priming L.O. Pump. And Confirm the bearing oil pressure (23) Shift the load gradually. TG071 G/T 2 STM IN PRESS L 55bar
reaches approx. 0.2~0.3bar.
2) Stopping TG073 G/T 2 EXH STM PRESS H 0.7bar
(8) Open the cooling water inlet and outlet valve on LO Cooler. TG074 G/T 2 EXH STM PRESS HH 1.0bar
(1) Shift all the load to the other generator.
(9) Start the cooling water pump and send the cooling water to the LO TG076 G/T 2 VACCUM L 300mmHg
Cooler. (2) Cut off the circuit breaker.

(10) Open the vent valves on the water heads of the LO Cooler and
confirm the cooling water is flowing.
(11) Check the steam pressure and temperature before the main stop
valve. Don’t start the turbine if the steam pressure and temperature
are lower than normal value.
(12) Supply the air to the sealing controller and check the sealing steam
supply. Confirm the packing steam pressure 0.01~0.2bar.
(13) Open the needle valve for gland steam exhaust.
(14) Fully open drain valves of the main stop valve and on main steam
piping.
(15) Put turning device on. After turning, take off the turning device
fully after turning.
(3) Shut the main stop valve by the handle or hand trip lever. Confirm
the priming LO Pump starts automatically when the turbine speeds
down.
(4) Open the drain valves on main steam line.
(5) Open the drain valve of the main stop valve and the casing draining
valve.
(6) Open the drain valve of exhaust valve.
(7) Rotate and turn the shaft. Carry out the turning for 120minute or
over.
(8) Stop the sealing steam supply and cooling water pump.
(9) Stop the priming LO pump. Closed all valves.

(16) Set the air synchronizer to the indication of “0” by turning the
synchronizer.

(17) Open the governor valve by the starting lever. Confirm the
governing valve opened.

(18) Open the main stop valve by hand. Start the turbine gradually and

Final Draft / 2007.12.28 2 - 72 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.11.2a Diesel Generator Engine

( To be added other system for D/G Engine e.g Air /C.F.W etc.)

Near G/E G.O

Service Tank Top
G/E M.D.O
Service Tank
(134.2 m3)
Finned Tube
Pipe (100A)

101V

126V
127V 128V
From M.D.O
Near 2nd Storage Tank

102V
Deck
To Boiler F.O
11S Pump Suction
(60 Mesh) V4
PI

S
RV4
115V

103V 9 bar Air

MT

S
105V

FI
FI IAS
104V

PX

PI
PX

V1
M.D.O Supply Line for
G/E Back-out Starting

M.D.O
PI
G/E M.D.O Service Pump L.O Purifier
Loose Supply
(2.95 m3/h x 4 bar) (3,000 L/H)
PX V5
PI CI
CI PI TX
ST
124V

122V
120V 119V 129V 12S

130V
Generator Engine
(Hyundai-B&W Model : 9L32/40) IAS (32 Mesh)

131V
No.2 M.D.O Purifier Supply Pump LS
PS PI CI
PIAL PX (3 m3/h x 3 bar)
MC
116V

109V

123V

121V

112V 118V 117V

No.1 Sludge Tank

(14 m3)

Key
Diesel Oil Line
Air Line
To F.O Drain Line
To F.O Drain Tank Drain Tank To F.O Drain Tank

Final Draft / 2007.12.28 2 - 73 Part 2 Machinery System

CLEAN FORCE
2.11.2 Diesel Generator Engine
1. General Description
Under normal circumstances, the diesel generator will be used as a stand -by
unit to the turbine generators. The main diesel generator can be used in parallel
with them when the ship is on cargo load/unload and port in/out operation.
The main switchboard control will provide facilities for monitoring the voltage,
frequency, power and phase as well as manual facilities for synchronisation,
speed and voltage adjustment.
1) Engine
Engines with the type designation 9L32/40 are turbocharged,
unidirectional, four-stroke, in-line engines with a cylinder bore of 320
mm and a stroke of 400mm. They are used for marine propulsion and
auxiliary applications, and as stationary engines in power stations.
The characteristic features of the larger engine types of MAN B&W
Diesel AG’s production program have been adopted for this engine. The
engine is moderately supercharged by means of one exhaust gas turbo-
charger and a two stage air cooler.
When viewed on the coupling end, the exhaust gas pipe is located at the
right (exhaust side), and the charge air pipe is at the left (exhaust
counter side).
The engine has two camshafts. One of them is used for scavenge/
exhaust valve actuation on the exhaust side, the second one serves to
drive the injection pumps on the exhaust counter side. Hydraulically
actuated adjusting devices permit adjustment of both the valve timing
and the injection timing, depending on the design ordered.
The turbochargers and charge-air coolers are at the free engine end of
the engine on generator engines. Cooling water and lube oil pumps are
driven via a drive unit also on the free end of the engine.
Engines of the type L32/40 have a large stroke/bore ratio and a high
compression ratio. These characteristics facilitate an optimization of the
combustion space geometry and contribute to a good part-load
behaviour and a high efficiency.
The engines are equipped with MAN B&W turbochargers of the NR
type.
2) Jacket Cooling Water System
Conditioned fresh water is normally used for cooling. Charge-air coolers
are also cooled by fresh water.
Final Draft / 2007.12.28
Machinery Operating Manual
Single-stage charge-air coolers are usually integrated in the secondary
circuit. Where two-stage charge-air coolers are used, engine cooling
water is passed through the first stage (primary/high-temperature circuit),
and fresh water from the secondary/low-temperature circuit is passed
through the second stage.
The cylinder head is cooled from the annular space around its lower part,
where the water is supplied through bore holes into the annular space
between the injection valve recess and the inner part of the cylinder
head, some of the water flowing around the valve seat rings. The other
large cooling spaces of the cylinder head are served from this annular
space.
The water leaves through a passage via the upper area of the backing
ring and into the return manifold, which runs along the supply pipe
(front). This return manifold recirculates the heated water to the charge-
air cooler or to the system at the drain connection.
3) Fresh Water Cooling System
Fresh water, supplied from the engine room central fresh water cooling
system, is used to cool the charge air, Lubricating oil, generator and
generator bearing LO cooler.
4) Lubricating Oil System
The engine is normally supplied with LO under pressure to all its
running parts by an engine driven gear type LO pump. The pump
discharges through the cooler, at which the temperature is regulated by a
three way valve, allowing the LO to pass through or by pass the cooler.
The oil then pass a duplex filter with one filter of 15㎛ mesh and the
second of 60㎛ mesh, before flowing through the various branches
throughout the engine.
All the lubricating points of the engine and of the turbocharger are
connected to the forced-feed oil circulation system.
The pressurised lubricating oil is supplied as follows:
- Turbocharger
- High pressure FO pump
- Fuel cam shaft bearing
- Valve cam shaft bearing
- Governor drive gear
- Main bearing
- Locker arm system on cylinder head
- Pump drive gear
An electric driven pre-lubrication pump is used to circulate LO through
the engine while it is in stand-by condition. This ensure that all the
running parts are prelubricated at all times.
2 - 74
5) Diesel Oil System
The fuel is supplied to the engine on its front face. The injection pumps are
connected to the distributor pipe at the exhaust gas counter side by a short
pipe. They deliver the fuel oil under high pressure through the injection
pipe to the injection valves. The injection pumps are operated by cams on
the camshaft.
Excess fuel not needed by the injection pumps is passed through the
overflow pipe and delivered into the manifold which returns it to the return
chamber.
6) Starting Air System
The following are the primary elements for engine starting:
- The main starting valve with the control valve, located at the free engine
end.
- The starting slide valve located beside the fuel injection pumps.
- The starting valves located in the cylinder heads:
a) On-off valve for jet system
b) On-off valve for shut down
These valves/slides are opened when certain prerequisites are met. The main
starting valve is opened by the control valve. Air is admitted to the starting
slide valves as soon as the solenoid valve in the control console is opened, and
they are finally opened in the order of ignition as soon as the relevant starting
cam of the camshaft approaches. The air flow from the starting slide valve
opens the relevant starting valve.
2. Operating Procedures
1) Starting
(1) Switch on the pumps for fuel oil, lube oil, and cooling water and prime
the engine.
(2) Check that all local instruments are at zero point.
(3) Check that the oil level in the sump tank is a normal as required.
(4) Confirm that the cooling water and LO temperature reach as required
degree.
(5) Start the electrically driven auxiliary lube oil pump in auto mode.
(6) Check the running gear as well as the injection pump drive and the
valve gear to verify that oil is supplied to all bearing points.
(7) Check the pipe connections and pipes for leakages.
Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

(8) Check the lube oil pressure upstream of the engine and upstream of 3. Control & alarm settings
the exhaust gas turbocharger.
IAS
(9) Drain the compressed air tank and check the pressure, top up if Description Setting
Tag No.
necessary.
DG001 G/E FWD BRG TEMP H/HH 90/95℃
(10) With the indicator cocks opened, turn the engine several DG002 G/E AFT BRG TEMP H/HH 90/95℃
revolutions using the turning gear.
DG043 G/E LUB OIL IN PRESS L 2.8bar
(11) Disengage the turning gear and confirm turning bar is in correct DG044 G/E MDO IN PRESS L 2.5bar
stowed position.
DG045 G/E LUB OIL PRESS LL 2.5bar
(12) Blow through the cylinders on air and check the indicator cocks for
DG046 G/E LO FILT DIFF PRESS H 1.2bar
any liquid is issuing.
DG047 G/E LUB OIL IN TEMP H 70℃
(13) Close the indicator cocks.

(14) Ensure that the shut-off elements of all systems have been set to the
in-service position.

(15) Operate the engine at low speed for approximately 10minutes.

(16) Check instrumentation during the test run.

(17) If the engine operates properly, load should be applied or the

engines should be shut down. Prolonged idle operation is to be
avoided. The engine should reach the service temperature as
quickly as possible because as it suffers higher wear while cold.

2) Stopping

(1) Remove the load from the engine and operate it at low load.

(2) Shut down the engine and confirm that the auxiliary LO pump starts
automatically.

(3) Open the indicator cocks and blow the engine over on air to clear the
cylinders.

(4) Close the indicator cocks and keep the engine in the stand-by
condition.

Final Draft / 2007.12.28 2 - 75 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.11.3 Emergency Diesel Generator
1. General Description
The Emergency Diesel generator is rated for 850kW at 450V, 60Hz for use in
emergency or dry-dock conditions. The generator feeds the emergency
switchboard and, through tie-breakers, the main switchboard. The unit will start
automatically should the main running unit fail, or it can be started manually
either from the emergency switchboard or engine starter panel.
Under normal operating conditions, the emergency switchboard is fed from the
main switchboard through a tie-breaker, with the emergency generator engine
operation switch in the auto condition at the starter panel. Under these
conditions, a loss of voltage in the bus bars will be sensed thus, starting the
emergency generator automatically and feeding electric power to the emergency
switchboard.
1) Engine
The engine is a V-12 turbocharged diesel engine, running at 1,800
rev/min. The engine has an air start motor and a manual hand
hydraulic system.
Crankshaft, camshaft and bearings etc. are lubricated by a forced
lubrication system from an engine driven gear pump. The pump draws
oil from the sump pan and, after passing through a cooler and a filter, a
pressure regulating valve maintains the line pressure. Heating elements
are fitted to the sump to provide preheating of the lube oil and heating
elements are also fitted to the cooling water jacket. These are normally
left on.
The generator is coupled to the emergency switchboard via a circuit
breaker, which is closed automatically by the engine starting sequence
or manually at the emergency switchboard. Manual control of voltage
is provided together with voltage, current and frequency meters at the
emergency switchboard.
The Emergency Generator starter panel in the emergency generator
room has two positions: AUTO and MANUAL with START and STOP
pushbuttons.
The Emergency Switchboard EG section has three (3) selector
switches: engine control mode ‘AUTO/MANUAL’, E/G mode
‘EMCY/FEED BACK’ and test switch ‘TEST/NORMAL’ for
controlling the emergency generator set.
When a no-volt signal is received at the emergency switchboard, this
initiates the engine start sequence. On receipt of the signal, the lube oil
heater and generator heater are switched off, the air start solenoid
operates and air is admitted to the starter motor. The generator ACB on
the emergency switchboard will be closed automatically when the
engine is running at the correct speed and voltage.
In the MANUAL position, the generator can be started and run
manually. Starting may be by manually operating the air start solenoid
valve and, when the generator is running, the circuit breaker can be
manually closed on the switchboard. Interlocks prevent the closure of
the circuit breaker when the emergency switchboard is being fed from
the main switchboard through the ACBs ELM1 and ELM2.
3. Operating Procedures
1) To Start the Generator Only at the engine starter panel.:
(1) Check the engine lube oil sump level and top up as required.
(2) Set the engine starter panel switches to the MANUAL position.
(3) Check the fuel tank level, check for water and top up the tank as
required.
(4) Open the fuel tank outlet quick closing valve and ensure that there is
fuel at the filters.
(5) Check the air start receiver air pressure. Drain off any moisture.
(6) Open the receiver outlet valve and the air line to the starter-motor.
(7) Push the START button, the engine will receive a start signal.
(8) When the engine is started, check instrumentation and for leaks around
the engine.
2) To Start the Generator from manual hand hydraulic system
(1) Carry out checks and inspections as above.
(2) Set the engine starter panel switches to the MANUAL position.
(3) Check that the feed tank is filled to the correct level with approved
hydraulic fluid.
(4) Raise pressure to between 281 and 351bar using hand pump.
(5) Pull the relay valve operating lever, the engine will be started by
hydrauric power
(6) When the engine is started, check instrumentation and for leaks
around the engine.

An engine-mounted radiator with v-belt driven fan cools the jacket 2. System Capacities and Ratings.
water, and an engine driven pump circulates the water through the
jacket spaces. Emergency Generator Engine: STX
Model KTA38DMGE
Fuel is supplied from the 5.0m3 Emergency GO tank located in the Combustion system Direct injection
Aspiration turbocharger & after cooler
emergency generator room, gravity fed to the fuel injection pump. Air
Bore / stroke 159 / 159 mm
for starting is supplied from a separate air reservoir, which is topped
up by the engine-driven emergency diesel generator starting air Generator
compressor or generator engine starting air compressors. Start air is Model HCM634K1
supplied to the starter motor after initiating the operation of a solenoid Maker NEWAGE
valve in the line. Type Horizontal, Self Exciting Brushless
Drip Proof-type
2) Generator Rated Speed 1800rpm

The generator gives an output of 850 kW at 450 volt 3 phase 60Hz at

1,800 rev/min. The generator is a brushless type self-excitation, self-
regulation system with automatic voltage regulator maintaining a
constant output. A space heater coil is fitted to the generator enclosure
to prevent condensation while the unit is idle.

Final Draft / 2007.12.28 2 - 76 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.12.1a Distribution and Loading

Definitions Abbreviations
MAIN POWER DISTRIBUTION SYSTEM No.1 Main 6600V SWBD HM1
No.2 Main 6600V SWBD HM2
No.1 Cargo 6600V SWBD HC1
NO.2 TURBO DESEL NO.1 TURBO No.2 Cargo 6600V SWBD HC2
TG2 GENERATOR DG GENERATOR TG1 GENERATOR No.1 Main 440V SWBD LM1
No.2 Main 440V SWBD LM2

NO.2 6.6KV SWBD NO.1 6.6KV SWBD No.1 Cargo 440V SWBD LC1
TG2 DG2 DG1 TG1 No.2 Cargo 440V SWBD LC2
440V Emergency SWBD ESB
No.1 Main Turbine Generator TG1
HB2 HB1
HC1 HT1 No.2 Main Turbine Generator TG2
HT2 HC2
Standby Diesel Generator DG
Emergency Diesel Generator EG
NO.2 6.6KV CSBD NO.1 6.6KV CSBD No.1 Main 6600V/440V Transformer HMTR1
CC2 CC1
No.2 Main 6600V/440V Transformer HMTR2
No.1 Cargo 6600V/440V Transformer HCTR1
CB2 CB1
CT1 No.2 Cargo 6600V/440V Transformer HCTR2
CT2
NO.2 440V NO.1 440V TG1 Circuit Breaker TG1
CSBD CSBD
TG2 Circuit Breaker TG2
CL2 ELC1 CL1
HCTR2 HCTR1 DG Circuit Breaker to HM1 DG1
HMTR2 HMTR1
DG Circuit Breaker to HM2 DG2
6600V Main Bus Tie Breakers HB1 & HB2
6600V No.1 Main SWBD to No.1 Cargo SWBD Breaker HC1
LL1 6600V Feeder to Cargo HC1 CC1
LL2
6600V No.2 Main SWBD to No.2 Cargo SWBD Breaker HC2
6600V Feeder to Cargo HC2 CC2
LB2 LB1
LE2
LE1 6600V Cargo Bus Tie Breakers CB1 & CB2
NO.2 440V SWBD NO.1 440V SWBD No.1 Main Step Down Transformer 6600V Breaker HT1
No.2 Main Step Down Transformer 6600V Breaker HT2
No.1 Main Step Down Transformer 440V Breaker LL1
No.2 Main Step Down Transformer 440V Breaker LL2
ESBD
440V Main Bus Tie Breakers LB1 & LB2
EC1 EB2 EB1
No.1 Cargo Step Down Transformer 6600V Breaker CT1
DS No.2 Cargo Step Down Transformer 6600V Breaker CT2
SC EG1 No.1 Cargo Step Down Transformer 440V Breaker CL1
No.2 Cargo Step Down Transformer 440V Breaker CL2
Emergency Diesel Generator Circuit Breaker EG1
SHORE EG EM'CY Feed to Emergency SWBD from No.1 LV SWBD LE1
GENERATOR
Feed to Emergency SWBD from No.2 LV SWBD LE2

Final Draft / 2007.12.28 2 - 77 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.12 Electrical Power Distribution The diesel generator can be connected via a breaker on either switchboard, can be arranged from emergency SWBD. The disconnecting switch (LC1E)
which are provided with separate synchronising panels. Each switchboard on the No.1 LV CSBD is not controlled remotely and would be normally open.
2.12.1 Distribution and Loading supplies its respective group starter panel. It’s position is monitored and indicated on the IAS.

1. Generating Plant Each distribution circuit, in general, is protected against overcurrent and The circuit breakers at the emergency switchboard EB1 and EB2 are
short circuit current by a moulded case circuit breaker fitted on the
interlocked such that only one breaker may be closed.
The electric power generating plant consists of the following: switchboard or panel board, with inverse time overcurrent trip and
instantaneous trip. Each steering gear motor is fed from an independent
circuit, two sets of steering gear motor are connected to the main The HV feeder HT1 and LV incomer LL1 are operating as a pair, and thus if
Turbine generator
switchboard and the other is connected to the emergency switchboard. HT1 is closed the LL1 will automatically close. The other pair is HT2 and
No. of sets: 2
Rating: 6,600 volt, 3 Ph, 60 Hz, 3,850 kW LL2.
Each supply system is provided with a device for continuously monitoring
Diesel generator the insulation level to earth, giving an audible and visual indication of an 4) Breaker Operation
No. of sets: 1 abnormal low insulation level.
Rating: 6,600 volt, 3 Ph, 60 Hz, 3,850 kW Only breakers that are interfaced with and selected to “IAS CONTROL” on
A shore connection is provided at the emergency switchboard to supply the breaker local panel will be possible to operate from IAS. A breaker will
Emergency diesel generator power to the main 440V switchboards, either independently or normally be individually operated from the control operator station. There are
No. of sets: 1 simultaneously. some HV and LV breakers in the power distribution system which differs from
Rating: 450 volt, 3 Ph, 60 Hz, 850 kW this.
2) 6.6kV System
One turbine generator is used during normal sea going conditions. Two
Under normal conditions at sea, the system will operate with one turbine See the below table with description of them.
generators are required when:
driven generator (TG1 or TG2) supplying power to the Main 6.6kV
- Maneuvering with bow thruster in use switchboard All main generators are capable of operating in parallel under No. Feeder Incomer Remark
- Cargo loading the control of the Power Management System (PMS), and Diesel generator 1 HT1 LL1 When HT1 is closed, LL1 will automatic close.
- Cargo discharging may be called to start and parallel automatically by the PMS system when 2 HT2 LL2 When HT2 is closed, LL2 will automatic close.
selected for Standby. 3 TG1 - Individually operated from TG1 operation menu.
Ring connections for the switchboard using cargo or low voltage switchboard is The condition is that TG1 PMS is selected ON.
allowed for a short predefined period during configuration changes. If the ring 4 TG2 - Individually operated from TG2 operation menu.
The bus tie breakers on the Main 6.6kV switchboard HB1 & HB2 will
connection is active for more than a predefined period (15sec.), an alarm will be The condition is that TG2 PMS is selected ON.
normally be CLOSED. Power to the Cargo switchboards HC1 and HC2 is
announced and the breaker which made the ring connection will be 5 DG1 - Individually operated from DG operation menu.
automatically opened. Synchronisation unit are installed for HV breakers HB1 achieved by closing the supply circuit breakers from the respective Main
6.6kV switchboards. The tie breakers on the Cargo switchboard CB1 and The condition is that DG1 PMS1 is AUTO
& HB2, LV breakers LL1/LB1 & LL2/LB2 and EB1&EB2. Since there is no
CB2 will normally be OPEN. SELECTED.
synchronisation unit on breakers CB1 & CB2 ring connection is only available
when HB1 & HB2 is closed. 6 DG2 - Individually operated from DG operation menu.
3) 440 Volt System The condition is that DG2 PMS2 is AUTO
Back feed from emergency switchboard is possible as follows; SELECTED.
Power supply to the two Main 440 Volt switchboards is achieved by the 7 EG1 - Individually operated from EG operation menu.
In case of using emergency generator only LV can be powered. In case of using use of two step down transformers, HMTR1 and HMTR2. Each rated
shore power it will be possible to use power both LV & HV switchboard. Main 6.6kV/440V, three phase 3300KVA using circuit breakers HT1/LL1 and
generator breakers (TG and DG) will interlock with shore breaker closed. HT2/LL2 respectively.

The single line diagram for the main power distribution is shown in illustration
2.12.1a.
2. Power Distribution System
1) General Description
The main switchboard is situated in the main switchboard room. The main
switchboard is divided into two parts. They can be operated independently,
but are normally linked together by a bus tie breaker on each switchboard.
One turbine generator supplies each switchboard.
The bus tie breakers LB1 and LB2 on the 440 Volt main switchboards will
normally be OPEN. Power to the two Cargo 440 Volt switchboards is
achieved by the use of two step down transformers HCTR1 and HCTR2
each rated 6600/440Volt Three Phase 540KVA (No.1) and 540KVA (No.2),
with circuit breakers CT1/CL1 and CT2/CL2 circuit breakers closed.
There is no interconnection available between the two 440 Volt Cargo
switchboards.
The supply to the emergency switchboard can be arranged from either 440
Volt main switchboard No1 or 440 Volt main switchboard No 2, using
circuit breakers LE1/EB1 & LE2/EB2. The supply to the No.1 LV CSBD

Final Draft / 2007.12.28 2 - 78 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.12.1a Distribution and Loading Definitions Abbreviations

No.1 Main 6600V SWBD HM1
No.2 Main 6600V SWBD HM2
PORT STBD
DG No.1 Cargo 6600V SWBD HC1
No.2 Cargo 6600V SWBD HC2
TG2 TG1 No.1 Main 440V SWBD LM1
No.2 Main 440V SWBD LM2
PMS PMS DG2 DG1 PMS PMS TG1 No.1 Cargo 440V SWBD LC1
TG2
No.2 Cargo 440V SWBD LC2
HM2, 6.6KV MAIN SWBD HB2 HB1 HM1, 6.6KV MAIN SWBD
440V Emergency SWBD ESB
SYNCHR SYNCHR No.1 Main Turbine Generator TG1
HT2 HT1 No.2 Main Turbine Generator TG2
HC2 HC1 Standby Diesel Generator DG
W SpraY 1 Ballast 2 Ballast 3 Ballast BOW
Pump Pump Pump Pump THRUSTER Emergency Diesel Generator EG
CC2 HC2
HC2, 6.6KV CARGO SWBD HC1, 6.6KV CARGO SWBD No.1 Main 6600V/440V Transformer HMTR1
CB2 CB1 No.2 Main 6600V/440V Transformer HMTR2
No.1 Cargo 6600V/440V Transformer HCTR1
CT2 CT1
No.2 Cargo 6600V/440V Transformer HCTR2
HMTR2 CARGO CARGO CARGO CARGO
NO.2 NO.1
CARGO CARGO CARGO CARGO HMTR1 TG1 Circuit Breaker TG1
PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP
HD COMP. HCTR2 HCTR1 HD COMP.
TK 1 TK 2 TK 3 TK 4 TK 4 TK 3 TK 2 TK 1 TG2 Circuit Breaker TG2
DG Circuit Breaker to HM1 DG1
CL2 CL1
LL2 DG Circuit Breaker to HM2 DG2
LL1
6600V Main Bus Tie Breakers HB1 & HB2
SUNCHR LC2, CARGO SWBD 440Vac LC1, CARGO SWBD 440Vac SYNCHR 6600V No.1 Main SWBD to No.1 Cargo SWBD Breaker HC1
6600V Feeder to Cargo HC1 CC1
LM2, MAIN SWBD 440Vac LM1, MAIN SWBD 440Vac
LB2
EG
LB1 6600V No.2 Main SWBD to No.2 Cargo SWBD Breaker HC2
ELC1 6600V Feeder to Cargo HC2 CC2
LE2 LE1
EG1 6600V Cargo Bus Tie Breakers CB1 & CB2
SHORE LC1E
EB2 POWER No.1 Main Step Down Transformer 6600V Breaker HT1
SYNCHR No.2 Main Step Down Transformer 6600V Breaker HT2
EB1 DS
No.1 Main Step Down Transformer 440V Breaker LL1
ESB, EMERGENCY SWBD 440V No.2 Main Step Down Transformer 440V Breaker LL2
440V Main Bus Tie Breakers LB1 & LB2
6600V 440V
No.1 Cargo Step Down Transformer 6600V Breaker CT1
No.2 Cargo Step Down Transformer 6600V Breaker CT2
No.1 Cargo Step Down Transformer 440V Breaker CL1
No.2 Cargo Step Down Transformer 440V Breaker CL2
Emergency Diesel Generator Circuit Breaker EG1
Feed to Emergency SWBD from No.1 LV SWBD LE1
Feed to Emergency SWBD from No.2 LV SWBD LE2

Final Draft / 2007.12.28 2 - 79 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

3. Normal Operation at Sea When the operator requests a breaker to be closed, IAS will send a close Selection of load sharing mode will be undertaken from the IAS and
request to the associated breaker. The Hi-Map synchronizer will carry performed by PMS.
1) Operating Modes out the synchronizing and the closing of the breaker where applicable.
4. Start Blocking of Heavy Consumers
To allow IAS to control the switchboard it must be selected to remote, and For the majority of the breakers, there is not a synchronizing unit
the synchronizing unit must be switched on with no faults present (PMS available. For these circuit breakers there will be “Close Interlock” To prevent overload of the power generation plant, the PMS contains start blocking
On and PMS Trouble). When a switchboard is in local control all IAS conditions in IAS to be met before the breaker will be closed. Interlock of the following consumers.
controlled breakers on that switchboard will revert to local control. mode will be indicated with an “I”.
Table 1. Heavy Consumers, Stbd side
The Hi-Map units for the generator breakers have the following control 4) Automatic Sequence Control Blocking No.of Gen.
functions: No. Service Description Time-out
Limit Required
In the event of a transformer (TR1 or TR2) high high temperature alarm 1 Cargo Pump 1S 559.5kW 1 60sec
PMS On/Off→ Selects the Hi-Map units on or off. (setting 135°C) IAS will perform a trip of the transformer after a short
2 Cargo Pump 2S 559.5kW 1 60sec
Load Sharing On/Off → Selects load sharing on or off. delay (10sec. adjustable). When only one transformer is connected and
Load Sharing Asym/Sym Selects between asymmetrical or LV bus tie closed, a sequence will energise the other healthy transformer 3 Cargo Pump 3S 559.5kW 1 60sec
→ symmetrical load sharing. and parallel the two transformers before performing trip of the faulty 4 Cargo Pump 4S 559.5kW 1 60sec
Auto/Manual → Selects between auto control from IAS transformer. If both transformers are connected, the LV bus tie will close
or manual control from Hi-Map unit 5 Ballast Pump 1 355kW 1 60sec
before performing trip of the faulty transformer.
front panel. For DG1 and DG2 only one 6 Ballast Pump 2 355kW 1 60sec
Hi-Map unit may be selected to Auto at
5) Short Time Paralleling 7 Water Spray Pump 400kW 1 60sec
any time.
8 HD Compressor 1 900kW 1 120sec
IAS sends the following commands to the generator breaker Hi-Map units: To allow change-over of power supply from one switch board to another
without blackout, it is allowed to parallel LV switchboards through both
Table 2. Heavy Consumers, Port side
Full Auto Close → Signal to Hi-Map to synchronize the transformers for a configurable amount of time (15sec.). When the ring
Blocking No.of Gen.
electrical supplies and close the is made the operator has 15 seconds to open a breaker to remove the No. Service Description Time-out
Limit Required
circuit breaker. paralleling mode. If he fails to do this IAS will open the last closed
Full Auto Start/Close → Signal to Hi-Map to start engine, breaker, and alarm is given. 1 Cargo Pump 1P 559.5kW 1 60sec
synchronize the electrical supplies and 2 Cargo Pump 2P 559.5kW 1 60sec
close the circuit breaker. The HC1 and HC2 switchboards can be used as bus-tie for HM1 and
3 Cargo Pump 3P 559.5kW 1 60sec
Full Auto Open → Signal to Hi-Map to reduce load and HM2 with HB1 and HB2 open. If HM1 and HM2 are connected with
open the circuit breaker. HC1 and HC2 and HB1 and HB2 are closed, IAS will automatically 4 Cargo Pump 4P 559.5kW 1 60sec
Full Auto Stop/Open → Signal to Hi-Map to reduce load and open CB1 and CB2 after 15. 5 Ballast Pump 3 355kW 1 60sec
open the circuit breaker and stop the
engine. 6 Bow Thruster 2000kW 2 120sec
For restoring of power after blackout it is also possible to short time
7 HD Compressor 2 900kW 1 120sec
parallel LV switchboards and emergency switchboard. See 6.3) Power
2) Local Operating Mode
restoration of ESB from EG to main power system
Upon a start request from the IAS or switchboard, the PMS will check whether the
In this mode only monitoring will be available in IAS and no operation.
6) Common available power is sufficient to allow starting of the electric motor. If not, a standby
This mode will be indicated with an “L” on the circuit breaker in
generator start request is given.
question. For those breaker where only monitoring is performed there
The selector switch at the main switchboards shall normally be selected
will be no indication for operation mode.
to IAS CONTROL (Remote), and generator breakers should be selected By default all heavy consumers are start interlocked based on available power. This
to IAS CONTROL and in SERVICE POSITION (Available) allowing is indicated with a blue lamp on the mimic next to the motor symbol. When a start
3) Remote Operating Mode
operation of the generators and circuit breakers from the IAS system via of the heavy consumer IAS activates a start request to PMS, and PMS check for
When the switchboard control is selected to remote IAS will in addition the operator work stations in the engine control room. available power. When there is sufficient available power PMS activates power
to perform monitoring also are able to perform operation. This mode will available to IAS.
be indicated with an “m” for manual mode or an “a” for auto mode in The selector switch at the PMS system should be selected to ECR
IAS. AVAILABLE which allows the operator to select the desired operation This will be indicated by blue lamp is switched to on. Also the power interlock is
mode of the PMS system from the operator work station in the engine removed and a start command will be given by IAS. When the consumer is running,
control room. PMS will deactivate power available signal to consumer.

Final Draft / 2007.12.28 2 - 80 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

5. Consumer Restart 31 Central C.F.W Pump 1 10sec LM1 1) HV Switchboard Reconnection

Upon power restoration after black out, each consumer shall resume operation 32 Central C.F.W Pump 2 10sec LM2 Starter in LM2 Breakers HT1/LL1, HT2/LL2 and EB1 and EB2 are protected by UVT
in the predetermined time set in the table below. This means if consumer where 33 Aux. S.W Circ. Pump 15sec LM1 devices in the switchboard, and in case of blackout they will open. The rest of
running prior the blackout it will be restarted again. the breakers will stay as is.
34 Main S.W Circ. Pump 15sec LM2
The power restoration conditions are as follows : Relevant Confirmed blackout 35 Main C.S.W Pump 1 20sec LM1
If the blackout is caused by a short circuit, a standby start signal will be sent
is restored.
36 Main C.S.W Pump 2 20sec LM2 to the standby diesel generator by PMS. The generator breaker on the
37 Cond. Drain Pump 1 23sec LM1 switchboard that detected the short circuit and the main bus tie (HB1 and
Time Fed from
No. Consumer Remark HB2) will be blocked for connection.
Delay SWBD 38 Cond. Drain Pump 2 23sec LM2
1 BOG Extraction Fan 1 0 sec LM1 39 E/R Supply Fan 3 23sec LM1 In case a total blackout, diesel generator will start and connect to the bus
2 BOG Extraction Fan 2 0 sec ESB Starter in LM2 40 E/R Supply Fan 4 23sec LM2 through the breaker with PMS AUTO selected.
3 Stern Tube L.O P/P 1 0 sec LM1 41 Boiler 1 F.O Serv. Pump 1 28sec LM1
In case of a blackout on HM1 or HM2 the diesel generator will start and
4 Stern Tube L.O P/P 2 0 sec LM2 42 Boiler 2 F.O Serv. Pump 2 28sec LM2 connect to the effected bus through the appropriate breaker.
5 Aux. L.O P/P for MFWPT 1 0 sec LM1 43 E/R Exhaust Fan 1 28sec ESB
2) Blackout and Recovery after Blackout
6 Aux. L.O P/P for MFWPT 2 0 sec LM2 44 E/R Exhaust Fan 2 28sec LM1
7 Boiler Seal Air Fan 1 0 sec LM1 45 No.1 Boiler F.D Fan 33sec LM1 If during normal at sea operations, a turbine generator breaker is tripped for
8 Boiler Seal Air Fan 2 0 sec LM2 46 No.2 Boiler F.D Fan 40sec LM2 whatever reason (Except short circuit), and a blackout results, the following
will occur.
9 D/G Engine D.O Service P/P 1 0 sec LM1 47 STBY Boiler F.D Fan 47sec LM1
10 D/G Engine D.O Service P/P 2 0 sec ESB Starter in LM2 48 Aux. Central C.F.W Boost P/P 1 54sec LM1 The PMS will initiate a start signal to the standby diesel generator, and a no-
11 Cargo Motor Room Sup. Fan 1 0 sec LC1 49 Aux. Central C.F.W Boost P/P 2 54sec LM2 voltage signal on ESB will initiate a start command to the emergency diesel
Can be started generator.
12 M/T Control Oil Pump 3 sec LM1
after supply fan
13 M/T Control Oil Pump 3 sec LM2 All distribution circuit breakers fitted with UVT protection devices on the
50 Aux. Central C.F.W Pump 1 15min LM1 have been
14 M/T Aux. L.O Pump 1 3 sec LM1 running for 15 6600Volt Main, and Cargo switchboards will open.
15 M/T Aux. L.O Pump 2 3 sec LM2 minutes
Can be started All distribution circuit breakers fitted with UVT protection devices, on the
16 H/D Comp. 1 L.O Pump 3 sec LC1
after supply fan 440 Volt main and cargo switchboards will open.
17 H/D Comp. 2 L.O Pump 3 sec LC2
51 Aux. Central C.F.W Pump 2 15min LM2 have been
18 L/D Comp. 1 L.O Pump 3 sec LC1 running for 15 When the PMS confirms voltage is available from the standby diesel
minutes generator, the relevant circuit breaker for the standby DG will be CLOSED
19 L/D Comp. 2 L.O Pump 3 sec LC2
automatically by the PMS system.
20 Bal & E/R VCR Hyd. Pump 1 3 sec LC1 Individual starter
6. Blackout Reconnection
21 Bal & E/R VCR Hyd. Pump 2 3 sec ESB Individual starter Closure of the circuit breaker from standby diesel generator, and subsequent
In the event of a blackout IAS will perform reconnection of breakers to restore restore of power in main switchboard, will initiate an automatic breaker
22 Cargo VRC Hyd. Pump 1 3 sec LC1 Individual starter
the plant to the state it was prior to blackout. The power should be restored reconnection sequence of the system from IAS.
23 Cargo VRC Hyd. Pump 2 3 sec ESB Individual starter
within 30 seconds, meaning that all switchboards should have power again if
24 Main Cond. Pump 1 6 sec LM1 there are no problems on them. Power will then be fed via the two main transformers to the two 440 Volt
main switchboards, by closure of circuit breakers HT1, HT2, LL1 and LL2.
25 Main Cond. Pump 2 6 sec LM2
In the event of a blackout the emergency generator will automatically be started.
26 Main Cond. Vacuum P/P 1 6 sec LM1 Power will be automatically restored to the main 6600Volt and 440 Volt cargo
27 Main Cond. Vacuum P/P 2 6 sec LM2 If for some reason power on ESB is not restored 30 seconds after blackout the switchboards by closure of circuit breakers HC1, CC1, HC2, CC2, CT1, CT2,
28 M/T Gland Exhaust Fan 6 sec LM1 emergency generator will automatically connect and power the ESB. The CL1 and CL2.
emergency generator will automatically stop 5minutes after restoring of normal
29 E/R Supply Fan 1 6 sec ESB
power. This is handled by ESB. PMS will automatically closeEB1 or EB2 after power is restored on LM1 or
30 E/R Supply Fan 2 6 sec LM2 LM2. In case the EG is running PMS automatically disconnect is.

Final Draft / 2007.12.28 2 - 81 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Restart of all other cargo services and equipment will only be achieved 5) Circuit Breaker Reconnection after Blackout
under operator control, and be dependent on available power on the
system. Some circuit breakers are equipped with under voltage relays which means
the breaker will be opened after a blackout. The IAS will reconnect the
3) Power Restoration of ESB from EG to Main Power System breakers after DG has started according to below table. This requires that
none of the breakers are blocked for any reason.
The operator should confirm that supply to the emergency switchboard is
available and that LE1 and LE2 circuit breakers are closed, IAS will As a means to stop the reconnection of the plant after blackout you have a
indicate the breaker status. configurable maximum time of blackout in the breaker in IAS. This is
normally set to 30 seconds. If power is not restored on the HV
With the main supply and the emergency generator supply available, switchboards within this time IAS will not perform reconnection of
synchronising will be performed by the synchronizing unit in the ESB breakers.
switchboard.
Reconnect
No. Breaker Remark
The operator will operate on the required circuit breaker (EB1 or EB2) Time Delay
from the IAS operator control station and close one of the circuit breakers 1 HT1 0, 3 sec Adjustable
in synchronism, the operation being protected by synchroniser unit. 2 LL1 Auto close when HT1 close
Closure of the circuit breaker (EB1 or EB2) will trip the emergency
generator supply circuit breaker EG1 after a short time (1 sec). 3 HT2 0, 3 sec Adjustable
4 LL2 Auto close when HT2 close
This is done in the ESB switchboard. This will revert the system to ESB will reconnect EB1
Normal at sea operation, with the emergency switchboard now being 5 EB1 N/A immediately after LL1
supplied via the 440 Volt main switchboards. reconnection
ESB will reconnect EB2
4) Blackout and Recovery after Blackout due to Short Circuit 6 EB2 N/A immediately after LL2
reconnection
If during normal at sea operations a turbine generator breaker is tripped
due to short circuit and a blackout or partial blackout results, the following 6) Back Feed from ESB to LV Switchboard
will occur under control of the PMS.
The blackout on the LV switchboards may be cancelled out by means of
First, the switchboard safety functions and protections will be handled by back feed from emergency switchboard. Energizing of LV will be done
the HV and LV switchboard respectively. If a short circuit is detected at with “Shore” connection or with emergency generator. This facility is
HM1 or HM2, the bus tie breaker HB1 and HB2 will be opened and provided to allow removal of the blackout signal to the LV drives when
blocked from closing. HV power is not available.

The two generator breakers on the side detecting the short circuit will then In this mode the operator must verify that any restart loads will not exceed
be tripped and blocked for reconnection. This will fully prevent power the supply capacity. “Back feed” mode will be selected locally in the
being applied to the side detecting the blackout. switchboard and the status will be interfaced to IAS.

During such a condition the IAS will reconnect the healthy side according 7) Back Feed from ESB to HV Switchboard
to normal procedure. This means closing breakers to the HV and LV cargo
The blackout on the HV switchboards may also be cancelled out by means
switchboard and LV main switchboard.
of back feed from emergency switchboard. The same conditions and
restriction apply as for back feed to LV switchboard. Back feed from ESB
Closure of tie breakers to the other HV cargo switchboard and LV main
to HV Switchboard is only available on shore power.
switchboard is a manual operation after making sure the fault did not
affect these switchboards.

Final Draft / 2007.12.28 2 - 82 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.12.2 Turbine Generators Illustration 2.12.2a Turbine Generators

Maker: HHI-EES GOV

V/V MSV
Type: HSJ7 719-4P Reduction
Stator Rotor Gear
Two turbine generators are provided. They each supply one of two main
switchboards independently, but under normal conditions the two switchboards
will be linked.

Each generator is rated at 4812.5kVA at AC6600V, 3Ph, 60Hz. They are of the
totally enclosed, self excited, brushless type. The load voltage is kept constant Exciter
by controlling the excitation current to the exciter. Output power from the stator Speed
is fed into a current/voltage compound transformer and the output of this is Sensing Relay
Governor
rectified and fed through the exciter stator windings. The magnetic field in the
exciter stator induces AC in the excited rotor, which is rectified by the rotary v A
Electric
diodes and passed to the DC main rotor windings. Initial voltage build-up is by Overspeed
A Trip Trip Signal
residual magnetism in the rotor. Constant voltage control is achieved by the
automatic voltage regulator, which shunts a variable current through the exciter
kw
windings via a thyristor to keep the AC stator output voltage constant.
Hz AVR
The generator is cooled by passing air over an integral fresh water cooler, using Power
a closed circuit air supply. The cooling spaces are fitted with internal baffles to Management Turbo Altermator
prevent water reaching the stator windings in the event of cooler leakage. Space Sensing Signal
heaters are fitted, which are energised when the generator circuit breakers are
open, which protect against internal condensation during shut down periods.
The breakers are normally operated by the power management system, but can Auto
be operated manually at the switchboard front. An embedded sensor monitors Synchroniser
the stator temperature in each phase and a water leakage and temperature sensor
is fitted in each air cooler. The bearings have a temperature sensor.
Close Contactor Signal

The electric power system is designed with discrimination on the distribution

system, so that the generator breaker is the last to open if any abnormalities Diesel Engine
occur. Start

A turbine generators, with the diesel generators on stand by at sea, provide

electrical power. The order of the stand-by start is selected through the power
D/G No.1 T/G
management system.

Starting of large motors is blocked until there is sufficient power available. A

diesel generator will be started to meet any shortfall. TG2 DG2 DG1 TG1
No.2 MSBD No.1 MSBD
Two generators will be required to operate in parallel when:
No.2 T/G Synch No.2 D/G No.2 Bus No.1 Bus No.1 D/G Synch No.1 T/G
Discharging cargo Panel Panel Panel Panel Panel Panel Panel Panel

Loading cargo HM2 6600 Volt HM1 6600 Volt

HC2 HB2 HB1 HC1

Maneuvering with bow thruster in use

HMTR2 HMTR1

Final Draft / 2007.12.28 2 - 83 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.12.3 Diesel Generator Illustration 2.12.3a Diesel Generator

Maker: HHI-EES. Stator Rotor

Type: HSJ7 908-10P
Diesel
Generator
A main diesel generator is provided. It can supply both main switchboards
independently, but under normal conditions the two switchboards will be linked.

The generator is rated at 4,812.5 kVA at AC6600V, 3Ph, 60Hz. It is of the totally
Exciter
enclosed, self excited, brushless type. The load voltage is kept constant by
Em'cy Stop
controlling the excitation current to the exciter. output power from the stator is Initiate
Start Switchboard
fed into a current/voltage compound transformer and the output of this is Panel
rectified and fed through the exciter stator windings. The magnetic field in the v A Diesel
Engine Local Start
exciter stator induces AC in the excited rotor, which is rectified by the rotary
Abnormal
diodes and passed to the DC main rotor windings. Initial voltage build-up is by A
residual magnetism in the rotor. Constant voltage control is achieved by the
automatic voltage regulator, which shunts a variable current through the exciter kw
windings via a thyristor to keep the AC stator output voltage constant.
Hz AVR
Power
The generator is cooled by passing air over an integral fresh water cooler, using a Management
closed circuit air supply. The cooling spaces are fitted with internal baffles to
prevent water reaching the stator windings in the event of cooler leakage. Space
heaters are fitted, which are energised when the generator circuit breakers are Local
open, which protect against internal condensation during shut down periods. The Auto Auto No Voltage Signal
breakers are normally operated by the power management system, but can be Synchroniser
Overload Signal
operated manually at the switchboard front. An embedded sensor monitors the
stator temperature in each phase. A water leakage and temperature sensor is fitted Close Contactor Signal High Load Request

in each air cooler. The bearings have a temperature sensor.

The electric power system is designed with discrimination on the distribution

system, so that the generator breaker is the last to open if any abnormalities occur.
The turbine generators, with the diesel generators on stand by at sea, provide
electrical power. The order of the stand by start is selected through the power
management system.
No.2 T/G D/G No.1 T/G
Starting of large motors is blocked until there is sufficient power available. A
diesel generator will be started to meet any shortfall.

TG2 DG2 DG1 TG1

The diesel generator will start the following conditions:
No.2 MSBD No.1 MSBD
ACB abnormal trip (Dead bus due to blackout)
Bus abnormal (High or low voltage, Low frequency) No.2 T/G Synch No.2 D/G No.2 Bus No.1 Bus No.1 D/G Synch No.1 T/G
ACB abnormal trip (Bus alive) Panel Panel Panel Panel Panel Panel Panel Panel
Over load
HM2 6600 Volt HM1 6600 Volt
HC2 HB2 HB1 HC1

HMTR2 HMTR1

Final Draft / 2007.12.28 2 - 84 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.12.6a Battery Charger Alarm Display Monitor

Alarm & Display Monitor

ERROR
MODE

ERROR MODE

ENTER

B/Z
E.Q/ DISPLAY
SET UP DOWN FLOAT
STOP/
MANU
RESET

ALARM SETTING MODE CHARGING OPERATING MODE

SYMBOL DESCRIPTION
ALARM BUZZER
P/F INPUT POWER ALARM
O/C OUTPUT OVER CURRENT ALARM
H/V OUTPUT HIGH VOLTAGE ALARM
L/V OUTPUT LOW VOLTAGE ALARM
E/L EARTH LEAKAGE ALARM

Final Draft / 2007.12.28 2 - 85 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.12.4 Batteries & Battery Charger 2. Battery (to be added location of battery)

1. Battery Charging Discharging Board (to be added 110V charger) 1) General

1) General The Lead-Acid battery cell consists of positive electrode, negative

The main DC24V system is supplied by the charge/discharge board.
In normal operation the battery charge/discharge switchboards can be fed
either from the emergency 440V switchboard or the No.1 440V
switchboard
In the event of power failure, the 24V system is supplied by two banks of
batteries automatically.
When the AC source is first switched to the charging/discharging board,
or reconnected after a source failure, battery charging is switched to
equalising mode, reverting to floating charging after 1 hour of equalising
charging.
electrode, insulators, electrolyte, cell container and other parts. Except
for the cell container, insulator and gaskets, the cell is built up of nickel-
plated steel to withstand the mechanical damage inescapable in practical
service.
The pocket type positive and negative plates are used for the electrode.
In the pockets, the active materials are firmly contained. The positive
active material is nickel hydroxide and in order to give necessary
conductivity, a small quantity of graphite is added. The negative active
material is finely divided cadmium powder with an addition of iron
powder to prevent caking of the material.
The insulator is made of high quality vinyl chloride to avoid any risk of
damage or erosion by the electrolyte for a long period of service.

An operator can select the equalising charging method with the push The electrolyte is a mixture of chemically pure potassium hydroxide and
button switch. The equalising charging reverts automatically to floating purified water. The specific gravity of the electrolyte is 1.21 at 20oC.
charging after an 8 hour equalising charging period.
2) Capacities and ratings
If the bus voltage is higher than 28V when the equalising charging is
turned on, the voltage-dropper which reduces feeder voltage is turned on Capacity: DC24V. 300AH x 2sets
and then when the equalising charging is finished the voltage-dropper is Type: Lead Acid Sealed
automatically turned off. Rating: 10Hour Discharging

2) Capacities and ratings

Maker: SEUN ELECTRIC

No. of sets: 1 set
Equalizing Voltage: DC28V
Floating Voltage: DC26.7 ~ 27.2V
Electric Power: AC 440V, 3phase, 60Hz
DC rated current : DC24V, 150A
Max. charging – 200A
IP Grade: IP 22

3) Alarm and Indication Lamps as follows

(1) Input Power Fail (Setting Point : 50sec)

(2) Earth Leakage (Setting Point : 5kΩ)
(3) Over Current (Setting Point : 157.5A)
(4) Output Under Voltage (Setting Point : 21.6V)
(5) Output Over Voltage (Setting Point : 30.8V)

Final Draft / 2007.12.28 2 - 86 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.13.1a Provision Refrigeration System

Fan Switchbo ard

Meat Room Fish Room Vegetable Room Dairy Room Lobby Room
(30.1 m 3) (20.2 m 3) (40.1 m 3) (20.2 m 3) (31.5 m 3)
HFS-4-SS HFS-4-SS HFS-3 HFS-1 HFS-1
GBC12S

GBC12S

GBC12S

GBC12S

GBC12S
BMSL6S

BMSL6S

TS.2-0.4,5(01)

TS.2-0.45(01)

TS.2-0.45(01)
TES2-1.2(03)

TS.2-1.3(03)

KVP22
GBC28S NRV28S

GBC28S NRV28S

GBC16S KVP15

GBC16S KVP15
GBC10S EVR6

GBC10S EVR6

GBC10S EVR6

GBC10S EVR6

GBC10S EVR6
Wall Mounting

GBC22S
Key Vent to Open Air
Refrigerant Gas Line
Refrigerant Liquid Line
Lubricating Oil Line

HE8.0
Fresh Water Line
Drain Line

Compressor Switchboard

P P
P P
Oil Oil
Separator Separator

[Engine Room]
No.2 No.1
P Compressor Compressor P

TI IT
Cool Fresh Water Out No.2 Provision No.1 Provision
Cool Fresh Water In Refrigeration Condenser Refrigeration Condenser
Shore Connection TI IT
Shore Connection

P P

Liquid
Charging
Valve

Final Draft / 2007.12.28 2 - 87 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.13 Accommodation Services sump will drop. When the system is charged to full capacity the excess oil will While running:
be separated out and returned to the sump.
2.13.1 Provision Refrigeration System During the operation the level as shown in the condenser level gauge will drop. a) Check the inlet and outlet pressure gauges
If the system does become undercharged, the whole system should be checked
1. General for leakage. When required, refrigerant can be added through the charging line, - High pressure control KP5: cut out: 19.5bar
after first venting the connection between the refrigerant bottle and the charging cut in: manual reset
The cooling unit for the meat room, fish room, and vegetable room is provided connection. The added refrigerant is dried before entering the system. Any trace
by a direct expansion R-404A system. of moisture in the refrigerant system will lead to problems with the thermostatic - Low pressure control KP1: cut out: 0.9bar
expansion valve icing up and subsequent blockage. cut in: 1.9bar
The plant, which is situated in the engine room on the 1st deck starboard side is
automatic and consists of two compressors two condensers, and an evaporating 2. Specification - Oil pressure control MP55: cut out: 0.4bar
air cooler in each of the seven cold rooms. Air in the cold rooms is circulated cut in: manual reset
through the evaporator coils by electrically driven fans. The meat room and fish Compressor time delay 60 sec
room evaporators are equipped with a timer controlled electric defrosting Maker: HI-PRES KOREA
element. The frequency of defrosting is controlled by means of a defrosting relay No. of sets: 2 b) Cool. Water Pressure Control: cut out: 0.4bar
built into the starter panel. Model: SBO42 cut in: 0.8bar
No. of cylinder 4
Under normal conditions one compressor/condenser unit is in operation, with the c) Check the oil level and oil pressure.
other on stand-by but on manual start up, with all valves shut until required. Condenser
Model: CRKF 271230 d) Check for leakages.
The plant is not designed for continuous parallel operation of the two systems No. of sets: 2
because of the risk of a transfer of Lubricating oil between the compressors. For 2) To Put the Cold Chamber System into Operation
bringing down the room temperatures after storing in tropical climates, both 3. Operating Procedures
compressors may be run in parallel operation for a short period only. (1) Open the refrigerant supply to one cooler room.
1) To Start the Refrigeration Plant
The compressor draws R-404A vapour from the cold room cooling coils and (2) Open the refrigerant returns from the cooler room.
pumps it under pressure to the central fresh water cooled condenser where the (1) All stop valves, except the compressor suction, in the refrigerant line
vapour is condensed. The liquid refrigerant is returned through a dryer unit and should be opened and fully back seated to prevent the pressure in the (3) Repeat the above for each of the cooler room.
filtered to the cold room evaporators. valve reaching the valve gland.
4. Defrosting
The compressors are protected by high pressure, low pressure and low (2) The crankcase heater on the compressor to be used should be
lubricating oil pressure cut-out switches. Each unit is also fitted with a crankcase switched on least three hours prior to starting the compressor. The air coolers in the meat room and fish room are fitted with electrical
heater. A thermostat in each room enables a temperature regulating device to defrosting i.e. the evaporator and drip trays are provided with electric heating
operate the solenoid valves independently, in order to reduce the number of starts (3) Check that the oil level is correct. elements. The frequency of defrosting is controlled by means of a defrosting
and the running time of the compressor. The air coolers accept the refrigerant as relay built into the starter panel. The defrosting sequence is as follows:
it expands into a super-cooled vapour under the control of the expansion valves. (4) Start up the ancillaries, pumps etc.
This vapour is then returned to the compressor through the non-return valves. 1) The compressor stops and all solenoid valves in the system close.
When all the solenoid valves at the air coolers are closed by the room (5) Open the valves for the condenser water. Check to make sure there is The fans in the meat room and fish room stop working but the fans in the
thermostats, the low suction pressure switches will stop the compressors. sufficient flow. other rooms continue the circulation of the warm air over the coolers, in
this way keeping the cooling surfaces free from ice.
A back pressure controlled constant pressure valve is included in the vegetable to (6) Open the suction valve one turn.
prevent these rooms dropping too far below the normal set point. This would 2) The electric heating elements in the meat and fish room switch on.
damage the provisions, should the inlet solenoid valve fail to close properly. (7) Start the compressor. As long as the coolers are covered with ice, the melting takes nearly all of
the heat supplied and the temperature of the cooler and the refrigerant is
Any leaks of refrigerant gas from the system will result in the system becoming (8) Continue opening the suction valve slowly, taking care not to allow constantly kept near zero. When the ice has melted, the refrigerant
undercharged. The symptoms of a system undercharge will be low suction and liquid into the compressor and keeping the suction pressure above the temperature rises in the meat and fish rooms. When the temperature
discharge pressures with the system eventually becoming ineffective. Bubbles cut out point. reaches the set point (approximately +10°C) of the defrosting thermostat,
will appear in the sight glass. A side effect of low refrigerant gas charge is the heating elements are switched off.
apparent low lubricating oil level in the sump. A low charge level will result in
excess oil being entrapped in the circulating refrigerant, thus the level in the

Final Draft / 2007.12.28 2 - 88 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.13.1a Provision Refrigeration System

Fan Switchbo ard

Meat Room Fish Room Vegetable Room Dairy Room Lobby Room
(30.1 m 3) (20.2 m 3) (40.1 m 3) (20.2 m 3) (31.5 m 3)
HFS-4-SS HFS-4-SS HFS-3 HFS-1 HFS-1
GBC12S

GBC12S

GBC12S

GBC12S

GBC12S
BMSL6S

BMSL6S

TS.2-0.4,5(01)

TS.2-0.45(01)

TS.2-0.45(01)
TES2-1.2(03)

TS.2-1.3(03)

KVP22
GBC28S NRV28S

GBC28S NRV28S

GBC16S KVP15

GBC16S KVP15
GBC10S EVR6

GBC10S EVR6

GBC10S EVR6

GBC10S EVR6

GBC10S EVR6
Wall Mounting

GBC22S
Key Vent to Open Air
Refrigerant Gas Line
Refrigerant Liquid Line
Lubricating Oil Line

HE8.0
Fresh Water Line
Drain Line

Compressor Switchboard

P P
P P
Oil Oil
Separator Separator

[Engine Room]
No.2 No.1
P Compressor Compressor P

TI IT
Cool Fresh Water Out No.2 Provision No.1 Provision
Cool Fresh Water In Refrigeration Condenser Refrigeration Condenser
Shore Connection TI IT
Shore Connection

P P

Liquid
Charging
Valve

Final Draft / 2007.12.28 2 - 89 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

3) The compressor starts.

When the coil surface temperature has gone below the freezing point, the
fans in the meat and fish start. The system is now back on the
refrigerating cycle again. If the defrosting is not completed at the
expiration of the predetermined defrosting period, the defrosting will be
restarted by the timer and a new cycle will commence.

5. System Running Checks at Regular Intervals

- Lubricating oil levels in the crankcase

- Lubricating oil pressure

- Moisture indicators

- Suction and discharge pressure and temperature and any unusual

variations investigated

- Check all room temperatures and evaporation coils for any sign of
frosting

6. The following conditions register in the central alarm system:

- Power failure

- Overcurrent trip

- High pressure trip

- Oil low pressure trip

- Cold room high temperature alarms

Final Draft / 2007.12.28 2 - 90 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.13.2a Accommodation and Air Conditioning Plant

Final Draft / 2007.12.28 2 - 91 Part 2 Machinery System

CLEAN FORCE
2.13.2 Accommodation and Air Conditioning Plant
1. General
Air is supplied to the accommodation by two identical air handling units located
in the accommodation on the Upper Deck. Each unit consists of an electrically
driven fan drawing air through the following sections:
- Mixing chamber for fresh and recirculated air
- Filter
- Heating section with steam
- Cooling section with refrigerant R-404A
- Humidifying section with steam
- Water eliminator section
The air is forced into the distribution trunk, which supplies the accommodation.
Air may be drawn into the system either from outside, or from the
accommodation via the recirculation trunk. With heating or cooling coils in use,
the unit is designed to operate on 36.8% return air supply. The ratio of
circulation air may be varied manually, using the damper in the inlet trunking.
The inlet filters are of the washable mat type, and heating is provided by coils
supplied by steam from the 6.0 bar system.
Cooling is provided by a direct expansion R-404A system. The plant is
automatic and consists of two compressor/condenser/dryer units, supplying two
(2) evaporator coils, in each of the two separate air handling units in the
accommodation.
Under emergency conditions it is possible that one compressor can serve both
of the air handling units by opening the cross connections on the delivery and
return lines.
Note
At no time must the cross connection valves be opened while both
compressors are in service
Direct expansion coils achieve cooling of the air. The coils are fed with
refrigerant from the air conditioning compressor as a superheated gas, which is
passed through the condenser where it is condensed to a liquid. The liquid R-
404A is then fed via filter drier units to the cooling coils where it expands,
under the control of the expansion valves, before being returned to the
compressor as a gas.
The compressor is fitted with an internal oil pressure activating unloading
mechanism, which affords automatic starting and variable capacity control. A
high and low pressure cut out switch and low Lubricating oil pressure trip
protects the compressor. A crankcase heater and cooler are fitted.
Any leakage of refrigerant gas from the system will result to the system
becoming undercharged. The symptoms of system undercharge will be low
Final Draft / 2007.12.28
Machinery Operating Manual
suction and discharge pressure, with the system eventually becoming (4) Check the oil level.
ineffective.
(5) Check the settings of the compressor safety devices.
A side effect of low refrigerant gas charge is an apparent low oil level in the
sump. A low charge level will result in excess oil being entrapped in the (6) Start up the ancillaries, cooling water pumps etc.
circulating refrigerant gas, thus the level in the sump will drop. When the
system is charged to full capacity, this excess oil will be separated out and (7) Open the valves for the condenser cooling water. Check there is
returned to the sump. During operation, the level as shown in the receiver level sufficient flow.
gauge will drop. If the system does become undercharged the whole system
pipe work should be checked for leakage. If a loss of gas is detected, additional (8) Set the capacity regulator to minimum capacity.
gas can be added through the charging line, after first venting the connection
between the gas bottle and the charging connection. The added refrigerant is (9) Open the compressor suction valve slightly. This will prevent excessive
dried before entering the system. Any trace of moisture in the refrigerant will pressure reduction in the compressor on start up, high could cause oil
lead to problems with the thermostatic expansion valve icing up and subsequent foaming in the crankcase.
blockage. Cooling water for the condenser is supplied from the low temperature
fresh water cooling system. (10) Start the compressor.
2. Specification (11) Continue opening the suction valve slowly until fully back-seated,
taking care not to allow liquid into the compressor, and keep the
Compressor suction pressure above the cut out point.
Maker: YORK
No. of sets: 2 (12) Open the main valve in the liquid line.
Model: CMO28
Speed 1,770rpm 3) Compressor Running Checks
Condenser - The Lubricating oil pressure should be checked at least daily.
Model: CRKC502320
No. of sets: 2 - The oil level in the crankcase should be checked daily.
3. Procedure for the Operation of the Air Conditioning System - The suction and discharge pressure should be checked regularly.
1) To Start the Ventilation System - The temperature of oil, suction and discharge should be checked
regularly. A regular check on the motor bearing temperatures should
(1) Check that the air filters are clean. also be kept.
(2) Set the air dampers to the outside position. - Check on any undue leakage at the shaft seal.
(3) Start the supply fans.
2) To Start the Air Conditioning Compressor
(1) All stop valves in the refrigerant line should be opened (except for
the main valve in the liquid line) and fully back seated to prevent the
pressure in the valve reaching the valve gland.
(2) Open the compressor discharge valve.
(3) The crankcase heater on the compressor to be used should be
switched on a three hours prior to starting the compressor.
2 - 92 Part 2 Machinery System
CLEAN FORCE Machinery Operating Manual

Illustration 2.13.2a Accommodation and Air Conditioning Plant

Final Draft / 2007.12.28 2 - 93 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

4) To Stop the Compressor for Short Periods procedure.

(1) Reduce the capacity regulator to the minimum setting. (1) Throttle the suction valve until the suction pressure is slightly below
atmospheric. It will be necessary to reduce the setting of the low
(2) Close the condenser liquid outlet valve. pressure cut out.

(3) Allow the compressor to pump down the system so that the low-level (2) Connect a pipe to the oil charging valve, fill the pipe with oil and
pressure cut-out operates. insert the free end into a receptacle containing refrigerator oil.

(4) Close the filter outlet valve. (3) Open the charging valve carefully, allowing atmospheric pressure to
force the oil into the crankcase and avoiding ingress of air.
(5) Isolate the compressor motor.
(4) Reset the low pressure trip.
(6) Close the compressor suction valve.

(7) Close the compressor discharge valve.

(8) Close the inlet and outlet valves on the cooling water to the condenser.

(9) Switch on the crankcase heater.

5) To Shut Down the Compressor for a Prolonged Period

If the cooling system is to be shut down for a prolonged period, it is
advisable to pump down the system and isolate the refrigerant gas charge
in the condenser.

Leaving the system with full refrigerant pressure in the lines increases the
tendency to lose charge through the shaft seal.

(1) Shut the liquid outlet valve on the condenser.

(2) Run the compressor until the low pressure cut-out operates.

(3) After a period of time the suction pressure may rise as the evaporators
warm up, in which case the compressor should be allowed to pump
down again, until the suction pressure remains low. It may be
necessary to reduce the setting of the low pressure cut out.

(4) Shut the outlet valve from the filter.

(5) Shut the compressor suction and discharge valves.

(6) Close the inlet and outlet valves on the cooling water to the condenser.

(7) The compressor discharge valve should be marked closed and the
compressor motor isolated, to prevent possible damage.

6) Adding Oil to the Compressor

Oil can be added to the compressor while running by using an oil pump
connected to the oil charging connection or by using the following

Final Draft / 2007.12.28 2 - 94 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.13.3a Package Air Conditioner

ELEVATOR

CONDENSATE DRAIN
(JIS 5K 25A FLAGNE)

SAFETY VALVE OUTLET

(JIS 5K 15A FLANGE)

LP DPS LP LP DPS LP

No. 1 No. 2
COMPRESSOR COMPRESSOR

No. 1 CONDENSER No. 2 CONDENSER

COOLING WATER IN COOLING WATER IN

COOLING WATER OUT COOLING WATER OUT

Final Draft / 2007.12.28 2 - 95 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.13.3 Package Air Conditioner 2. Boiler Test Room 2) Stop the compressor.

1. General Comprising a fan, compressor, refrigerant circuit, filters and controls, these are 3) Close the compressor stop valves on the suction and discharge lines.
all self-contained and are air cooled.
Each unit consists of an electrically driven fan drawing air through the 4) Switch off the cooling ON/OFF selection switch.
following sections: (1) Model : HIP-3WGE

Mixing chamber for fresh and recirculated air (90%) Capacity : Cooling Capacity – 9,000kcal/H
Filter Heating Capacity – 8,600kcal/H
Heating coils
Evaporator coils Type: Package type
Fan
Refrigerant : R-404A
The air is forced into the distribution trunk, which supplies the engine control
room. The inlet filters are the washable mat type. 3. Work Shop

Cooling is provided by a direct expansion R-404A system. The plant is Comprising a fan, compressor, refrigerant circuit, filters and controls, these are
automatic and consists of two compressor, condenser units, supplying all self-contained and are air cooled.
evaporator coils, one in each of the two separate air handling units in the engine
room. Each compressor and condenser unit has 50% of the total capacity (1) Model : HIP-20WGDE
requirement and, under normal conditions, two compressors would be in use,
each supplying their own air handling unit. Direct expansion coils achieve Capacity : Cooling Capacity –54,000kcal/H
cooling of the air. The coils are fed with refrigerant from the air conditioning Heating Capacity – 43,000kcal/H
compressor as a superheated gas, which is passed through the condenser where
it is condensed to a liquid. The liquid R-404A is then fed via filter drier units to Type: Package type
the cooling coils where it expands, under the control of the expansion valves,
before being returned to the compressor as gas. Refrigerant : R-404A

The compressor is fitted with an internal oil pressure activated unloading 4. Procedure for the Operation
mechanism, which affords automatic starting and variable capacity control. A
high and low pressure cut out switch and low lubricating oil pressure trip (1) Starting
protects the compressor. A crankcase heater and cooler are fitted.
1) Open the condenser refrigerant inlet and outlet valves.
Any leakage of refrigerant gas from the system will result in the system
becoming undercharged. The symptoms of system undercharge include low 2) Make sure that the air filter is clean.
suction and discharge pressure, and an ineffective system.
3) Turn on the power switch at least six hours beforehand.
A side effect of low refrigerant gas charge is an apparent low oil level in the
sump. A low charge level will result in excess oil being entrapped in the 4) Start the fan.
circulating refrigerant gas, thus the level in the sump will drop. When the
system is charged to full capacity, the excess oil will be isolated and returned to 5) Start the compressor by switching on the cooling ON/OFF
the sump. During operation, the level in the condenser level gauge will drop. If selection switch.
the system becomes undercharged, the whole system pipe work should be
checked for leakage. (2) Shutting Down

1) Close the condenser refrigerant outlet valve.

2) Allow the compressor to shut down on the low suction pressure

trip.

Final Draft / 2007.12.28 2 - 96 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Illustration 2.14.1a Fresh Water General Service System

(P) F.W Filling (S) From/To To Accommodation To Accommodation To Fresh Water

Accommodation Fresh Water Sanitary Water Hydrant
To Galley Fire Fighting System Service (Compressor Room (S))
Upper Deck Upper Deck
FS
55V Silver Ion

12V

(A)
Sterilizer
(5,000 L) Key
Steering Gear Room

51V
69V SF-1 Fresh Water
Line
Mineralizer Drinking Hot Fresh

S
(5,000 L/H)

45V
Drinking Water Water Line
Sett. Fountain 22V
LIAHL Water 6 bar Air Line
IAS Tank (P)
(197.1 m3) 44V Drain Line
37V Wash
LX
Basin
68V Ultra Violet
Toilet

35V
Sterilizer
(2,000 L/H) 36V To Deck Washing Tub
Scupper (For Boiler
Distilled E/R Toilet
Water Water Test)
LIAHL
IAS Tank (P)
(268.4 m3) 49V
LX

To Auxiliary Condensate 14V

To Deck Scupper
Water System E/Casing (C-Deck)
On : 5.5 bar F.W Service
PI PS PS Wash Basin 53V
9 bar Air Off : 6.5 bar (In Workshop)
5V 6V 7V 8V
Work Shop F.W. Service
27V No.2 Sett.
7.2 bar To Main Cooling F.W
Drinking 28V Expansion Tank
PI F.W Trans. Water
Pump 26V No.1 2nd Deck F.W Service
Hyd. Unit
(25 m3/h (1,000 L) To Deck Scupper 20V 50V
CI x 25 MTH) To I.G.G. Jacket Rinsing
Pump No.1 & 2
(6 m3/h x 65 MTH) To I.G.G. Tower Rinsing
1V 2V 9V
15V

To I.G.G. Cooler
PI PS PS
On : 6 bar 18V
9 bar Air Off : 7 bar I.G.G. Air Dryer Cleaning
I.G.G. Ref. Cooler
24V No.2 Sett. 54V
7.7 bar (20 m) Generator Engine T/C
F.W 25V Cleaning
Cooling 11V

3V
Water 23V No.1 Hyd. Unit To Water Washing for

43V
Tank (2,000 L) PI PI
Compressor Side (G/E)
(70.7 m3) No.2 AFT FW-31V
39V 41V B/H Steering Gear Room
Pump No.1 & 2 Sett.
(10 m3/h x 70 MTH) 8.8 bar Fresh Water Service
FW-30V

PI
PI PI
Steering Gear Room No.1 Poop Deck F.W Service

TI
38V 40V
No.2 Distilled Plant No.1 Distilled Plant Calorfier To Hot Foam System
(60 Ton/day) (60 Ton/day) (1,500 L)
To Air Control Unit of 42V

58V
Distilled 67V Hot Water S/T System (Cleaning) Floor Fresh
To Deck Circulating Pump Water Service
LIAHL Water Scupper
IAS Tank (S) SX SX (2 m3/h x 10 MTH)
10V Oily Bilge Separator Filling
(268.4 m3) 48V
S S
LX 4th Deck Fresh Water
To Bilge Main Line Service (Near F.W Gen.)
S

To Purifier 47V
(For Rinsing Water) Salinity Salinity Operating Floor F.W Service
Domestic FI Panel FI Panel Water System
Fresh 66V 57V PI PI 46V
LIAHL Water 3rd Deck (AFT)
IAS To Deck Fresh Water Service
Tank (S) To Distilled Scupper
13V 19V Plant Chem. 34V
(197.1 m3) 60V 3rd Deck (FWD)
17V

16V

LX 21V Dosing Unit Fresh Water Service

4V
Chemical Store Shower

Final Draft / 2007.12.28 2 - 97 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

2.14 Fresh Water General Service Systems 5) Close the air supply. 2.14.2 Distilled Water Filling Service System

2.14.1 Fresh Water General Service System
1. General
3
Domestic fresh water and Drink water tank is stored in 197.1m fresh water tanks
port and starboard, both equipped with level transmitters for alarm generation.
Drinking water is stored in port side tank, and domestic fresh water is stored in
starboard side. The tanks provide drinking water and water to general services
throughout the ship. The tanks can be filled either from fresh water generators or
via shore connections.
6) Repeat steps (2)~(5) until the tank is at the operating pressure, with the
water level at about 75%.
7) Switch one hydrophore pump to automatic operation.
8) Open the hydrophore tank outlet valve slowly, until the system
pressurises.
9) Start one hot water circulating pump.
10) Vent air from the calorifier.
1. General
Distilled water is stored in 268.4 m3 water tanks port and starboard, both
equipped with level transmitters for alarm generation. The tanks can be filled
either from fresh water generators or via shore connections.
The distilled water system serves the following:
- Condensate make- up for the boilers
- Emergency feed for boiler feed pumps via valve

Fresh water is supplied to general services via a 2m3 hydrophore tank, 11) Start the electric heater for the calorifier. - Spill return from condensate drain pump system
pressurized to 7 bars. Two pumps in a duty standby configuration supply the
tank. The pumps are controlled and monitored from IAS. A thermostatically 12) Switch the other supply pump to stand-by. 2. Control and Alarm Settings
controlled heater uses steam or electricity to provide hot water, which are being
circulated to avoid extensive run off to get hot water at outlets. 13) Supply steam to the calorifier when steam is available. IAS No. Description Alarm

The fresh water system supplies the following 14) Shut down the electric heater. FW005 DIST WATER S TK LEVEL H/L 5.45/0.7m

FW006 DOM WATER S TK LEVEL H/L 5.45/0.7m

- Sanitary system
FW018 DIST WATER P TK LEVEL H/L 5.45/0.7m
- Cooled fresh water for accommodations
FW019 DOM WATER P TK LEVEL H/L 5.45/0.7m
- Hot water service for accommodations
3. IAS Display
- L.O. & D.O. purifier operating water system

- Inert gas fan washing

- Fresh water cooling system header tank

- Chemical dosing unit

- Oily water separator

- Auxiliary engine turbocharger cleaning and hot foam system

2. Preparation for the Operation of the Fresh Water System

1) Start one FW hydrophore pump.

2) Fill the hydrophore tank to about 75%.

3) Stop the pump.

4) Crack open the air inlet valve to the tank until the operating pressure is
reached.

Final Draft / 2007.12.28 2 - 98 Part 2 Machinery System

CLEAN FORCE Machinery Operating Manual

Part 3 : Integrated Automation System (IAS)

3.1 General Principles of the IAS ............................................................ 3 - 3

3.1.1 General.................................................................................... 3 - 3
3.1.2 IAS System Lay-out ............................................................... 3 - 3
3.1.3 Alarm and Monitoring ............................................................ 3 - 4
3.1.4 Log in and Access System ...................................................... 3 - 4
3.1.5 System Navigation .................................................................. 3 - 5
3.1.6 OS Group/Command Group ................................................. 3 - 5
3.2 Alarm Extension System.................................................................... 3 - 6
3.2.1 Functional Description ............................................................ 3 - 6
3.2.2 Panel Operation ...................................................................... 3 - 7

Illustrations

3.1a IAS Overview .................................................................................. 3 - 2

3.1.2a Engineer’s Alarm System Logic ................................................... 3 - 4
3.1.5a Navigation Panel Lay-out ............................................................. 3 - 5
3.2a Alarm Extension System .................................................................. 3 - 6
3.2b Watech Cabin Unit ........................................................................... 3 - 6
3.2c Extension Panel Alarm Indicators ................................................... 3 – 6

Part 3
Integrated Automation System (IAS)
Part 3 Integrated Automation System (IAS)
CLEAN FORCE Machinery Operating Manual

Abbreviations LT Low Temperature

LV Low Voltage (440V / 220V systems)
ABC Automatic Boiler Control MCC Motor Control Center
ASC Anti Surge Control MCR Maximum Continuous Rate
ASV Anti Surge Valve MHI Mitsubishi Heavy Industries
AVR Automatic Voltage Regulation MT Main Turbine
BGB Boiler Gauge Board NDU Network Distribution Unit
BOG Boil Off Gas OS Operator Station
CCR Central Control Room PMS Power Management System
CTS Custody Transfer System PP Pump
DG Diesel Generator PV Process Variable
DO Diesel Oil RCS Remote Control System
DP Differential Pressure RCU Remote Control Unit
ER Engine Room RIO Remote Input Output
ECR Engine Control Room RPB Remote Push Button
ELA Electric Load Analyses SP Set Point
EOP Emergency Operator Panel SVC Simrad Vessel Control
EOT Engine Order Telegraph SW Sea Water
ESD Emergency Shutdown TG Turbine Generator
ESDS Emergency Shutdown System UVR Under Voltage Release
F&G Fire & Gas UVT Under Voltage Trip
FDF Forced Draft Fan VDU Video Display Unit
FDS Functional Design Specification VV Valve
FO Fuel Oil
FS Field Station (Cabinet with controller and/or RIO
modules)
FW Fresh Water
GMS Graphic Modeling System
HD High Duty
HFO Heavy Fuel Oil
HS Hand Switch
HT High Temperature
HV High Voltage
I/O Input / Output
IAS Integrated Automation System
IGC code International Code for the Construction and
Equipment of Ships carrying Liquefied Gases in Bulk.
IGV Inlet Guide Vane
KM Kongsberg Maritime
LD Low Duty
LNG Liquefied Natural Gas
LO Lubrication Oil
LR Lloyds Register

Final Draft / 2007.12.28 3-1 Part 3 Integrated Automation System (IAS)

CLEAN FORCE Machinery Operating Manual

Illustration 3.1a IAS Overview

OS 34 OS 35
C B Inkjet Printer Alarm Printer Alarm Printer A

Watch Call Panel x 13

No.2 LV Switchboard Room No.1 LV Switchboard Room

NDU-A2 FS-46 FS-44 FS-42 FS-45 FS-43 FS-41 NDU-B2

Boiler Control Panel 2 SPBus (FS-46) SPBus (FS-45) Boiler Control Panel 1
RIO Modules RIO Modules

Group Start Panel 2 SPBus (FS-45) SPBus (FS-45) Group Start Panel 1
RIO Modules RIO Modules
GSP 2 BCP 2 BCP 1 GSP 1

Patrol Alarm System 3 x start/stop

Remote Remote Remote Remote Hardware I/O (FS-41)
I/O I/O I/O I/O
Units Units Units Units

2 x SPBus, 2 x RIO Power (FS-42) 2 x SPBus, 2 x RIO Power (FS-41)

Key
A-net 2 x SPBus, 2 x RIO Power (FS-46) 2 x SPBus, 2 x RIO Power (FS-45)
B-net
C-net
SPBus
Power Management System (Hyundai, FS-42) Ship Performance Monitor (Kyma, FS-41)
Serial Line
Canbus Oil Mist Detector (FS-42) Power Management System (Hyundai, FS-41)

Hardware I/O E/R Tank Level (FS-42)

Final Draft / 2007.12.28 3-2 Part 3 Integrated Automation System (IAS)

CLEAN FORCE Machinery Operating Manual

Part 3 : Integrated Automation System (IAS) 7) Ballast Control System These can be installed in a number of different ways, for example in a standard
Kongsberg Maritime console or as separate units for desktop operation.
3.1 General Principles of the IAS 8) Trend Function
2. Field Stations
3.1.1 General 3.1.2 IAS System Lay-Out
Twelve Field Stations (FS) are installed in the system. All logic with respect to
The IAS is a distributed monitoring and control system, which due to its 1. Operator Stations control and monitoring is located in the field stations.
flexibility and modular architecture can be extended to cover a wide range of
applications and types of vessels. Five Operator Stations (OS) and one (1) Historical Station (for trend) are FS
S/
Location Type PS RCU Redund Remark
installed in the system. OS no.31 located in Wheelhouse will be with Line

integrated history station for event. Dual Profibus to FS31-

The IAS is built from a full range of hardware and software modules to form IAS I/O FS 400-
1, Redundant serial
FS31 -x5 cabinet R1 NON Dual CPU
optimum solution to any requirement. Normal configuration of the IAS includes room IS
lines to be split on
HS / different TBSS cards.
machinery control and monitoring, propulsion/thruster control and monitoring as OS Location Type Screen Printer Remark
WCI IAS I/O
well as cargo and ballast control and monitoring integrated in the same FS31
- cabinet
FS-240 Includes Stah1 remote
Alarm - To be installed in -1 IS IS modules
equipment. All connected equipment can be controlled from any operator station OS32 - CCR Built-in Dual
Printer CCR console room
throughout the vessel. Alarm - To be installed in IAS I/O FS 400-
Dual Profibus to FS32-
OS33 - CCR Built-in Dual 1, Redundant serial
Printer CCR console FS32 -x3 cabinet R1 NON Dual CPU
lines to be split on
All operator stations and field stations are self-contained units and independent room IS
Alarm - To be installed in different TBSS cards.
OS34 WCI ECR Built-in Dual
of the other units, i.e. a failure in one station will not cause any other station to Printer ECR console IAS I/O
FS32 FS-240 Includes Stah1 remote
break down. All process logic including equipment safety and control functions Alarm - To be installed in - cabinet -
OS35 WCI ECR Built-in Dual -1 IS IS modules
Printer ECR console. room
are contained in the respective field station controller.
- History station for IAS I/O
OS31 W/H Built-in Dual - event to be installed FS33 - cabinet FS-400
Each operator station contains a hard with all system configuration and acts as in W/H for console room
backup for each other during system start-up. System configuration / update can Lap To be installed in chief IAS I/O
OS40 Single - FS34 - cabinet FS-400
be done on-line without need of any additional equipment. Top engineer day room
room
No.1 LV FS 400- Connected to RIO
A sophisticated login / password system protects the system against mal FS41 -x3 Swbd R1 NON Dual CPU modules located in
Room IS GSP1
operation.
No.2 LV FS 400- Connected to RIO
FS42 -x3 Swbd R1 NON Dual CPU modules located in
The IAS supports trend facilities and alarm / event recording. Process events and Room IS GSP2
alarms are stored on hard discs and can be recalled on request. Monitor No.1 LV FS 400-
FS43 - Swbd R1 NON Dual CPU
Room IS
Redundant network based on the Ethernet principle is installed as standard. The
No.2 LV FS 400-
two nets are installed in different cable paths as far as possible. Each unit is FS44 - Swbd R1 NON Dual CPU
interfaced to both nets and if a failure on one net is detected, the system will Room IS
automatically use the healthy net. No.1 LV FS 400- Connected to RIO
FS45 Swbd R1 NON Dual CPU modules located in
Room IS BCP1
IAS Main Tasks No.2 LV FS 400- Connected to RIO
FS46 Swbd R1 NON Dual CPU modules located in
Room IS BCP2
1) Cargo Control System

2) Gas Handling (Heaters – Vaporizers) Operator Panel - FS - 400R1 NON IS : Cabinet for maximum 384 IO’s, Dual processor
The Operator Stations (OS) are the main interface between the operator and the and power supply
3) Engine Room Alarm and Monitoring processes that are under the operator’s control.
- FS - 400 : Cabinet for maximum 384 IO’s.
4) Cargo System Alarm and Monitoring An OS has three main parts:
y A colour monitor - FS 240 IS : Cabinet for approximately 180 IO’s, All IS Loops. Profibus
5) Alarm / Event Recording y An operator panel with buttons and a trackball connection to RCU’s at field station.
y A graphics controller (computer)
6) Alarm Extension / Patrol Man System

Final Draft / 2007.12.28 3-3 Part 3 Integrated Automation System (IAS)

CLEAN FORCE Machinery Operating Manual

3. Printers Cargo Watch Public panel 7. Operator Panel Relay Kit:

8 Yes Yes -
Office Cabin type setup
Six printers are installed in the system. Four of them are alarm printers and All operator stations will have installed a relay kit used for activation of
Officers Watch Public panel
two of them are hard copy printers. The alarm printers will be connected to an 9 Yes Yes - ‘alarm columns’. The relay will be triggered in parallel with the panel alarm
mess room Cabin type setup
operator station through a standard parallel port while the hard copy printers buzzer. Electrically the relay will be interfaced to one of the field stations
will be connected to operator stations through the IAS administrative network Public panel which again are interfaced to alarm columns.
Officers Watch
(C-net). 10 Yes Yes - type setup,
lounge Cabin
extra buzzer 3.1.3 Alarm & Monitoring
S/ Locat Type Colour Crew mess Watch Public panel
Printer Printer Remark 11 Yes Yes -
Line ion Printer /Matrix The Alarm and Monitoring system is an integrated function within the IAS
room Cabin type setup
Epson Alarm system. All alarms from the different sub-systems, such as cargo systems, power
1 OS32 CCR Matrix - Chief Cabin panel
LX-300 /Event
Watch distribution system, engine room auxiliaries, etc. are pooled via the redundant
Epson Alarm 12 Yes Officer Yes CCR type setup,
2 OS33 CCR. Matrix - Cabin network to form a uniform alarm system for the vessel.
LX-300 /Event Bed room extra buzzer
Epson Alarm
3 OS34 ECR Matrix - Crew Watch Public panel
LX-300 /Event 13 Yes Yes - Alarms are indicated on the video display units of the IAS operator stations.
Epson Alarm lounge Cabin type setup,
4 OS35 ECR. Matrix - They will also activate the buzzer in the IAS keyboard.
LX-300 /Event
Public panel
- Default Duty mess Watch
HP Hard 14 Yes Yes - type setup, Alarms and events (e.g. pump start / stop, valve open / closed) are logged by the
printer for room Cabin
5 - ECR Business Colour Copy
OS34, extra buzzer system and can be printed on an alarm/event printer. Such information is also
Inkjet2300 (Network)
OS35
stored in the history station and can be recalled on request.
- Default for
HP Hard 5. Patrol Man System:
OS32
6 - CCR Business Colour Copy
Inkjet2300 (Network)
OS33 and The alarm system supports three priority levels, which are marked with different
OS31
Three start panels are supplied from KM. A software start panel is also colours. The alarm priority/colour coding is:
available on VDU’s.
4. Extension Alarm Panels: 1) Low priority alarms ⇒ With yellow colour
NOTE
14 Extension Alarm Panels (EAP), for unmanned engine room applications, KM are awaiting final location of start panels 2) High priority alarms ⇒ With red colour
are installed in the system.
3) Critical priority alarms ⇒ With magents colour
DMA Interfaced Type
Location Remark
Can Type LCD Managing Panel To FS Panel
WCP Location Remark
Bus WCP Type Group Critical Priority
1 FS41 - Start Low Priority Alarms High Priority Alarms
Alarms
Watch
1 Yes Wheelhous Yes - Main Panel 2 FS41 - Start Number Î 1 2 3
Bridge
3 FS41 - Start Colour Î Yellow Red Magenta
Cabin panel
C/E Watch Fire alarms and
2 Yes Yes ECR/CCR type setup, Alarms that will lead
bedroom Cabin Illustration 3.1.2a Engineer’s Alarm System Logic Pre-warning of an system related
extra buzzer to immediate action
Used for Î unwanted situation alarms like network
from the operator of
in the process error, IO-device
Cabin panel the system
nd
2 /E Watch XA Patrol Man System On failure etc.
3 Yes Yes ECR/CCR type setup, 0
≥1
(Signal Light Column)
bedroom Cabin Start Patrol Man 0
≥1
0 0
&
[W/H Extension Alarm Panel]
extra buzzer 0 0 0
XA
UMS Active & 0 0
27 min
Patrol Man Alarm Prewarming
(Signal Light Column) 3.1.4 Log-In and Access System
Active Mach Alarm
Cabin panel
Cargo Watch Reset Patrol Man timer
4 Yes Yes CCR type setup, XA Patrol Man Alarm
When logging on to the IAS operator stations, a user name and password must be
Engineer Cabin 3 min
(Signal Light Column)
extra buzzer [Engineer's Extension Alarm Panels]
entered in order to access the system. Each user is a member of a user group,
CCR Watch Public panel where access rights and user privileges are defined. The figure below illustrates
5 Yes Yes -
console Cabin type setup 6. Engineer Alarm System how users belong to user groups and the different user groups are part of the
rd
3 /E Watch Cabin panel The engineer alarm system will be interfaced with machinery spaces locally access and security system.
6 Yes Yes ECR
bedroom Cabin type setup installed push buttons. When any of these buttons are pushed IAS will relay this
th
4 /E Watch Cabin panel the EAP with machinery responsibilities and alarm with buzzer.
7 Yes Yes ECR
bedroom Cabin type setup

Final Draft / 2007.12.28 3-4 Part 3 Integrated Automation System (IAS)

CLEAN FORCE Machinery Operating Manual

By default, the following user groups are defined; 3.1.6 OS Group/Command Group The Command Group can be taken directly when this is initiated from an
User Group Description OS Group granted such privilege.
The operator stations are defined in operator station groups. For this system,
Guests Members can only monitor the system
three OS groups will be defined and they will be set up with command control A - Acquirable Control
Users Members can monitor and operate the system rights. The OS groups are as follows: The Command Group is available for the actual OS Group, but not without
Power Users Members can monitor, operate and change parameters acceptance from the OS Group in command.
- CCR (OS32, OS33)
Administrators Members have full access to the system
O - Display Command Groups
System For Kongsberg Maritime internal use only - ECR (OS034, OS035) The Command Group will be displayed in the command control overview
dialog box.
- Bridge (OS31)
By default, the following users are created:
Id
User Member of user group
To form a sensible way of operating the different systems onboard, “command The Command Group will be given an internal identifier just to separate the
Guest Guests groups” are defined for giving the operators access to different systems where different command groups. That is, these identifiers are only for internal
Operator Users
control is defined to be available. A command group can be controlled from one purposes and are not required to understand this system.
OS group exclusively or it can be shared between several OS groups. A
Captain Power Users command group can also be transferred between OS groups. Only the OS group Shared
Chief Power Users in command is granted access to operate equipment and acknowledge alarms that The Command Group is available for several OS Groups at the same time.
might occur within a command group. This system will be set up with the
Administrator Administrators
following command groups: When a command transfer is done, this will be indicated on all operator stations
in the ‘Message Manager’ box.
Password is by default the same as user name. This can be changed by members 1. Machinery
of “Administrators”, and additional users and user groups can be added. Table showing relations between OS Groups and Command Groups:
Members of a specific user group are granted access to a set of security objects. 2. Cargo
The following security objects are defined for the different groups.
OS GROUPS Bridge CCR ECR
3. Ballast Shar
Command ed
3.1.5 System Navigation Groups
Id D T A O D T A O D T A O
4. N2 Machiner
1 False X X X X X X
The operator panel comprises 20 navigation buttons for quick access to the most y
commonly used mimics. The mimic will normally have hotspots for further 5. Fire Cargo 2 False X X X X X X
navigation to related views or sub-views. Each navigation button has an alarm
indicator lamp. The lamp will start to blink if an alarm occurs at the mimic 6. ESD Ballast 3 False X X X X X X X X
linked to the navigation button or to one of the related views. An acknowledged,
N2 4 False X X X X X X X
but still active alarm will cause a steady light. 7. Low Duty Compressors
Fire 5 True X X X X X X X X X X
Illustration 3.1.5a Navigation Panel Lay-out 8. Power
ESD 6 False X X X X X X

BOILER BOILER
MB1 MB2
STEAM
MACHINERY
Each OS group is defined with a set of command group rights. The following Power 7 False X X X X X X X X
COMMON PORT SYSTEMS
defines these rights: LD
Compres 8 False X X X X X X X X
D - Default Control sors
MAIN FIRE AND
TURBINE
POWER
BILGE
KYMA The Command Group will by default be given to this OS Group when System 9 True X X X X X X X X X X X X
powering on the system. If two operator stations are defined in an OS
* Command Groups must be typed in one word in the Svc Sys Conf database.
Group and one of the operator stations is powered off, the command control
GAS IGG
will be decided by the remaining operator station. That is, if the command
CARGO MANAGEMENT
N2 BALLAST If all operator stations within an OS group are “offline”, i.e. stopped application
control is transferred to another location (OS Group) and the second
or without net communication, the system will report an alarm specifying that a
operator station is powered on again, nothing will be done regarding control
command group is without command control. The system will not automatically
location of the transferred command group.
FIRE
ESD CTS
PATROL
SYSTEM
transfer the command control to a different OS group. This must be done
AND GAS MAN
manually by the operator by simply taking the control via the command control
T - Take-able Control
dialog boxes.

Final Draft / 2007.12.28 3-5 Part 3 Integrated Automation System (IAS)

CLEAN FORCE Machinery Operating Manual

3.2 Alarm Extension System Public panel Illustration 3.2c Extension Panel Alarm Indicators
Officers Watch
10 Yes Yes - type setup,
lounge Cabin
Illustration 3.2a Alarm Extension System extra buzzer
Group
number
Description

A Boiler abnormal
Crew mess Watch Public panel B MT abnormal Extension
11 Yes Yes - panel alarm Panel text
OS31 room Cabin type setup C Machinery gas detection indicator

Machinery
D Critical alarm 1 Machinery critical
EAP
Public panel E Non critical alarm 2 Machinery non critical
Bridge Crew Watch F Dead man alarm 3 Cargo critical
12 Yes Yes - type setup, G Machinery fire alarm 4 Cargo non critical
EAP EAP lounge Cabin
extra buzzer H Machinery IAS abnormal 5 Fire

CAN Bus 6 Dead Man Alarm

EAP G1 Emergency shutdown
OS34 OS35 EAP
Public panel type G2 Gas detection
7 Repeat Alarm

ECR EAP EAP Duty mess Watch G3 Essential alarm (=> Critical alarm)
8 System
13 Yes Yes - setup, extra

Cargo
room Cabin G4 Non essential alarm (=>Non critical alarm)
EAP EAP buzzer G5 Cargo IAS abnormal
G6 Cargo fire alarm
Dual EAP EAP
Net EAP EAP The Alarm Extension system will alarm engineers/officers on duty in case any
EAP EAP monitored parameter exceeds its set value, as monitored by the alarm and
monitoring system. In the IAS system, machinery alarms will be grouped into 3.2.1 Functional Description
EAP EAP

EAP EAP
eight different groups, as indicated in IO-list from yard. In the same way, the
n number of reset
panels (Yard Suppl y) cargo alarms will be grouped into six different groups. When an alarm occurs, The ‘Alarm Extension’ system is basically an extension of the Event
FS41 EAP
system for the IAS system and this system has two main functions:
Start Star t Star t Panel Panel the alarm group will be indicated on the alarm page in the IAS system.
Pan el Pane l Pane l Reset Reset

Illustration 3.2b Watch Cabin Unit - Alarm Extension: This is a group alarm status and on-duty officer
indication facility with built-in on-duty
acceptance, fault indication and test facilities.

Alarms
- Officer Call: This is an individual and general calling
Can Type LCD Managing On
WCP Location Remark Duty facility for officers that can be activated from
Bus WCP Type Group
Select
selected vessel control locations.
Watch Switch
1 Yes Wheelhouse Yes - Main Panel
Bridge Tag The ‘Alarm Extension’ system comprises two kinds of panels:
Details
Cabin panel
C/E Watch
2 Yes Yes ECR/CCR type setup, - Watch Bridge Unit (WBU)
bedroom Cabin
extra buzzer
- Watch Cabin Unit (WCU)
nd Cabin panel
2 /E Watch
3 Yes Yes ECR/CCR type setup,
bedroom Cabin Lamp Test Sound Off The WBU and the WCU are units required by the classification society
extra buzzer
to run a vessel with unmanned engine room.
Cabin panel
Cargo Watch On the alarm extension panels, only eight alarm indicators are available
4 Yes Yes CCR type setup, The main functions of the WBU are to indicate engine room alarms on
Engineer Cabin (indicators on right side of drawing above). The last three indicators are
extra buzzer the bridge, to indicate and accept the transfer of machine watch
dedicated to repeat alarm, dead man alarm and system alarm. This means that
CCR Watch Public panel several machinery alarm groups will be mapped to two alarm indicators on the responsibility to and from the bridge.
5 Yes Yes -
console Cabin type setup extension panel. Cargo alarm groups will be mapped to another two extension
rd
3 /E Watch Cabin panel panel alarm indicators. Fire alarms will also have a dedicated alarm indicator on The main functions of the WCU are to indicate alarms with buzzer and
6 Yes Yes ECR light in the cabins and the public quarters of the engineer on duty while
bedroom Cabin type setup extension panels. All extension panels have an LCD display, where a full alarm
th text will appear for each alarm. The figure below shows the different alarm in bridge control.
4 /E Watch Cabin panel
7 Yes Yes ECR groups, and routing into extension panel alarm indicators.
bedroom Cabin type setup
The ‘Watch Call’ system is communicates with the operator stations
Cargo Watch Public panel located in the ECR by a CAN Bus Interface. Two operator stations are
8 Yes Yes -
Office Cabin type setup required and will work in a master/slave configuration, i.e. the ‘Watch
Officers Watch Public panel Call’ system will be operating with only one operator station up running
9 Yes Yes -
mess room Cabin type setup at the time. The ‘Watch Call’ system can be managed from two different

Final Draft / 2007.12.28 3-6 Part 3 Integrated Automation System (IAS)

CLEAN FORCE
managing groups:
- ECR Manager
- CCR Manager
From the operator stations in the ECR, the duty officer can be selected
for the ECR and the watch responsibility can be requested to be
transferred to and from the bridge. From the operator stations in the
CCR the duty officer for the CCR can be selected. Selecting/Changing
the duty officer must be done when watch responsibility is in the ECR.
The ‘Alarm Extension panels will be set up to belong to a unit group.
Three different main unit groups are available:
- Bridge Group
- Officer Group
- Public Group
For the officer group several groups can be defined, i.e. ‘Officer
Group1’, ‘Officer Group2’, ‘Officer Group3’, and up to ‘Officer
Group8’. The panels belonging to officer groups are defined as duty
panels whilst panels belonging to the public group are defined for
installation in public quarters.
The officer groups will be set up with a ‘Duty Officer Qualification’,
which defines the type of alarms the panel will subscribe to. Two
different types of ‘Duty Officer Qualification’ are available:
- Machinery
- Cargo
The alarm groups defined in the system will be set up to belong to either
machinery or cargo. When an alarm is triggered in the system the
‘Alarm Extension Panel Interface’ application will read the alarm group,
check which group it is belonging to (engine or cargo) and then route
the alarm to the correct duty panel(s), to all public panels and the bridge
panel if in bridge watch.
3.2.2 Panel operation
1. Alarm acknowledge during wheelhouse watch mode
Initially alarms will sound on the bridge panel, on-duty engineer panel
and on public panels.
Pressing the “Ack” button on a public panel will turn off the sound only
on the panel operated. The alarm indicator will continue to flicker until
the alarm is acknowledged, then change to a steady light. The indicator
will be turned off when the alarm condition is no longer present.
Final Draft / 2007.12.28
Machinery Operating Manual
Pressing the “Ack” button on the bridge panel will turn off the sound
only on the bridge panel. The alarm indicator will continue to flicker
until the alarm is acknowledged, then change to a steady light. The
indicator will be turned off when the alarm condition is no longer present.
Pressing the “Ack” button on the duty engineer panel will turn off the
sound on the duty panel and public panels (Bridge panel must be silenced
separately). The alarm indicator will continue to flicker until the alarm is
acknowledged, then change to a steady light. The indicator will be turned
off when the alarm condition is no longer present.
Operating the “Ack” function on the OS in the ECR (for machinery
alarms) or the OS in the CCR (for cargo alarms), will silence all panels
and give a steady alarm indication. Indicators will be turned off when the
alarm condition is no longer present.
2. Alarm acknowledge during ECR/CCR watch mode
Extension panels will only show alarm status. No sound device will be
set off.
3. Duty engineer/officer selection
To transfer machinery responsibility to bridge (bridge watch mode), the
operator must first select a duty engineer on duty from the software panel
on the VDU. The duty lamp is activated on all panels. Then the “Bridge
watch” button is then selected and the buzzer/lamp is activated at the
bridge panel. Pressing the “Bridge watch” button on the bridge panel will
accept the watch transfer and a lamp indicator will indicate bridge watch
mode. A transfer from bridge to ECR must be initiated from the ECR; a
buzzer/lamp is activated at the bridge panel. Upon acceptance from the
bridge, watch responsibility is transferred to the ECR.
If a duty engineer is selected from the software panel on the VDU,
without transferring the watch responsibility to the bridge (Harbour
mode), alarms will be routed to the duty engineer panel as well as public
panels. Repeat alarms and dead man alarms will be activated as normal
during this condition.
4. Engineer/officer call from ECR/CCR
Two types of call functions are supported, “Call Duty” or “Call all”.
The “Call Duty” operation will activate buzzer/lamps on the designated
duty engineer panel and on public panels. The “Call Duty” button will not
work unless a duty engineer is selected.
Acknowledging the call on the designated duty engineer panel will
silence all panels.
3-7
Acknowledging the call on a public panel will silence that specific panel
only. Indicator lamps will continue to flicker on all panels.
The “Call all” function is more of an emergency operation. Pressing the
“Call all” button will activate the buzzer/lamp on all panels.
Acknowledging the call on one engineer/officer panel will silence that
specific panel only. Acknowledging the call on a public panel will silence
that specific panel only.
5. Duty engineer/officer call from wheelhouse
Operating the “Call Duty” from the bridge panel will activate
buzzer/lamp on the selected duty engineer panel and on public panels.
Again, the “Call Duty” function requires that an engineer/officer actually
has been set on duty.
Acknowledge functions are the same as calls initiated from the ECR/CCR.
6. Repeat alarm
The system has two repeat alarms. Repeat alarm (one) 1 will be triggered
when an active watch call group alarm has not been acknowledged from
an operator station within a predefined time. This predefined time is
normally set to three (3) minutes. Repeat alarm (one) 1 will be given at
the bridge panel, duty engineer/officer panel and at public panels.
Repeat alarm (two) 2 is set off if the active alarm is still not
acknowledged from an operator station within a predefined time after
repeat alarm 1. Repeat alarm (two) 2 will be given at the bridge panel, all
engineer/officer panels and at public panels. Time limits should be
considered to.
1) Allow duty engineer to take action before repeat 1.
2) Notifying all engineers (repeat 2) within time limits specified by
Class requirements.
7. Patrol man alarm
When a “Patrol Man Alarm” is activated all officers with machinery
qualification are called. The public area panels will also call these officers
Part 3 Integrated Automation System (IAS)
CLEAN FORCE Machinery Operating Manual

Part 4 : Main Boiler Control System

4.1 Burner Sequences .............................................................................. 4 - 2
4.1.1 Fuel Oil Burning ..................................................................... 4 - 2
4.1.2 Gas Burning ............................................................................ 4 - 6
4.1.3 Burner Automatic Increase / Decrease .................................... 4 - 8
4.1.4 Fuel Mode Changeover ........................................................... 4 - 9
4.1.5 Fuel Oil Boost Up ................................................................. 4 - 11
4.1.6 Nitrogen Purge of Gas Supply Lines .................................... 4 - 12

Illustrations
4.1a Boiler FO & Gas Burning System ................................................... 4 - 1
4.1.1a Flowchart for Furnace Purging ..................................................... 4 - 2
4.1.1b Flowchart for Starting FO BNRs, the First FO BNR .................... 4 - 3
4.1.1c Flowchart for Starting FO BNRs, when Another FO BNR on .... 4 - 4
4.1.1d Flowchart for Stopping Fuel Oil BNRs ........................................ 4 - 5
4.1.2a Flowchart for Starting Fuel Gas BNRs ......................................... 4 - 6
4.1.2b Flowchart for Stopping Fuel Gas BNRs ....................................... 4 - 7
4.1.3a Flowchart for Burner Automatic Decrease.................................... 4 - 8
4.1.4a Flowchart for Changeover FOÎ Dual Mode ............................... 4 - 9
4.1.4b Flowchart for Changeover DualÎ GAS Mode .......................... 4 - 10
4.1.4c Flowchart for Changeover GasÎ Dual Mode ............................ 4 - 10
4.1.4d Flowchart for Changeover DualÎ FO Mode ............................. 4 - 11
4.1.5a Flowchart for Fuel Oil Boost Up ................................................ 4 - 11
4.1.6a Nitrogen Purge of Gas Supply Lines........................................... 4 - 12
4.1.6b Flowchart for N2 Purging of Main Line ..................................... 4 - 12
4.1.6c Flowchart for N2 Purging of Boiler Header................................ 4 - 13
4.1.6d Flowchart for N2 Purging of Boiler Burner ................................ 4 - 13

Part 4
Main Boiler Control System
Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

Illustration 4.1a Boiler FO & Gas Burning System

F-4V F-3V
LS
ABC To H.F.O Transfer Pump
E Control
AFT H.F.O.
281V P Air AFT Bunker
230V 231V Side Wall Tank (P)

280V
BV405-1

249V
248V
279V 278V 277V (164 m3)
LS
FI Extraction Fan
(A) No.2 No.1 (60 m3/min. x 40 mmAq) 252V
CV231 250V

SF-2

SF-1

Pipe (250A)
F.O Return
DPX
ACC
H.F.O
For Temp. TI
No.2 Main Boiler Boiler Hood Room Settling

204V
TX
H/L Alarm IAS ACC E
BV423 BV422 Control Air
F.O Boiler No.3 Burner BV424
P Tank (P)
TS LS LS LS 203V
Trip (518.1 m3)
BV405-2 BV404-1 BV404-2
BV401 LS LS LS A440 CV221 BV420
Control Air
BV425 275V

Furnace
TI From Seal BV425
F-46V

206V
Air Fan DFX PIL

218V CV031 219V

PX

Gas Header (250A)

BMS
BV423 BV422 TX ACC For F.G. Trip From G/E M.D.O
Base Burner BV424 LS LS
TX IAS
PIH
BMS
ABC Service Tank Low Sulphur

220V
BV405-2 BV404-1 BV404-2 For F.G. Trip
F.O Tank (P)

211V
BV401

F-68V
LS LS LS A440 Control Air
BV425 276V
(288.7 m3)

Control Air
For Pressure DPX For

212V
PS P
Performance

Furnace
Low Trip (F.O) PI From Seal E FI
For Pressure Air Fan Monitor
PS BV406 F-13V

210V
Low Trip (Dual) To Coaming BV425 239V
BV415

214V

213V
LS
Inside No.2 Burner BV423 BV422
For Dual PIAL PX BV424 LS LS
Burning IAS
Control Air
To No.4
BV431

F-69V
DPX
For F.O PAL BV405-2 BV404-1 BV404-2 Vent Riser
BV401 LS LS LS A440 LS
CI CI
Burning IAS
PI PI PAH PAL
21S
PI BV402 BGB IAS IAS IAS (60 Mesh)

No.2

No.1

207V
IAS From Seal BV430 LS

N2 Purge Header (50A)

On. PI BV403 Air Fan LS
TI 205V
B.G.B BGB LS
(F.O Recirc. Line)

(Burner Coaming) PI PI
BV428

209V

208V
ACC PX BV402
LS To H.F.O
BV427
TX Transfer Pump
From N2 Buffer
LS Tank In E/R 216V 125V For Performance DPI
282V

283V BV428 Monitor

Duplex
BV426 Pressure Gauge
246V For Master LS Boiler F.O
Gas Valve Trip A447 217V Service Pump
LS ACC PX

F-70V
TS (13 m3/h x 29.4 bar)
To F.O BV428 Boil-off PS
Drain Tank TX
BV428 Gas
244V

253V
TX F-14V
LS
270V

222V

221V
IAS PX
269V

BV428
N2 Purge Header (50A)

TI TI
(F.O Recirc. Line)

PI
LS BGB
BV402 BV427

F-66V
LS BV430 PI PI

No.2 Boiler F.O

No.1 Boiler F.O

Heater (A421)

Heater (A421)
LS BV434 BV434
ACC PX BV403 BV428
(Burner Coaming) LS Low Sulphur
On. PI
B.G.B BGB BV405-2 BV404-1 BV404-2 From Seal BV433 BV433 F.O Tank (S)

225V
BV402 BV431
BV401 Air Fan
PI
LS LS LS
LS PI PI PAH PAL F-43V (282.6 m3)
IAS BV423 BV422 BGB IAS IAS IAS BV435 BV435
For F.O PAL PI BV424 LS LS
Burning IAS
BV406 To Coaming BV425
DPX
238V Control Air 201V
For Dual PIAL PX
BV415 LS A440
Burning IAS Inside No.2 Burner
TI TI
Furnace

224V

223V
For Pressure
PS BV405-2 BV404-1 BV404-2 From Seal

202V
Low Trip (Dual)
BV401 LS LS LS Air Fan BV425 262V H.F.O
For Pressure
Gas Header (250A)

Low Trip (F.O)

PS
BV423 BV422
DPX Settling
BV424 Viscosity Control 251V
LS LS Control Air Tank (S)
IAS
TX IAS PIH For F.G. Trip Temperature Control (537.8 m3)
A440 ABC
Base Burner TX ACC
BMS 232V
BV425 For F.G. Trip
PIL

Viscorator
PX To F.O Heater
Furnace

XFD BMS
BV405-2 BV404-1 BV404-2 From Seal

234V
TI BV401 Air Fan
BV425 261V Temperature 233V F-2V F-1V
LS LS LS LS
Control Valve To H.F.O
BV423 BV422 Control Air Drain Valve & Transfer Pump AFT H.F.O.
BV424 LS LS LS Press. Gauge to
Bunker

ORI-21
be Provided on PI
F.O Boiler 226V 229V
TS
Trip
No.3 Burner A440 CV121 BV420 Each Strainer Tank (S)
For Temp. TI
TX
No.1 Main Boiler ACC 237V
TIALH
IAS 22S DPX DPAH To F.O Key
(252.7 m3)
H/L Alarm IAS E Control Air IAS
ABC DPX
P (60 Mesh) Drain Tank Fuel Oil Line
TX 228V
E Control ACC
Methane Vapour Line
P Air
BV405-1 227V
F.O Chamber
265V CV131 264V 263V Nitrogen Line

236V
FI Air Line
266V

(A) PIAL
267V PX IAS Drain Line

Final draft / 2007. 12. 28 4-1 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

Part 4 : Main Boiler Control System Illustration 4.1.1a Flowchart for Furnace Purging

4.1 Burner Sequences - Start From Burner Start Seq. OR

Furnace Start - Start From Burner Stop Seq
4.1.1 Fuel Oil Burning Purging Start Permissive - Manual Purge (If "Manual Purge" In BGB Is On,
Terminate Then Bnr1,2 or 3 Start Button Will Activate
Starting fuel oil burners: Manual Purge)
Condition for Next Step Action
- The individual fuel oil burners can be started and stopped either from the - Burner 1 Register Opened &
Open All Burner Registers Error
operator station or from the BNP. In addition burners can be started and - Burner 2 Register Opened &
Timeout : 20 Sec.
stopped from EOP - Burner 3 Register Opened - All Burner Registers Closed &
- All Fo Emcy Shut Vlv Closed (BV-405-2) &
The following start sequences (including furnace purge) can be performed when - Fg Emcy Shutoff Vlv Closed (BV-420) &
fuel mode operation is set to “fuel oil mode”. - Air Flow > ??? m3/H - Air Supply OK (From Shd Cabinet) &
& Sensor Not Abnormal or Force Fd Fan Vane Fully Open - Not Boiler Trip &
Error - Not FO Trip &
- Start FO burner 1 ( by activating the “START FO 1” pushbutton ). - Both Flow Sensors Abnormal Timeout : 20 Sec.
& FDF Fully Opened - FO Master Shutoff Valve Opened
- Start FO burner 2 ( by activating the “START FO 2” pushbutton ).
- Controllers in Auto or Manual (BNP) Cont
- Start FO burner 3 ( by activating the “START FO 3” pushbutton ).

Note
Normally burner No.1( centre) should be used as initial burner. In order to
use No.2 or No.3 burner, the burner bypass must be operated from IAS Error - Boiler Shut-down Condition
60s Normal
to bypass mode.

Starting Furnace purging

The FD fan needs to be started manually before the purge sequence can be Force Fd Fan Vane To Error
activated by burner start/stop sequences when needed. Once the sequence is - Fd Fan Vane In Start Position Start Position
started, the FD fan inlet vane will open 100%, and all burner registers open. The Timeout : 20 Sec.
system will then check that sufficient airflow is supplied to the furnace. When
the burner registers open limit switches, and sufficient air supply is detected, a
60seconds furnace purge timer starts. If airflow is below limits during the purge
period sequence is cancelled. 18 sec

After the furnace purge time has elapsed, all burner registers will close, the FD
fan inlet vane will go to burner ignition position, and a burner start without
further furnace purge will be permitted for 5minutes (as long as the air supply is - Burner 1 Register Closed &
still sufficient and no fuel gas or fuel oil piston valve closed indication Close All Burner Registers Error
- Burner 2 Register Closed &
disappears.) In normal operation No.1 FD fan will supply No.1 boiler with air, Timeout : 20 Sec.
- Burner 3 Register Closed
and No.3 FD fan is used for air supply to No.2 boiler. If one FD fan is abnormal,
No.2 fan will be back-up to the abnormal fan. The boiler can also be supplied
with air from the standby FD fan Release Fd Fan Vane
Set Set Boiler
Manual Purge : - Purge Status > 5min Or Purged Status
- Air Supply Not OK (From SHD Cab) Or (No Set If Man.
Reset Close All Burner Registers
Manual purge can be selected on BGB. In this case a burner start order will - Any FO Piston V/V Open Command Or Purge)
activate the purge sequence, but will not proceed to start burner sequence. - FO Emcy Sh Valve Open & Any Bnr On
Note End
No post purge system is adopted by trips. So before relighting, operator
must act a manual purge for post purge first.

Final draft / 2007. 12. 28 4-2 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

Starting FO burners, the first FO burner; Illustration 4.1.1b Flowchart for Starting Fuel Oil Burners, the First FO burner

The fuel oil burners can be started one by one from the IAS operator stations or - Burner On From BNP (Local) If All Bnr Off
Note : Only One Burner Can Be Start Oil Burner Start - Burner On From Monitor (IAS) If All Bnr Off OR
from the BNP, but only one burner can be started at the time. Started At The Time (The First FO Burner) Start Permissive - Start Req From FG=Dual Seq.
Terminate
Condition for Next Step Action
When a burner start command is activated the atomizing steam will be prepared Close Steam Purge Valve - FO Master Shut-off Valve Opened (BV-405-1)
- Steam Purge V/V Closed (BV-414) Error
and then the furnace purge sequence will be started automatically if needed. Next Timeout : 10 Sec.
-
-
All FO Piston Valves Closed (BV-404)
Not FO Trip
the fuel oil emergency shut-off valve is opened, the fuel oil accumulator valve is - Burner Register Closed Of any FG Bnr On
- Not F/E Abnormal
closed and the FD fan vane and FO control valve are positioned to ignition - Burner 1 Atm Steam V/V Opened & Open All Atomize Steam Valves
Error - All Bnr FG Shut-off Valves Closed Or Any FG
- Burner 2 Atm Steam V/V Opened & (BV-408) - FG Emcy Shut-off V/V Closed Of FG Burner On
position. - Burner 3 Atm Steam V/V Opened Timeout : 10 Sec. - If Ignitor Is Bypassed Then portable Ignitor Must
Be Inserted Or FG Burner On &
- FO Emcy Shut-off V/V Closed
Start Furnace Purge Sequence
The igniter is pushed down and energized simultaneously. Once the igniter in - Boiler Purged Status Set Or If Required Error
- Not Boiler Trip
- Not Bnr Bypass On
down position is confirmed and the igniter is charged, the fuel oil piston valves - Any Other Burner Is Active Timeout : 3 min
- Stop Seq. Not Active
Direct Error : Rurm Purge Seq. Fail
- Controllers In Auto OR (Local And Manual)
will open. When oil flame is detected the burner register is opened again. - Air Supply OK
Open All FO Emcy Shut-off Valve - Not Seq. Jam
Error
- All FO Emcy Shut-off Valves Opened (Close Recirc) (BV-405-2)
All burners are equipped with a retractable igniter, but in addition there is one Timeout : 10 Sec.
- FO Master Shut-off V/V Closed (BV-405-1)
portable igniter that can be used in case of trouble. This igniter must be manually - FO Emcy Shut-off Valve Shut-down (BV-405-2)
inserted, and a checkback signal is returned to ABC when the igniter is in Close FO Accumulator Valve Error
- Burner FO Piston V/V Shut-down (BV-404)
- FO Accumulator Valve Closed (BV-406) OR
position. Then, if the operator wants to use this igniter instead of the retractable Timeout : 10 Sec. Note : If All Burner Flame On Signals Are
Lost Before a Flame Is Detected On
during the oil burner start sequence, a bypass switch in the BGB must be Sequence Will Be Terminated.
activated to bypass the normal igniter. - Fd Fan Vane In Start Position Or
Set Fd Fan Vane To Start Pos. Error
If No Other Burner Is Active
- Any Other Burner Is Active
Timeout : 10 Sec.
If oil flame is not established within 6secconds, the fuel oil piston valves and the
fuel oil emergency shut-off valve will close(re-circulated side opens). In any case, - FO Ctrl Valve In Start Position Or
Set FO Ctrl V/V To Start Position Error
If No Other FO Burner Is Active
the igniter will be de-energised and retracted. - Any Other FO Burner Is Active
Timeout : 5 Sec.

Finally the forcing of the fuel oil control valve and the FD fan vane will be reset - Igniter In Down Position
If Corresponding FG Bnr Is Off:
& Charged
Lower & Activate
and the fuel oil accumulator valve is opened. & Bypass Switch Off Or
Retractable Igniter Error
- Portable Igniter In Position
Or
& Charged
Activate Portable Igniter
& Bypass Switch On Or
Note - Burner FG Detect (FG -> Dual)
Timeout : 30 Sec.

In normal operation when the boiler is firing, the fuel oil master valve and
the fuel oil emergency shutoff valve will be shut down by “all burner flame - Differential Pressure Normal If Corresponding FG Bnr Is Off: Error
(35 < p < 200 mmAq) Or Check Wind Box Diff Pressure
fail” after 3seconds (which is time to prevent mis-catch, due to glitter of - FG Burner Active Timeout : 5 Sec.
- Close Burner FO Piston Valve
flame). If only one oil burner is firing this means that when the fuel oil (BV-404)
emergency shutoff valve and the fuel oil piston valves are opened, but no - Burner FO Piston Valve 1 Opened &
- Deactivate & Retract lgniter
- Burner FO Piston Valve 2 Opened & Open Burner FO Piston Valve
oil flame is detected within 3seconds, the shutdown cabinet will shut - Oil Flame Detected (BV-404)
Error
- Close Burner Register
down the boiler. Direct Error If: Timeout : 10 Sec.
If Gas Burner In Not Active
- FO Piston V/V Open & No Flame In 6s
- Close FO Emcy Shut-off Valve
To avoid this shutdown during start-up of the first oil burner this time limit is Open Burner Register
(Open Recirc) ( BV-405-2)
- Burner Register Opened
increased to 6seconds by sending a signal “furnace purge finished” to the Timeout : 20 Sec. - Close All Atomize Steam Valves
If No Other Burner Is Active
shutdown cabinet. This signal will be reset 6seconds after fuel oil piston valves
- Igniter Deactivated & Deactivate & Retract Ignitor - Release FDF Vane
are opened, and if the oil flame is still not detected the boiler will be shut down. - Igniter Retracted Timeout : 20 Sec.
- Release FO Ctr V/v

Release Fd Fan Vane & - Open FO Accumulator V/v

- Fd Fan Vane Released &
FO Control Valve
- FO Control Valve Released
Timeout : 5 Sec.

Open FO Accumulator Valve

- FO Accumulator Valve Opened (BV-406)
Timeout : 10 Sec.

End

Final draft / 2007. 12. 28 4-3 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

Starting FO burners, when another burner is on: Illustration 4.1.1c Flowchart for Starting Fuel Oil Burners, when Another FO Burner is ON

Starting the second or third fuel oil burner is dependent of the boiler demand and - Burner On From BNP (Local) If Any Fame On
the fuel oil pressure. Only when the boiler demand and the FO pressure are Note : Only One Burner Can Be Start Oil Burner Start - Burner On From Monitor (IAS) If Any Flame On OR
above certain limit, the start sequence can be performed. An indication in the Started At The time (Next FO Burner) Start Permissive - Start Req. From FG=Dual Seq.
Terminate
IAS mimic display and the BNP will be activated when “burner increase
possible” Condition for Next Step Action
- Steam Purge V/V Closed & Close Steam Purge V/V (BV-414) & - Any Oil Burner Is Active
Error - Burner Increase Possible
Burner increase possible; - Bnr N2 Purge V/V Closed & Stop Bnr N2 Purge
- FG Shutoff V/V2 Closed If FG Bnr Off Timeout : 10 Sec. - Atomize Steam Valve Open (BV-408)
- FO Master Shutoff V/V Opened (BV-405-1)
FO Mode; - Burner FO Piston Valves Closed (BV-404)
- Not Boiler Trip &
Open FO Emcy Shutoff Valve - Not FO Trip
- 1 burner active : FO pressure > 13bar - FO Emcy Shutoff Valve Opened (Close Recirc) (BV-405-2)
Error
- Drum Pressure Normal (Not High Switch)
- 2 burner active : FO pressure > 13bar Timeout : 10 Sec. - Not Bnr Bypass On
- Not Seq. Jam
Dual Mode;
Adjust FO Pressure According To
Error
- 1 burner active : Total Calorie input > 8Gcal/h & FG pressure - FO Pressure OK Number Of Oil Burners - FO Master Shutoff V/V Closed (BV-405-1)
>300mmH2O Timeout : 120 Sec. - FO Emcy Shutoff Valve Shut-down
- Burner FO Piston V/V Shut-down
- 2 burner active : Total Calorie input > 8Gcal/h & FG pressure
OR
>300mmH2O Note : If Any Burner "Flame On"
- Igniter In Down Position Signal Is Lost Before a Flame Is Detected,
If Corresponding FG Bnr Is Off: The Start Sequence Will Be Terminated.
& Charged
Lower & Activate
& Bypass Switch Off Or
In addition another oil burner must be active, atomizing steam valve must be - Portable Igniter In Position
Retractable Igniter Error
opened and burner fuel oil piston valves and burner register mist be closed. Or
& Charged
Activate Portable Igniter
& Bypass Switch On Or
Timeout : 30 Sec.
- FG => Dual sequence active
The fuel oil emergency shutoff valve is automatically opened (the recirc. valve is
closed) and the fuel oil pressure is then adjusted according to number of oil
burners. Next the retractable igniter is prepared and the fuel oil piston valves are
opened and burner register is opened. - Burner FO Piston Valve 1 Opened Open Burner FO Piston Valve
- Burner FO Piston Valve 2 Opened (BV-404) Error
- Burner Register Opened & Open Burner Register After 2 s - Close Burner FO Piston Valve
If oil flame is not established within 6seconds, the fuel oil piston valves are - Oil Flame Detected Timeout : 10 Sec. (BV-404)
closed. The fuel oil emergency shutoff valve is only closed if no other oil burner
- Deactivate & Retract lgniter
is active (the recirc. valve is then opened.)
- Close Burner Register
- Ignitor Deactivated &
This sequence will be used by the “burner increase/decrease” sequence and the Deactivate & Retract Ignitor Error If Gas Burner In Not Active
- Ignitor Retracted &
Timeout : 20 Sec.
sequences for changing fuel burning modes. - Portable Ignitor Deactivated
- Close FO Emcy Shutoff Valve
(Open Recirc) (BV-405-2)

- Close All Atomize Steam Valves

Reset FO Pressure Adjustment If No Other Burner Is Active
- FO Pressure Adjustment Reset Error
Timeout : 5 Sec.
- Release FDF Vane

- Release FO Ctr V/V

- Open FO Accumulator V/V

End

Final draft / 2007. 12. 28 4-4 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

Stopping fuel oil burners : Illustration 4.1.1d Flowchart for Stopping Fuel Oil Burners

The individual fuel oil burners can be stopped either from the operator station or
Start
from the local operator panel. Stop FO Burner - Burner Off from BNP (in Local)
Start Permissive
- Burner Off from Monitor (in Remote)
Terminate
The following stop sequences can be performed when fuel mode operation is set - Stop Request from Bnr Auto Inc/Dec Seq. OR
to either “fuel oil mode” or “dual fuel mode” - Stop Request from Dual -> FG Seq.
Condition for next step Action
- BNR Flame Fail
Close Burner FO Piston Valves
- Stop FO burner 1 ( by activating the “STOP FO 1” pushbutton). - Burner FO Piston Valve 1 Closed OR (BV-404) Error
- Stop FO burner 2 ( by activating the “STOP FO 2” pushbutton). - Burner FO Piston Valve 2 Closed Deactivate & Retract Igniter
- Stop FO burner 3 ( by activating the “STOP FO 3” pushbutton). Timeout : 10 Sec.

The stop of burners is always available and will terminate any start attempt.
Open Steam Purge Valve (BV-414)
The following commands are executed : If Any Other Burner Is Active - Burner Start Order (Only After FO Emcy
(Close V/V After 60 Sec.) Closed)
- Closing individual fuel oil piston valves.
- De-energizing igniter (if energized).
- Retracting Igniter (if inserted).
- Closing burner register if gas burner is not active (individual gas closed). Wait 5
- Closing fuel oil emergency shutoff valve (and opening recirc. valve) Seconds
- Steam purging of burner for 60seconds (if any other burner is active).

- Bnr Register Closed OR Close Burner Register

- Gas Burner Is Active OR
- Furnace Purge Seq. Active
- FO Emcy Shut-off Valve Closed
- Any Other Oil Burner IS Active
Error
If Gas Burner Is Not Active
Timeout : 20 Sec.
- Close Burner FO Piston Valve
(BV-404)
Close FO Emcy Shut-off Valve
- Deactivate & Retract Igniter
If No Other Oil Burner Is Active Error
(Open Recirc) (BV-405-2)
- Close Burner Register
Timeout : 10 Sec.
If Gas Burner Is Not Active

- Close FO Emcy Shut-off Valve

If No Other Oil Burner Is Active
Start Bnr Possible
(Open Recirc) (BV-405-2)

- Close Steam Purge Valve

(BV-414)

- Any Other Burner Is Active OR

Start Furnace Purge Sequence
- Purge Status Is Set OR Error
If No Other Burner Is Active
- Furnace Purge Seq. Running OR
Timeout : 30 Sec.
- Boiler Trip Condition

END

Final draft / 2007. 12. 28 4-5 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

4.1.2 Gas Burning Illustration 4.1.2a Flowchart for Starting Fuel Gas Burners

The following start sequence can be performed when fuel mode operation is set Start - Burner On From BNP (Local and Dual)
Note : Only One Burner Can Be Start Gas Burner - Burner On From Monitor (IAS and Dual)
to either “FO mode” or “dual mode” Started At The Time Start Permissive OR
Terminate - Start Req From Bnr Auto Inc/Dec Seq.
- Start Req From FO -> Dual Seq.
- Start dual burner 1. Condition for Next Step Action
- Start dual burner 2. - Master FG Valve Open (BC-Mastergas)
Error
- Start dual burner 3. - Corresponding FO Bnr ON Check Corresponding FO Bnr ON - FG Emcy Shut-off Valve Opened
- Burner FG Shut-off Valve 1 Closed (BV-422)
- Burner FG Shut-off Valve 2 Closed (BV-423)
Starting fuel gas burners - Not Boiler Trip
Close Main Line N2 Vent Valves - Not FO Trip
Gas burners can be started once the corresponding FO burner is in operation. In - Main Line N2 Vent V/V 1 Close & (BV-430) & Error - Not FG Trip &
- Main Line N2 Vent V/V 2 Close & Close Header N2 Vent Valve - Main Line N2 Purge Sequence Not Active
addition the master gas supply valve must be opened, the burner fuel gas shutoff - Header N2 Vent Valve Closed (BV-431) - Header N2 Purge Sequence Not Active
valves must be closed and nitrogen purging sequences must be completed. Timeout : 10 Sec. - Header N2 Purge Valve Closed (BV-427)
- Burner N2 Purged
- Burner N2 Purge Valve Closed (BV-428)
First the main line nitrogen vent valves will be closed if no other gas burner is Set Gas Ctrl V/V To Start Pos. - Not Seq. Jam
active (these valves are opened as a part of the gas burner stop sequence when no - Gas Ctrl Valve In Start Position OR If No Other Gas Burner Is Active Error
- Any Other Gas Burner Is Active (CV-121/221)
other gas burner is active in any boiler). At the same time the boiler header - Master FG Valve Closed (BC-Mastergas)
Timeout : 20 Sec.
nitrogen vent valve is closed if no other gas burner is active in the corresponding - FG Trip
boiler (this valve is also opened automatically as a part of the gas burner stop
Adjust FO Pressure Note: If Corresponding Oil Burner OR
sequence if no other gas burner is active in the corresponding boiler). - FO Pressure FO -> Dual OK OR Error
If Mode Change From FO -> Dual " Flame On" Signal Is Lost Before Gas
- Other Gas Burner Is Active Flame Is Detected, The Start Sequence
Timeout : 120 Sec.
Then the fuel gas emergency shutoff valve is opened(by manual operation) and Will Be Terminated.

the fuel gas control valve will be set to ignition position if no other gas burner is Adjust FG Pressure According To Error
in operation. Next the fuel oil pressure is adjusted if no other gas burner is active - FG Pressure OK Number Of Gas Burners
and fuel mode operation is to be changed from fuel oil to dual fuel. If any other Timeout : 120 Sec.
fuel gas burner is in operation in the corresponding boiler the fuel gas pressure is
adjusted according to number of gas burners to ensure a proper ignition pressure. - Burner FG Shut-off Valve 1 Opened & Open Burner FG Shut-off Valves
Error Close Burner FG Shut-off Valves
- Burner FG Shut-off Valve 2 Opened & (BV-422 & BV-423)
(BV-422 & BV-423)
- Gas Flame Detected Timeout : 30 Sec.
Finally the fuel gas shutoff valves will be opened and hopefully gas flame is
detected. The fuel gas control valve and fuel pressure adjustments are thereafter
reset, and the boiler is released for automatic operation. Release Gas Control Valve Close FG Emcy Shut-off Valve
- Gas Control Valve Released (CV-121/221) If No Other Gas Burner IS Active
Timeout : 5 Sec. (BV-420)
If anything fails during the start sequence or the gas flame is not established
within step timeout, the fuel gas shutoff valves are closed. The fuel gas
Reset FO Pressure Adjustment Force Gas Ctrl V/V To Fully Open
emergency shutoff valve is only closed if no other fuel gas burner is active in the - FO Pressure Adjustment Reset
Timeout : 5 Sec. If No Other Gas Burner Is Active
corresponding boiler.

If no other gas burner is active in the corresponding boiler, the fuel gas control Reset FG Pressure Adjustment Open Header N2 Vent Valve
- FG Pressure Adjustment Reset If No Other Gas Burner Is Active
valve is forced to a fully open position and the boiler header nitrogen vent valve Timeout : 5 Sec.
(BV-431)
is opened for nitrogen purging. When no other gas burner is active in any boiler,
the main line nitrogen vent valves are opened for nitrogen purging.
Reset FO Pressure
Adjustment

Reset FG Pressure
Adjustment

End

Final draft / 2007. 12. 28 4-6 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

Stopping fuel gas burners Illustration 4.1.2b Flowchart for Stopping Fuel Gas Burners

The individual fuel gas burners can be stopped either from the operator station or Start - Stop From BNP (Local Mode)
Note : Only One Gas Burner Stop Start Gas Burner
from the local operator panel. Start Permissive - Stop From Monitor (IAS)
Sequence Can Be Active At The Time
- Stop Request From Burner Inc/Dec OR
The following stop sequences can be performed when fuel mode operation is set - Stop Request From Dual -> FO Seq.
Condition for Next Step Action - Bnr Flame Fail
to either “dual fuel mode” or “fuel gas mode”
Close Burner FG Piston Valves Error
- Burner FG Piston Valve 1 Closed &
- Start FO mode (dual => FO only) (BV-422 & BV-423)
- Burner FG Piston Valve 2 Closed
Timeout : 30 Sec. - Both FG Shut-off Valve Not Closed
- Stop dual burner 1 (by activating the “stop burner 1” pushbutton).
- Stop dual burner 2 (by activating the “stop burner 2” pushbutton).
- Stop dual burner 3 (by activating the “stop burner 3” pushbutton). Reset FG Pressure Error
- Stop one gas burner in case of three gas burners firing at FG mode. - FG Pressure Adjustment Is Reset Adjustment
Timeout : 20 Sec.
The stop of burners is always available and will terminate any start attempt. The
following commands are executed: Close FG Emcy Shut-off Valve
Close Burner FG Shut-off Valves
- FG Emcy Shut-down Valve Closed OR If No Other Gas Burner Is Active Error
(BV-422 & BV-423)
- If fuel mode operation is to be changed from dual fuel to fuel oil, the fuel - Any Other Gas Burner Is Active (CV-420)
gas pressure is adjusted to a proper changeover pressure. Timeout : 20 Sec.
- Closing individual fuel gas shutoff valves. Close FG Emcy Shut-off Valve
- If no other gas burner is active in the corresponding boiler, the fuel gas Force Gas Ctrl V/V To Fully Open If No Other Gas Burner IS Active
control valve is forced to open position for nitrogen purging. - Gas Control Valve Fully Opened OR If No Other Gas Burner Is Active Error (BV-420)
- If no other gas burner is active in the corresponding boiler, the fuel gas - Any Other Gas Burner Is Active (CV-121/221)
control valve is forced to open position for nitrogen purging Timeout : 20 Sec.
- Closing burner register if corresponding oil burner is not active. Close Burner Register
- If no other gas burner is active in the corresponding boiler, the header If Oil Burner Is Not Active
Close Burner Register Error
- Burner Register Closed OR
nitrogen vent valve is opened. If Oil Burner Is Not Active
- Oil Burner is Active
- If no other gas burner is active in any boiler, the master gas valve are Timeout : 20 Sec.
closed and after timer main line N2 purge is started (all gas firing is Open Header N2 Vent Valve
If No Other Gas Burner Is Active
stopped)
Open Header N2 Vent Valve (BV-431)
- Boiler header nitrogen purge sequence is started if no other gas burner is - Header N2 Vent Valve Opened OR If No Other Gas Burner Is Active Error
active in the corresponding boiler. - Any Other Gas Burner Is Active (CV-431)
- Burner nitrogen purge sequence is started. Timeout : 10 Sec.

Reset FG Pressure
Start Header N2 Purge Sequence Adjustment
- Header N2 Purge Status Is Set OR
If No Other Gas Burner Is Active
- Any Other Gas Burner Is Active
Timeout : 5 Min.

Start Header N2 Purge Sequence

- Burner N2 Purge Status Is Set For Corresponding Gas Burner
Timeout : 5 Min.

End

Final draft / 2007. 12. 28 4-7 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

4.1.3 Burner Automatic Increase / Decrease Illustration 4.1.3a Flowchart for Burner Automatic Decrease

When burner auto mode is selected, the number of burner of burners is controlled automatically according to the boiler
demand. This mode is not applicable in gas only firing of one gas burner. The system will monitor the boiler demand e.g.
output from master pressure controller and the FO pressure or total fuel calorie. Also during manoeuvring a minimum Start - FO Mode : Boiler Demand & FO Pressure
Burner Decrease Start Permissive - Dual Mode : Boiler Demand & Total Calorie OR
numbers of burners are considered. Terminate - FG Mode : Boiler Demand & FG Pressure

Condition for Next Step Action

The priority for starting is predefined as follows: - Number of Burners are 2 or More
Check Burner 3 is ON : - Auto Mode Selected
- Burner 3 is ON (Flame Detected) No
Timeout : 1 Sec. - Manovr Sone Lift OFF or 3 Burner Firing
No.1 burner Î No.2 burner Î No.3 burner - Number of Burner Protect Is Off
- Burner Increase Seq. Off
- FO -> Dual Seq. Off
&
- Dual -> FG Seq. Off
(In case No.2 or No.3 burner is selected as first ignition burner; - FO Burner 3 is OFF &
Stop FO Burner 3 &
- FG -> Dual Seq. Off
Stop FG Burner 3 No
No.2 burner Î No.1 burner Î No.3 burner - FG Burner 3 is OFF - Dual -> FO Seq. Off
Timeout : 60 Sec.
- FO Boost Up Seq. Off
No.3 burner Î No.1 burner Î No.2 burner) - Not Burner Abnormal
- Not Seq. Jam

The priority for stopping is predefined as follows:

- Boiler Trip

No.3 burner Î No.2 burner Î No.1 burner

1. Burner Increase Condition for Next Step Action

Check Burner 2 is ON : Error

- Burner 2 is ON
Request for next burner will be calculated as follows: Timeout : 1 Sec.

Mode No.of Burner Limit Stop FO Burner 2 & Error

- FO Burner 2 is OFF &
Stop FO Burner 2 if
1 Burner Boiler demand > 10Gcal/h & FO pressure > 11bar - FG Burner 2 is OFF
Timeout : 60 Sec.
FO
2 Burner Boiler demand > 25Gcal/h & FO pressure > 12bar
1 Burner Boiler demand > 8Gcar/h & total fuel calorie > 8Gcal/h
DUAL
2 Burner Boiler demand > 21Gcar/h & total fuel calorie > 8Gcal/h
GAS 2 Burner Boiler demand > 21Gcal/h & GAS Pressure > 3000mmH2O
Alarm : Burner Dec. Failed

2. Burner Decrease
End

Request for stopping burner will be calculated as follows:

Mode No.of Burner Limit

3 Burner Boiler demand < 19Gcal/h & FO pressure < 7bar
FO
2 Burner Boiler demand < 14Gcal/h & FO pressure < 6.5bar
3 Burner Boiler demand < 18Gcal/h & total fuel calorie < 18Gcal/h
DUAL
2 Burner Boiler demand < 11Gcal/h & total fuel calorie < 10.18Gcal/h
GAS 3 Burner Boiler demand < 17Gcal/h & GAS header pressure < 620mmH2O

Final draft / 2007. 12. 28 4-8 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

4.1.4 Fuel Mode Changeover Illustration 4.1.4a Flowchart for Changeover FO Î Dual Mode

There are three different modes of fuel selection. - Local Mode :

Start
Mode: FO -> Dual Start Permissive Dual Button From BNP Is Pressed.
OR
- Fuel Oil only : only oil burners ON Terminate - IAS Mode :
Dual Button From Monitor Is Pressed.
- Dual fuel : both gas and oil burners ON
- Fuel Gas only : only gas burners ON Condition for Next Step Action
- All FG Shut-off Valves Closed
Check Burner 1 Is ON No - Master FG valve open
Available sequence for change-over is: - FO Burner 1 Is ON
Timeout : 1 Sec. - Any FO Burner On & Corresponding
Gas Burners N2 Purge OK.
Fuel oil ÎÍ Dual fuel ÎÍ Fuel Gas - FG Emerg Shut-off Valve Open
- Burner Mode = Auto
1. FO Î Dual Fuel: Start Gas Burner 1 Error - Bnr Increase Seq. Off
- Dual Burner 1 Is ON &
Timeout : 60 Sec. - Bnr Decrease Seq. Off
- Dual -> FG Seq. Off
If activated the system will start up gas burners where oil burner is already on. - FG -> Dual Seq. Off
The sequences as used by manual start are used by this sequence. - Dual -> FO Seq. Off
- FO Boost Up Seq. Off
Wait 5 Sec.
- Not Burner Abnormal
Timeout : 5 Sec.
- Not Seq. Jam

- Boiler Trip
- FO Trip OR
- FG Trip
Check Burner 2 Is ON
- FO Burner 2 Is ON No
Timeout : 1 Sec.

Start Gas Burner 2 Error

- Dual Burner 2 Is ON
Timeout : 60 Sec.

Wait 5 Sec.
Timeout : 5 Sec.

Check Burner 3 Is ON
- FO Burner 3 Is ON No
Timeout : 1 Sec.

Start Gas Burner 3 Error

- Dual Burner 3 Is ON
Timeout : 60 Sec. - Stop FG Burner 1 &
- Stop FG Burner 2 &
- Stop FG Burner 3

End Alarm : Dual Mode Failed

Final draft / 2007. 12. 28 4-9 Part 4 Main Boiler Control System
CLEAN FORCE Machinery Operating Manual

2. Dual Î GAS:
In case one of the following conditions should occur in FG mode, FO auto backup will be activated;
When mode switch is changed from dual to GAS, the system will stop oil firing.
- Maneoubring zone
Illustration 4.1.4b Flowchart for Changeover Dual Î GAS Mode - Turbine trip
- CT press low
Start - Local Mode : - LD compressor running & tank protection controller active
Mode: Dual -> FG Start Permissive FG Button From BNP Is Pressed.
OR
Terminate - IAS Mode : - BOG heater abnormal
FG Button From Monitor Is Pressed.
- Both LD compressors stopped.
Condition for Next Step Action
- Master FG valve open
Check Burner 3 Is ON - Any Gas Burner On
- Dual Burner 3 Is ON
Timeout : 1 Sec.
No
- FG Emerg Shut-off Valve Open
Illustration 4.1.4c Flowchart for Changeover GasÎ Dual Mode
- UV Detected on Dual Bnrs
- Bnr Mode = Auto
- Bnr Increase Seq. Off Start - Local Mode :
- Bnr Decrease Seq. Off Mode: FG -> Dual Start Permissive Dual Button From BNP Is Pressed.
Stop FO Burner 3 Error OR
- FO Burner 3 Is OFF - FO -> Dual Seq. Off Terminate - IAS Mode :
Timeout : 60 Sec. Dual Button From Monitor Is Pressed.
- FG -> Dual Seq. Off &
- Dual -> FO Seq. Off - FO Auto Backup Order
Condition for Next Step Action - FG Inc Order
- FO Boost Up Seq. Off
- Only 1 FG Bnr In FG Mode
- Not Burner Abnormal Open All Atm Valves
Wait 2 Sec. - All Atm Valves Opened
- Not Seq. Jam Open FO Emcy Valve
Timeout : 2 Sec. - FO Emcy Valve Opened
Error
- FG Press OK Close FO Acc Valve - FO Emerg Shut-off Valve Closed
- FO Acc Valve Opened
- LD Comp 1 or 2 Running Set FO Ctrl Valve To Start - FO Burners No Interlock Active
- FO Ctrl Valve in Start Pos.
- Not FO Auto Backup Order Active Close Bnr Stm Prg Valves - Burner Mode = Auto
- Bnr Stm Prg Valve Closed
- FO Press < 0.28 MPa Timeout : 10 Sec. - Bnr Increase Seq. Off
- Bnr Decrease Seq. Off
- FO -> Dual Seq. Off
Check Burner 2 Is ON - Boiler Trip
- Dual Burner 2 Is ON No Error
- Dual -> FG Seq. Off
Timeout : 1 Sec. - FO Trip Open Bnr 1 FO Piston Valves &
- Bnr 1 FO Piston Valve 1 & 2 Opened - Dual -> FO Seq. Off
- FG Trip OR Timeout : 10 Sec. - FO Boost Up Seq. Off
- Auto Backup Order - Not Burner Abnormal
- FO Boost Up Order - Not Seq. Jam
Stop FO Burner 2 Error
- FO Burner 2 Is OFF Wait 8 Sec.
Timeout : 60 Sec.
Timeout : 8 Sec. - Boiler Trip
- FO Trip OR
- FG Trip

Wait 2 Sec. Open FO Rec Valve

Timeout : 2 Sec. - FO Rec Valve Opened Error
Reset FO Ctrl Valve Start Pos.
- FO Ctrl Valve Start Pos. Reset
Timeout : 10 Sec.

Check Burner 2 Is ON
- FG Burner 2 Is ON No
Check Burner 1 Is ON Timeout : 1 Sec. Close All Atm Valves
- Dual Burner 1 Is ON No Close FO Emcy Valve
Timeout : 1 Sec.
Open FO Acc Valve
- Close FO Piston Valves
Reset FO Ctrl Valve To Start
Start FO Burner 2 Error Open Bnr Stm Prg Valves
- Close FO Emcy Shut-off Valve - FO Burner 2 Is ON
Timeout : 60 Sec. Close FO Piston Valves
Stop FO Burner 1 Error
- FO Burner 1 Is OFF - Close Atomize Steam Valve
Timeout : 60 Sec.

- Open Purge Steam Valves

Wait 2 Sec.
Timeout : 2 Sec.

End Alarm : Dual -> FG Failed

Check Burner 3 Is ON
- FG Burner 3 Is ON No
Timeout : 1 Sec.
3. GAS Î Dual Fuel:

When mode switch is changed from FG to dual, the system will start up oil burners where gas burners are firing. - FO Burner 3 Is ON
Start FO Burner 3 Error
Activate Dual -> FG Sequence
Timeout : 60 Sec.

FG=>Dual will automatically activate by one of the following conditions;

End Alarm : FG -> Dual Failed

- FO auto back-up
- FG increase order
- Only 1 FG burner in FG mode

FO Auto Backup.

Final draft / 2007. 12. 28 4 - 10 Part 4 Main Boiler Control System

CLEAN FORCE Machinery Operating Manual

4. Dual Î FO Fuel oil Boost Up Condition

When mode switch is changed from dual to FO, the system will stop gas firing. The following conditions will activate FO boost-up if burner mode is auto and burners are gas only firing:

Illustration 4.1.4d Flowchart for Changeover DualÎ FO Mode - Master gas valve close action
- Low temperature in fuel gas line after heater
Start - Local Mode : - Gas detection in the gas pipe duct
Mode: Dual -> FO Start Permissive FO Button From BNP Is Pressed.
OR
Terminate - IAS Mode : - Ventilation failure in the gas pipe duct (both fan trip)
FO Button From Monitor Is Pressed.

Condition for Next Step Action

Activate Min FG Press
- Any FO Burner On Illustration 4.1.5a Flowchart for Fuel Oil Boost Up
No - Bnr Mode = Auto
- FG Press OK Control
- Bnr Increase Seq. Off
Timeout : 180 Sec.
- Bnr Decrease Seq. Off Start
- FO -> Dual Seq. Off Fuel Oil Boost Up Start Permissive
& FO Boost Up Condition
- Dual -> FG Seq. Off
Terminate
- FG -> Dual Seq. Off
- FO Boost Up Seq. Off
Check Burner 3 Is ON - Not Burner Abnormal Condition for Next Step Action - Burners Firing In FG Only
- Dual Burner 3 Is ON No
Timeout : 1 Sec. - Not Seq. Jam - All FO Piston Valves Closed
Open : All Atomize Steam Valves - FO Supply No Shut-down Active &
- Boiler In Auto Mode
- Boiler Trip Open : FO Emcy Shut-off Valves - Not ESDS Activated
OR
Stop FG Burner 3 Error - FO Trip
- FG Burner 3 Is OFF
Timeout : 60 Sec. Close : All Steam Purge Valves

Force FO Control Valve To FO FO Trip

Boost Position
Wait 2 Sec.
Timeout : 2 Sec. Open :
FO Piston Valve 1 If Gas Flame On
FO Piston Valve 2 If Gas Flame On
FO Piston Valve 3 If Gas Flame On

Check Burner 2 Is ON
- Dual Burner 2 Is ON No
Timeout : 1 Sec.
Wait 6 Sec.

Stop FG Burner 2 Error

- FG Burner 2 Is OFF
Timeout : 60 Sec. Close FO Piston Valve 1 &
Air Register
If No IR Flame Or
Purge Steam Valve Not Closed Or
Wait 2 Sec. Atomize Steam Valve Not Open
Timeout : 2 Sec.
Close FO Piston Valve 2 &
Air Register
If No IR Flame Or
Purge Steam Valve Not Closed Or
Atomize Steam Valve Not Open
Check Burner 1 Is ON
- Dual Burner 1 Is ON No
Timeout : 1 Sec.
Close FO Piston Valve 3 &
Air Register
If No IR Flame Or
Purge Steam Valve Not Closed Or
Stop FG Burner 1 Error
- FG Burner 1 Is OFF Atomize Steam Valve Not Open
Timeout : 60 Sec.

- Close FG hut-off Valves

Close :
Error
- Close FG Emcy Shut-off Valve - All FG Shut-off Valves Closed FG Shut-off Valves
Timeout : 10 Sec.
Release FG Min Press
- Release FG Min Press Ctrl
Control

Release FO Control Valve Release FO Control Valve

Force Control Force Control
End Alarm : Dual -> FO Failed

Close :
Error
- FG Emcy Shut-off Valve Closed FG Emcy Shut-off Valves
4.1.5 Fuel Oil Boost Up Timeout : 10 Sec. Alarm : Fuel Oil Boost Failed

In case of gas only firing and trip cause pf master FG valve is detected, the fuel oil burners will be started. Ignitors will not
End
be used in this case.

Final draft / 2007. 12. 28 4 - 11 Part 4 Main Boiler Control System

CLEAN FORCE Machinery Operating Manual

4.1.6 Nitrogen Purge of Gas Supply Lines vent valves and then open the main line N2 purge valve

Purging of gas supply lines can be done from the IAS operator stations. The following sequences are available: Note
The boiler header N2 vent valves are not closed. If backpressure turnes out to be a problem, the closing of these
- Purge Main Line valves can be included in the purge sequence.
- Purge No.1 MB Gas Header
- Purge No.2 MB Gas Header After purge time has elapsed the N2 purge valve will close again, while the header vent valves will be opened. The main line
- Purge No.1 MB Gas Burner (No.1, No.2, No.3) vent valves will remain open. A status indication “Main line purged” will be set after successful sequence is performed. This
- Purge No.2 MB Gas Burner (No.1, No.2, No.3) status will be reset when the master fuel gas valve closed indication disappears. This sequence will be performed automatic
when the master fuel gas valve is closed, but can also be manually started from a pushbutton on the IAS operator stations or
Illustration 4.1.6a Nitrogen Purge of Gas Supply Lines from the local panel by activating the “Main line N2 purge” button

ACC
E Control Air
Boiler Hood Room Illustration 4.1.6b Flowchart for N2 Purging of Main Line
BV423 BV422 P
No.3 Burner BV424 LS LS LS

A440 CV221 BV420

BV425 275V
Control Air
Nitrogen Purging Start - Main Line Purge From BNP (Local)
Start Permissive OR

Furnace
From Seal Main Line - Main Line Purge From Monitor (Remote)
BV425
Air Fan PX
DFX PIL
Terminate - Master FG Valve Closed After 150 Sec.
Gas Header (250A)

BMS
BV423 BV422 TX ACC For F.G. Trip
Base Burner BV424 LS LS PIH ABC
TX IAS BMS Condition for Next Step Action
For F.G. Trip - Master FG Valve Closed (BC-Mastergas)
A440 BV425 276V
Control Air Open Main Line Valve - Boiler 1 FG Emcy Shut-off Valve Closed (BV-420)
- Main Line Vent Valve 1 Opened & Error
DPX (BV-430) - Boiler 2 FG Emcy Shut-off Valve Closed (BV-420)
- Main Line Vent Valve 2 Opened

Furnace
From Seal
Air Fan
Timeout : 10 Sec. - Boiler 1 Header N2 Purge Valve Closed (BV-427)
BV423 BV422
BV425 239V - Boiler 2 Header N2 Purge Valve Closed (BV-427)
No.2 Burner BV424 LS LS - All Burner N2 Purge Valves Closed (BV-428)
Control Air
To No.4 &
BV431 DPX
Vent Riser - No Gas Burners Active
A440 LS Open Main Line N2 Purge Valve
Error - No MB 1 Hdr/Bnr N2 Purge Sequence Active
PI PI PAH PAL
- Main Line N2 Purge Valve Opened (BV-426)
BGB IAS IAS IAS
- No MB 2 Hdr/Bnr N2 Purge Sequence Active
From Seal BV430 Timeout : 10 Sec.
N2 Purge Header (50A)

Air Fan LS - Main N2 Gas Supply Valve Open (BC-N2-Main-

LS
Open)
BV428
LS - N2 Pressure Normal
BV427 From N2 Buffer Wait 60
LS Tank In E/R
BV428 Seconds
BV426 - Main N2 Gas Supply Valve Not Open (BC-N2-
For Master LS
Gas Valve Trip Main-Open)
LS OR
BV428
TS - N2 Pressure Not Normal
Boil-off
Gas Close Main Line N2 Purge Valve - Master FG Valve Not Closed (BC-Mastergas)
BV428 Error
253V

LS TX - Main Line N2 Purge Valve Closed (BV-426)

IAS PX Timeout : 10 Sec.
BV428
N2 Purge Header (50A)

PI
LS BGB
BV427
LS BV430
BV428 LS
LS
From Seal
Air Fan BV431
LS PI PI PAH PAL Close Main Line N2 Purge Valve
BV423 BV422 BGB IAS IAS IAS
BV424 LS LS (BV-426)
Set Set Main Line
DPX Control Air
BV425 238V
No.2 Burner A440 Purged Status
- Master Gas Valve Not Closed Reset
Furnace

From Seal
Air Fan BV425 262V
Gas Header (250A)

DPX
BV423 BV422
BV424 LS LS Control Air End
TX IAS PIH For F.G. Trip
A440 BMS ABC
Base Burner TX ACC For F.G. Trip
BV425
PIL
PX
Furnace

XFD BMS
From Seal BV425 261V
Air Fan
BV423 BV422 Control Air
BV424 LS LS LS

No.3 Burner A440 CV121 BV420

E Control Air
P
ACC

1. N2 Purging of Main Line to Vent

When the main line is purged, the line from the master fuel gas valve outlet to each of the fuel gas emergency shutoff valve
inlets is purged with N2. Main line N2 purging can be started when there are no gas burners firing in any boiler, the master
fuel gas supply valve is closed and both fuel gas emergency shutoff valves are closed. The boiler header N2 purge valves and
all burner N2 purge valves must also be closed. The system will open the main line vent valves and then open the main line

Final draft / 2007. 12. 28 4 - 12 Part 4 Main Boiler Control System

CLEAN FORCE Machinery Operating Manual

2. N2 purge of Gas Header burner stop sequence. When the fuel gas shutoff avle is closed and there is at least one flame in the furnace or sufficient air
flow during furnace after purge, the burner N2 purge valve will be opened. Then the burner fuel gas shutoff valve at burner
When the gas header is purged, the line from each boiler fuel gas emergency shutoff valve outlet to each burner fuel gas side will open if the purge valve is successfully opened. After purge time has elapsed the burner N2 purge valve and the fuel
shutoff valve inlet is purged with N2. The gas header can be purged when no gas burners are firing in that boiler and the gas shutoff valve at burner side will close again.
boiler fuel gas emergency shutoff valve is closed. The main line N2 purge valve and the burner N2 purge valves must also be
closed. The system will force the gas control valve to a fully open position, open the boiler header N2 vent valve and then A status indication “Burner <X> purged” will be set. This status will be reset when the burner fuel gas shutoff valves closed
open the header N2 purge valve. indication disappears. This sequence will be performed automatic when fuel gas shutoff valves are closed, but will also be
executed after the header N2 purge sequence is finished.
After purge time has elapsed the N2 purge valve will close again and the forcing of the gas control valve is reset. The header
N2 vent valve will remain open. A status indication “header purged” will be set. This status will be reset when the boiler fuel Illustration 4.1.6d Flowchart for N2 Purging of Boiler Burner
gas emergency shutoff valve closed indication disappears. This sequence will be performed automatic when the fuel gas
emergency shutoff valve is closed, but can also be manually started from a software pushbutton on the IAS operator stations Nitrogen Purging
Boiler Burner
Start
Start Permissive
- Purge Boiler Hdr/Bnr From BNP (Local)
- Purge Boiler Hdr/Bnr From Monitor (Remote) OR
Terminate
or from the local panel by activating the “Header/burner N2 purge” button - Purge Request From Gas Burner Stop Sequence

Condition for Next Step Action

- Any Boiler Flame Detected or Furnace After
Open Burner 1 FG Shut-off Valve 2 If Purge OK
- Burner 1 FG Shut-off V/V 2 Opened OR
Illustration 4.1.6c Flowchart for N2 Purging of Boiler Header - FG Shut-off Valve No.2 Not Closed OR
- Burner Purge Status Is Set
FG Shut-off Valve No.1 Is Closed
(BV-423)
- FG Main Line N2 Purge Valve Closed (BV-426)
- Header N2 Purge Valve Closed (BV-427)
Timeout : 20 Sec. - No Main Line N2 Purge Sequence Active
- No Header N2 Purge Sequence Active
&
- Main N2 Gas Supply Valve Open (BC-N2-Main-
Nitrogen Purging Start - Purge Boiler Hdr/Bnr From BNP (Local) Open Burner 2 FG Shut-off Valve 2 If
Open)
Start Permissive - Burner 2 FG Shut-off V/V 2 Opened OR - N2 Pressure Normal
Boiler Header - Purge Boiler Hdr/Bnr From Monitor (Remote) OR - FG Shut-off Valve No.1 Not Closed OR
FG Shut-off Valve No.1 Is Closed
- FG Shut-off Valve Closed For At Least
Terminate (BV-423)
- Purge Request From Gas Burner Stop Sequence - Burner Purge Status Is Set
Timeout : 20 Sec.
One Burner

Condition for Next Step
- Gas Control Valve Fully Open
- Boiler Header N2 Vent Valve Opened
- Boiler Header N2 Supply Valve Opened
- Boiler Header N2 Supply V/V Closed
Action - Main N2 Gas Supply Valve Not Open (BC-N2-
- Boiler FG Emcy Shut-off Valve Closed (BV-420) Open Burner 3 FG Shut-off Valve 2 If Main-Open)
Force Gas Control V/V To Fully Open - All FG Shut-off Valves Closed (BV-422 & BV-423) - Burner 3 FG Shut-off V/V 2 Opened OR
FG Shut-off Valve No.1 Is Closed - N2 Pressure Not Normal
Error - FG Shut-off Valve No.1 Not Closed OR OR
(CV-121/221) - FG Main Line N2 Purge Valve Closed (BV-426) - Burner Purge Status Is Set
(BV-423)
Timeout : 20 Sec. Note : If No Boiler Flame Is Detected,
Timeout : 40 Sec. - Burner N2 Purge Valves Closed (BV-428) The Purge Sequence Will Be Terminated.
- No Main Line N2 Purge Sequence Active
- No Burner N2 Purge Sequence Active - Burner 1 N2 Purge Valve Open OR Open Burner 1 N2 Purge Valve (BV-428)
& - Bnr 1 FG Shut-off V/V 1 Not Closed OR If FG Shut-off Valve 1 Closed & Error
- Main N2 Gas Supply Valve Open (BC-N2-Main-
Open Boiler Header N2 Vent Valve - Burner 1 Purged OR FG Shut-off Valve 2 Opened
Error Open) - Bnr 1 FG Shut-off V/V 2 Not Opened Timeout : 20 Sec.
(BV-431)
- N2 Pressure Normal
Timeout : 10 Sec.
Close Burner 1, 2, 3, N2 Purge Valves
- Burner 2 N2 Purge Valve Open OR Open Burner 2 N2 Purge Valve (BV-428)
- Bnr 2 FG Shut-off V/V 1 Not Closed OR If FG Shut-off Valve 1 Closed & Error Close Burner 1, 2, 3 FG Shut-off Valves
- Main N2 Gas Supply Valve Not Open (BC-N2- - Burner 2 Purged OR FG Shut-off Valve 2 Opened No.1 (Burner Side)
Open Boiler N2 Purge Valve Main-Open) - Bnr 2 FG Shut-off V/V 2 Not Opened Timeout : 20 Sec. If Corresponding No.1 (Header Side)
Error OR
(BV-427) - N2 Pressure Not Normal Shut-off Valve Is Closed
Timeout : 10 Sec. - Boiler FG Emcy Shut-off V/V Not Closed (BV-420)
- Burner 3 N2 Purge Valve Open OR Open Burner 3 N2 Purge Valve (BV-428)
- Bnr 3 FG Shut-off V/V 1 Not Closed OR If FG Shut-off Valve 1 Closed & Error
- Burner 3 Purged OR FG Shut-off Valve 2 Opened
- Bnr 3 FG Shut-off V/V 2 Not Opened Timeout : 20 Sec.
Wait 20
Seconds
Wait 30
Close Header N2 Purge Valve Seconds
(BV-427)
Set Set Burner 1 Purged Status
Close Header N2 Purge Valve Burner 1 FG Shut-off Valve No.1 If N2 Supply Valve Opened And
(BV-427) Not Closed Reset FG Shut-off Valve No.2 Opened
Timeout : 10 Sec. (BV-422)

Reset Gas Control Valve Forcing

Set Set Burner 2 Purged Status
To Fully Open Burner 2 FG Shut-off Valve No.1 If N2 Supply Valve Opened And
Not Closed Reset FG Shut-off Valve No.2 Opened
Reset Gas Control Valve Forcing
(BV-422)
- Gas Control Valve Released To Fully Open
Timeout : 5 Sec. Set Set Burner 3 Purged Status
Burner 3 FG Shut-off Valve No.1 If N2 Supply Valve Opened And
Not Closed Reset FG Shut-off Valve No.2 Opened
(BV-422)

Set Set Boiler Header

- Burner 1 N2 Purge Valve Closed & Close All Burner N2 Purge Valves
- Burner 2 N2 Purge Valve Closed & (BV-428)
Purged Status - Burner 3 N2 Purge Valve Closed Timeout : 20 Sec.
- Boiler FG Emcy Shut-off V/V Not Closed Reset

Close Burner 1 FG Shut-off Valve No.2

- Burner 1 FG Shut-off V/V 2 Closed OR
(BV-423) IF FG Burner 1 Is Off
- FG Burner 1 On
End Timeout : 20 Sec.

Close Burner 2 FG Shut-off Valve No.2

- Burner 2 FG Shut-off V/V 2 Closed OR
(BV-423) IF FG Burner 2 Is Off
3. N2 purge of Gas Burner - FG Burner 2 On
Timeout : 20 Sec.

Close Burner 3 FG Shut-off Valve No.2

When the gas burner is purged, the line from each burner fuel gas shutoff valve outlet to each gas burner is purged with N2 - Burner 3 FG Shut-off V/V 2 Closed OR
- FG Burner 3 On
(BV-423) IF FG Burner 3 Is Off
Timeout : 20 Sec.
The gas burners can be purged as ling as there is at least one burner firing in that boiler. The fuel gas main line N2 purge
valve and the header N2 purge valve must be closed. Burner purge sequence is performed automatically as a part of the gas End

Final draft / 2007. 12. 28 4 - 13 Part 4 Main Boiler Control System

CLEAN FORCE Machinery Operating Manual

Part 5 : Main Turbine Remote Control System

5.1 Main Turbine Control System............................................................ 5 - 1
5.2 Function of the Remote Control System ............................................ 5 - 4
5.2.1 W/H Manoeuvring .................................................................. 5 - 5
5.2.2 ECR Manoeuvring ................................................................ 5 - 10
5.2.3 Machine Side Manoeuvring .................................................. 5 - 10
5.2.4 Automatic Slow Down .......................................................... 5 - 10
5.2.5 Program Interlock ................................................................. 5 - 13
5.2.6 Control System Monitoring Function ................................... 5 - 13
5.2.7 Safety System ....................................................................... 5 - 14
5.2.8 Safety System Monitoring Function ..................................... 5 - 15

Illustrations
5.2a Block Diagram of Remote Control System ..................................... 5 - 3
5.2.1a Telegraph Lever Position .............................................................. 5 - 5
5.2.1b Time Program for Acceleration / Deceleration ............................. 5 - 5
5.2.1c Brake Steam Supplied Sequence ................................................... 5 - 6
5.2.1d Example of Typical Control in Deceleration ................................ 5 - 6
5.2.1e Manoeuvring Valve Lift In Reversing Operation
(Ahead to Astern)........................................................................... 5 - 6
5.2.1f Manoeuvring Valve Lift In Reversing Operation
(Astern to Ahead)........................................................................... 5 - 6
5.2.1g Auto Spinning Sequence ............................................................... 5 - 7
5.2.1h Block Diagram for Auto Spinning ................................................ 5 - 8
5.2.1i Control Pattern of Overspeed Preventer Control ........................... 5 - 9
5.2.1j Block Diagram of Rough Sea Control ........................................... 5 - 9
5.2.2a Conrol Pattern in Condition a), b), c), d), e), f), g) ..................... 5 - 10
5.2.2b Control Pattern in Condition of Main Steam Drum Level High or
Low ............................................................................................ 5 - 11
5.2.8a Blcok Diagram for Safety System............................................... 5 - 15

Part 5
Main Turbine Remote Control System
Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

Part 5 : Main Turbine Remote Control System operated by detecting manoeuvring valve lift and also remotely
Good Bad
operated by the selector switch.

Packing Steam Press. (0.02 MPa)

Packing Steam Press. (0.02MPa)

5.1 Main Turbine Control System Change over switch (CLOSE, AUTO, OPEN) is provided on the ill v
alve e
f sp alv
machinery control room console. o lv
ion pi l
uat f s
Act on
o
1. Control System ti
tua
Ac
2) Bleeder valve operation
Ac
The remote control system serves for controlling the main turbine from the tua
tio
Act
navigation console or the engine control room (ECR). (1) HP bleeder valves uat
ion
no
fm
of m ak
e-u
In conventional operation, according to manoeuvring orders, the engine When the change over switch is AUTO, this valve is ake
-up
valv
p va
lv e
telegraph lever on the bridge or manoeuvring lever in the control room is set to automatically operated in accordance with the steam pressure at e

the desired position.
When any trouble occurs in the engine telegraph or manoeuvring lever system,
the main turbine is controlled by the direct control switch regulator on the
machinery control console or locally at the machine side.
1) Engine Telegraph (from navigation console)
Engine telegraph system is for transmitting / receiving manoeuvring
orders from bridge to other control consoles.
2) Lever control (from machinery control room and navigation console)
Lever control system consists of the revolution control, valve position
control, and program by-pass control.
When select switch on the control console for selection of maneuvering
method is set to “LEVER” position, main turbine is controlled by means
of manoeuvring lever.
When revolution control switch on the control console is changed to
“BY-PASS” position, the revolution control is automatically cut.
When program by-pass switch on the control console is changed to
“PROGRAM BY-PASS” position, astern & ahead program control is
canceled.
3) Emergency manoeuvring control (from engine control room and
machine side)
When the select switch on the control console for selection of
manoeuvring method is set to ‘DIRECT’ position, the main turbine is
controlled by means of the direct control switch regulator with the
control lever.
4) Spinning
When the change over switch for auto spinning is set to ‘ON’ position
and the main shaft revolutions are reduced to between +3 rpm and -3
rpm during navigation, auto-spinning is automatically done.
Change over switch (ON, OFF) is provided on the machinery control
room console.
In addition a warming through mode is provided for safe operation
during hand spinning for completion of warming up of the main turbine.
the HP bleeding point and also remotely operated by selector Valve Lift Valve Lift
switch.
Change over switch (CLOSE, AUTO) is provided on the
If the control valves are not functioning properly, the packing steam
machinery control room console.
pressure is controlled by the manually operated by-pass valve of the
make-up valve and the spill valves.
(2) IP & LP bleeder valves
When the change over switch is AUTO, these valves are
6) Lub-oil temperature control valve operation.
automatically operated in accordance with the steam pressure at
The temperature of the lube-oil to the bearings and the gear mesh is
the IP bleeding point and also remotely operated by selector
controlled automatically by the lube-oil temperature control valve.
switch.
Change over switch (CLOSE, AUTO) is provided on the
7) Astern spray water valve operation
machinery control room console.
This valve is automatically operated by detecting that the astern
manoeuvring valve is open.
3) Drain valves operation
Drain valves for manoeuvring valve, HP turbine steam chest, HP
8) Dump spray water valve operation
turbine 2nd stage, HP bleeder and HP turbine casing.
This valve is automatically operated by detecting that the dump valve is
When the change over switch is ‘AUTO’, these valves are automatically
open.
operated by detecting manoeuvring valve lift and also remotely
operated by selector switch.
Change over switch (AUTO, OPEN) is provided on the machinery
control room console.
4) Condensate recirculation valve
The valve is automatically controlled by a signal from the condensate
level transmitter for the main condenser hot well.
5) Packing steam pressure control valves operation
Packing steam is controlled normally by two air operated control valves.
In case of low packing steam pressure, the make-up valve is opened and
supplies the packing steam to the glands.
In case of high packing steam pressure, the spill valve is opened and the
packing steam is spilled to the main condenser.
In order to prevent hunting or cycling, the packing steam controller
should be adjusted as shown in the following figures.

2. Operation of Control Valve

1) Astern guardian valve operation

When the change over switch is ‘AUTO’, this valve is automatically

Final draft / 2007. 12. 28 5-1 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

Table 1-1 Setting of Valve Action

Emergency
Remarks
Valve Name Setting Case
( Alternatively )
(Air Failure)
Open at 14bar (manual from IAS)
HP Bleeder
Bleeder Close at 11bar With Manual
Close
Valve IP Bleeder Open at bar Operating Handle
LP Bleeder Close at bar
With Manual
Astern Guardian Valve (T-3) Open
Operating Handle
Manoeu. Valve
Drain
(T-51)
Open : below ahead abt. 72 rpm (MV lift)
HP Steam Chest
Close : above ahead abt. 75 rpm (MV lift)
DRAIN (T-52)
Drain With Manual
HP Turbine 2nd Open
Valve Operating Handle
Stage Drain (T-53)
HP Casing Drain
(T-54)
HP Bleeder Drain Open at HP bleed valve close
(T-55) Close at HP bleed valve open
Main Condenser Level Control
Normal Level Open
(T-42)
Automatically control by signal of main
Cond. Water Recirculation With Manual
condenser hot well level transmitter Close
(T-43) Operating Handle

Packing Make-up (T-302) 0.196 bar Open With Manual

Steam Spill (T-303) 0.216 bar Close Operating Handle

Open : not full close of steam dump valve

Spray Water for Steam Dump. With Manual
Close : full close of steam dump valve and Close
(T-56) Operating Handle
timer
Open : astern MV open and not auto spinning
Spray Water for Astern condition With Manual
Close
Operation (T-57) Close :astern MV close and timer Operating Handle
(about. 10 sec.)

Caution
1. When the supplied air pressure to the air operated type valve is already established, do not control the
pressure reduction valve.
2. When the manual operating handling is operated, stop the air supply.

Final draft / 2007. 12. 28 5-2 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

Illustration 5.2a Block Diagram of Remote Control System

ACTUATOR & CAM SW. BOX

MAIN
VALVE LIFT
BOILER
FEED BACK FAIL

FUNCTION SY
GENERATOR REV. PICK UP

MOTOR
W/H ENGINE TELEGRAPH DRIVER M/T
TIME SCHEDULER HYDRAULIC
(WITH MANOEUV. LEVER) (LEVER) PM MANOEUV. HPT
FUNCTION CYLINDER
FUNCTION VALVE
GENERATOR
GENERATOR MOTOR
POTENTIO DRIVER
METER (DIRECT) AST LPT P P

CONTROL
MATCHING
PI
REGULATOR

ECR ENGINE TELEGRAPH

(WITH MANOEUV. LEVER) AUTO SLOW
REV. PICK UP FAIL
DOWN
LOGIC
POTENTIO CIRCUIT
MORE THAN
METER ASR CUT LEVEL

MANOEUV.
WRONG WAY AL ARM LEVER TURBINE TRIP
WRONG
WAY
AUTO SPIN
LOGIC
CONTROL POSITION CIRCUIT
SELECT SWITCH

PROGRAM BY - PASS
AUTO. SPINNING
SELECT SWITCH
LONG TIME STOP

LEVER & DIRECT

AUTO. SPINNING
SELECT SWITCH
OVER SPEED

DIRECT CONTROL
PUSH BUTTON SWITCH

AUTO. SPINNING
SELECT SWITCH

VALVE LIFT
INDICATOR

RPM F.B.
CHANGE OVER SW.
(ASR CUT)

Final draft / 2007. 12. 28 5-3 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

5.2 Function of the Remote Control System 3. System Configuration for Remote Control System

1. General W/H
Teleg. Repeater
The main turbine remote control system is designed to control the propeller shaft revolutions via manoeuvring valve lift
from Bridge Wings, Wheel House (W/H), and Engine Control Room (ECR) by operating the telegraph lever on the
console in each of these operating positions. Also, in the ECR and locally at the turbine, it is possible to operate the main
turbine by operating the switch to increase or decrease the valve lift. Telegraph
Transmitter
with Buzzer,
2. Manoeuvring Method Indicator

The control operation from each manoeuvring position and method are shown in Table 1-1.
Clock
Signal
Table 1-1 Manoeuvring Method at Manoeuvring Positions

Manoeuvring Shaft Revolution / Safety System / W/H Sub. Panel

Manoeuvring Method
Position Manoeuv. Control Valve Lift Interlock AC Souce

Corresponding to the electrical - Manual Trip DC 24V

Automatic control by signal of the - Auto Trip
telegraph transmitter telegraph transmitter, the micro - Auto Slow Down
W/H Lever
(Micro computer computer drives the servo - Boiler Interlock
-Servo Motor) motor actuating the control - Rough Sea Control ECR
valve. (Over-speed Prevention)
- Manual Trip
Corresponding to the electrical
Automatic control by - Auto Trip
signal of telegraph receiver,
telegraph receiver - Auto Slow Down
Lever the micro computer drives the
(Micro computer - Boiler Interlock
servo motor actuating the
-Servo Motor) - Rough Sea Control AC Main
Telegraph
ECR control valve. Souce
(Over-speed Prevention) Receiver with Buzzer
AC Souce
Manual control by Contact signal of Ahead/Astern Direct
Ahead / stern control control switch is amplified to - Manual Trip
Direct Control DC 24V
switch (Electric-Servo drive servo motor actuating the - Auto Trip
motor) control valve AC Sol. Maneuv.
V Sorrce Control
The remote control Box
DC 24V
system makes auto trip of Trip
control oil
Manoeuvring valve is Operator directly controls for Servo motor, while the
Mechanical
Machine Side operated by Manoeuvring valve by handle is not in neutral
Handle
mechanical Handle. operating Mechanical Handle. position, so that the Valve Ind.
ECS Sub. Panel
remote control system
cannot affect the handle
operation M/S

Telegraph
Gong
Pluse Pluse
Generator Generator
for Safety for R/C Actuator Cam SW. Box Gauge Emerg.
Panel Control
Panel Telegraph
(with Teleg. Receiver & Rev. Ind.) Gong

Illustration 5.2b System Configuration for Remote Control System

Final draft / 2007. 12. 28 5-4 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

5.2.1 W/H Manoeuvring manoeuvring control box. RPM feedback control is carried out in the valve in accordance with the time program as shown in
range of the manoeuvring zone. When one of the following conditions Illustration 5.2.1b, and while the program is implemented, IN
1. Telegraph Lever Manoeuvring takes place, the RPM feedback control is by-passed and the PROGRESS is indicated in the W/H and ECR, and a signal is
manoeuvring valve lift control is performed; output for monitoring in the IAS.
When manoeuvring with the telegraph lever, propeller revolutions or
manoeuvring control valve lift is controlled corresponding to the lever position. - Telegraph lever in normal sea going zone. AH Full
The telegraph lever has eleven divisions (from EMERGENCY FULL to
① : ab. 60 sec
NAVIGATION FULL), and is normally positioned by latch at the centre of
- The manoeuvring valve position (cam angle) is in normal sea- ② : ab. 60 min
each division discretely so as to select the eleven points of revolution or 100% ② ③ ③ : ab. 55 sec
going zone.
manoeuvring valve lift. In addition, it is also possible to change the lever Time
program
④ : ab. 30 sec
About 60min ⑤ : ab. 55 sec
position continuously to achieve a fine control. order of

- RPM FEEDBACK switch provided on the manoeuvring control

maneuv.
valve lift
① ④ ⑥ : ab. 80 sec
⑦ : ab. 55 sec
The relation between the lever position and the propeller revolution or the box is set to BY-PASS position.
manoeuvring valve lift is preset as shown in Illustration 5.2.1a 0%
Time
For the control system diagram, refer to Illustration 5.2a - REVOLUTION SIGNAL TROUBLE occurs, for which the ⑤
remote control system detects an excessive difference in signals of ⑦
The control system has two zones as follows : speed detectors provided on the propeller shaft.
(In this case, MAIN TURBINE REMOTE CONTROL SYSTEM 100%
⑥
- Manoeuvring zone FAIL alarm sounds in the W/H and ECR, and the cause of the AST Full
When the telegraph lever is operated to any desired position, the propeller fault : REVOLUTION SIGNAL TROUBLE is indicated on the
revolutions are controlled to the corresponding telegraph lever position by
manoeuvring control box: RPM feedback control is available after Illustration 5.2.1b Time Program for Acceleration /
the rpm feedback control circuit.
the operator selects a normal detector by change-over of the REV. Deceleration
- Normal sea going zone SIGNAL select switch manually.)
The manoeuvring valve lift is controlled to correspond to the telegraph lever (2) Program By-Pass
position by manoeuvring valve lift feedback control. 2) Manoeuvring Valve Lift Feedback Control When operating the ‘PROGRAM BY-PASS’ switch on W/H or
During the manoeuvring valve lift feedback control, the manoeuvring ECR console, the manoeuvring valve lift is not controlled by
: Manoeuvring zone
valve lift corresponds to the telegraph lever position. following the time program; the valve lift is controlled to
(RPM feedback control) For feedback of the valve lift, two detectors are provided in the driving immediately match the telegraph lever position.
: Normal Sea-going zone motor box. During operation, one of these two detector outputs is used However, this program by-pass is not effective while the
(Valve lift feedback control)
for a feedback signal according to V. LIFT F.B. SIGNAL selector manoeuvring valve lift is changing under the time program, where
switch on the manoeuvring control box. The remote control system the ‘IN PROGRESS’ indication lamp is lighting on.
Rev. Order Signal compares the signals from these detectors. To operate the program by-pass,
(Valve Lift) - Force the time program to finish by operating the telegraph
In case the difference between the two signals exceeds a preset value, transmitter so that its desired valve lift moves to coincide with
Normal MAIN TURBINE REMOTE CONTROL SYSTEM FAIL, alarm actual lift. Ensure IN PROGRESS lamp turning off.
Zone changes, when sea-going sounds in the W/H and ECR, and the cause of the fault : VALVE LIFT - Operate the telegraph lever to the desired position, after the
valve lift exceeds a zone
preset value. FEEDBACK TROUBLE is indicated on the manoeuvring control box. ‘PROGRAM BY-PASS’ push button is pressed.
In this case, the manoeuvring valve is kept at its current lift, and is
controllable by the telegraph lever. However, Direct Control is still 4) Operation of the Telegraph Lever to ‘STOP’ Position
available to operate the manoeuvring valve in the ECR or machine side
in this condition. In case one of the signals is abnormal at the signal (1) When the telegraph lever is moved to the STOP position, the
Astern Ahead manoeuvring valve closes in accordance with the profile (③ and
select switch position “NO.1 WORKING NO.2 S/B” in the
Full Full Half Slow Dead Stop Dead Slow Half Full Rung Up manoeuvring control box, control signal for valve lift changes to the ④ in ahead operation, (⑦ in astern operation) of Illustration
Again Slow Slow normal one automatically. So valve lift feedback control is still 5.2.1b, and propeller revolutions decrease gradually.
available. (2) The astern (ahead) manoeuvring valve starts opening by RPM
feedback control circuit to decrease the revolutions to zero, and
Illustration 5.2.1a Telegraph Lever Position 3) Time Program the braking steam is supplied.
(3) When the revolutions are less than “A” RPM, the manoeuvring
1) RPM Feedback Control (1) Acceleration / Deceleration Time Program valve is closed upon elapse of a preset time.
The remote control system has two speed detectors for control, and for During the operation with telegraph lever except for STOP (4) When the revolutions exceed “B” RPM ahead (astern) due to
RPM feedback control one of these two detector outputs is used for a operation, the remote control system controls the manoeuvring inertial rotating, the astern (ahead) manoeuvring valve is opened
feedback signal according to the ‘REV. SIGNAL’ selector switch on the

Final draft / 2007. 12. 28 5-5 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

again by the RPM feedback control circuit, and the braking steam 5) Reversing Operation (2) Astern to Ahead
is supplied. When the telegraph lever is operated from Astern to Ahead,
(5) When the revolutions are in the range of “A” to “B” RPM for (1) Ahead to Astern the reversing of rotating direction is performed in accordance
more than the period of the preset time “T2” after the When the telegraph lever is operated from Ahead to Astern, the with the following procedure.
manoeuvring valve is closed as in c), the astern (ahead) reversing of rotating direction is performed in accordance with the
manoeuvring valve start opening. When the revolutions come following procedure. - The astern manoeuvring valve is closed in accordance with
down to less than “A” RPM ahead (astern), the astern (ahead) the deceleration (7) of Illustration 5.2.1b
manoeuvring valve is closed after elapse of the preset time “T3”. - The ahead manoeuvring valve is closed in accordance with the
(6) The above procedures 3) ~ 5) are repeated, until the revolutions deceleration profile (③ and ④) of Illustration 5.2.1b - The ahead manoeuvring valve is opened to the lever
decrease to zero. position in accordance with the time program described in
(7) When the revolutions are within zero ± “G” RPM, and the auto - The astern manoeuvring valve is opened to the position paragraph Time Program.
spinning switch provided on ECR console is selected to ON equivalent to AST. “E” RPM in accordance with the
position, then auto spinning is automatically started. acceleration profile (⑤) of Illustration 5.2.1b and the brake
AH Shaft Revolution
steam is applied. Then, when the propeller revolutions reach
“D” RPM, further acceleration is performed to astern side
Shaft
Revolution again.
0 rpm
“B” rpm - The manoeuvring valve lift is controlled by RPM feedback
(ab. 10 rpm)
control, so that the revolutions match the telegraph transmitter
“A” rpm
(ab. 3 rpm) position.
AST
0 rpm
0% AH AH Manoeuv. Valve Lift
*
*
*
Shaft Revolution ①
T1 T1 T2 T3 Valve Close
Manoeuv. 0 rpm
Valve Lift “A” rpm : Propeller stopping speed Each setting value “D” rpm ⑦
(To Counter Direction) “B” rpm : Inertial rotating speed is variable.
AST
Maneuv. Valve Lift AST
AH
Illustration 5.2.1c Brake Steam Supplied Sequence

③&④ Illustration 5.2.1f Manoeuvring Valve Lift In Reversing Operation

AHD Valve (Astern to Ahead)
(AST) ⑤
⑥
Shaft Revolution
“E” : Equivalent to steam chest press.
AST
Manoeuv. Lever at ab. 24.5bar
Shaft Revolution
“D” rpm : Astern program hold reset speed Each Setting value
“E” rpm : Astern program hold maneuv. valve lift is variable.

Manoeuv. Valve Lift

Illustration 5.2.1e Manoeuvring Valve Lift In Reversing Operation
Time (Ahead to Astern)

AST
(AHD)

Illustration 5.2.1d Example of Typical Control In

Deceleration

Final draft / 2007. 12. 28 5-6 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

6) Auto Spinning
When the following conditions are satisfied ;
AH
- CONTROL MODE switch provided on ECR console is set to
LEVER position.
2.5min 3min 3min
- The telegraph lever in duty position is set at STOP position.
“F” rpm
- AUTO SPINNING switch provided on ECR console is set to ON
position. (ab. 6 rpm)
- The main turbine is in trip-reset condition. “G” rpm
- The propeller revolution is within zero ± G rpm.

The auto spinning mode is activated automatically, and the SPIN ZONE
“G” rpm
lamp provided on W/H and ECR console turns on. Shaft Revolution
“F” rpm
After approximately 2.5 minutes without the revolutions exceeding zero
±“G” rpm, the astern manoeuvring valve is opened to a preset lift and
the AUTO SPINNING ON lamp provided on the W/H and ECR
console turns on. Then, if the revolutions exceed AST. “F” rpm, the
AST Shaft Revolution
astern manoeuvring valve is closed. Normally, the ahead manoeuvring
valve is opened 3 minutes after the astern manoeuvring valve is opened. Maneuv. Valve Lift
When the revolutions are increased to AH “F” rpm or more, after the
direction of spinning is changed from astern to ahead, auto spinning is
“F” rpm : At the speed to close maneuvering valve
applied in the astern direction again. Thus, the auto spinning operation Each setting value
continues to repeat, changing its direction approximately every 3 “G” rpm : To start auto spinning after abs. of shaft
minutes. (See Illustration 5.2.1g) is variable.
rev. under the speed for 2.5 min.
When the telegraph lever is operated to any position during the auto
spinning operation, the auto spinning circuit is by-passed immediately,
and the manoeuvring valve is controlled in accordance with the lever
Illustration 5.2.1g Auto Spinning Sequence
position. If the AUTO SPINNING change over switch is set to OFF, the
auto spinning control is stopped immediately and the AUTO
SPINNING OFF lamp provided on W/H and ECR consoles turns on.

When AUTO.SPINNING change over switch is set to ON, AUTO

SPINNING ON lamp flickers twice.
Then AUTO SPINNING ON and AUTO SPINNING OFF lamps turn
off.

Final draft / 2007. 12. 28 5-7 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

7) Monitoring Function during Auto- Spinning Control Illustration 5.2.1h Block Diagram for Auto Spinning

(1) Shaft Stop

When the propeller revolutions are less than ±“G”rpm (about
Telegraph Telegraph AUTO
AUTOSPINNING AUTO
AUTOSPINNING
1rpm) for longer than 3 minutes, the SHAFT STOP indication Telegraph
“Stop”
Telegraph
“Stop”
SPINNING
ON
SPINNING
OFF
“Stop” “Stop” ON OFF
lamp on the manoeuvring control box turns on. Position
Position Position
Position
<W/H> <ECR> <W/H> <ECR>
When the turning gear is engaged and the propeller revolutions
<W/H> <ECR>
are less than ±0.1 rpm for longer than 3 minutes, the “SHAFT NOT
NOT
STOP” indication lamp on the manoeuvring control box turns on.
This function is available regardless of auto. spinning control
Lever ASTERN
ASTERNMANOEUV.
MANOEUV.V.
V. ASTERN
ASTERNMANOEUV.
MANOEUV.V.
V.IS
IS PROPELLER
PROPELLERREVOLUTION
REVOLUTION ASTERN
ASTERNMANOEUV.
MANOEUV.V.
V.
Control OPENING
OPENINGORDER
ORDER OPENING
OPENINGTO
TOPRESET
PRESETLIFT
LIFT EXCEEDS
EXCEEDSAST.
AST.“F”
“F”(6)
(6)RPM
RPM IS
ISCLOSED.
CLOSED.
(2) Auto Spinning Failure
When the propeller revolutions do not reach AH/AST “F” rpm
“YES”
(about 6rpm) in either direction within 3 minutes opening the PROPELLER REVOLUTION
manoeuvring valve the auto spinning started, AUTO. SPINNING MANOEUV. DUTY MANOEUV. DUTY EXCEEDS AH. “F” (6) RPM
“W/H” “ECR”
FAILURE indication lamp on the manoeuvring control box and “NO”
W/H turns on.
“AUTO SPIN OFF” on the ECR sub panel indicator lamp flickers.

(3) Auto Spinning Over Speed AHEAD

MAIN AHEADMANOEUV.
MANOEUV.V.
V. PROPELLER
PROPELLERREVOLUTION
REVOLUTION AHEAD
AHEADMANOEUV.
MANOEUV.V.
V.IS
IS AHEAD
AHEADMANOEUV.
MANOEUV.V.
V.
When the propeller revolutions are above AH/AST “H” rpm MAINTURBINE
TURBINE IS
TRIP-RESET ISCLOSED.
CLOSED. EXCEEDS
EXCEEDSAH.
AH.“F”
“F”(6)
(6)RPM
RPM OPENED
OPENEDTO
TOPRESET
PRESETLIFT
LIFT OPENING
OPENINGORDER
ORDER
TRIP-RESET
(about 12rpm), the AUTO SPINNING OVER SPEED indication CONDITION
CONDITION
lamp on the manoeuvring control box turns on. Then the main 3 MINUTES
turbine comes to tripped condition. “AUTO SPIN OFF” on the
ECR sub panel indicator lamp flickers. TURNING
TURNINGGEAR
GEAR
DISENGAGE
DISENGAGE
AUTO
AUTOSPINNING
SPINNING TURBINE TRIP
Note OVER
OVERSPEED
SPEED
When “ Warming through” switch is selected under the direct control
<MCB>
mode at ECR and the propeller revolution is more than AH/AST “H” rpm, PROPELLER
“AUTO SPIN PROPELLERREVOLUTION
REVOLUTION
the turbine trips and “SPINNING OVERSPEED” indication lamp on the OFF” Lamp
EXCEEDS
EXCEEDS±±“H”
“H”(12)
(12)RPM
RPM
manoeuvring control box turns on. is off

<ECR>
PROPELLER
PROPELLERREVOLUTION
REVOLUTION
NOT
NOTEXCEEDS
EXCEEDS±±“G”
“G”(1)
(1)RPM
RPM
PROPELLER
PROPELLERREVOLUTION
REVOLUTION
IS
ISWITHIN
WITHIN±±“G”
“G”(1)
(1)RPM
RPM AUTO “YES”
AUTOSPINNING
SPINNING SHAFT
SHAFTSTOP
STOP
FAILURE
FAILURE
<W/H> <MCB>
<W/H> <ECR>
PROPELLER
PROPELLERREVOLUTION
REVOLUTION
2.5
2.5MINUTES
MINUTES NOT
NOTEXCEEDS
EXCEEDS±±“F”
“F”(6)
(6)RPM
RPM

TELEGRAPH
TELEGRAPHIS
ISUPRATED
UPRATED
SPIN
SPINZONE TO
ZONE TOOTHER
OTHERDIVISION.
DIVISION.
<W/H> <ECR>

AUTO
AUTOSPINNING
SPINNINGCHANCEL
CHANCEL

Final draft / 2007. 12. 28 5-8 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

8) Overspeed Preventer Control

When the “OVERSPEED PREVENTER ON” push button is pressed,

Telegraph Lever Control A
the overspeed preventer control to prevent overspeed is effect as
described below N
- Once propeller revolutions exceed the racing trip level (105% of
D
MCR) due to some cause, the order to manoeuvring valve is
reduced by preset value. Shaft revolutions exceed the racing
- Shaft revolutions are reduced to the racing trip reset level.
trip level (105% of MCR).

- When the revolutions reach the reset level, overspeed preventer

Push Button
control is canceled, and shaft revolutions return to the lever
position according to the time program. OVERSPEED
Set Point of
PREVENTER
rpm/Valve Lift ON
Unexpected revolution Rpm feedback Set point returns
raise-up occurs due to control operates to lever position
rough sea condition with set point at according to time
such as racing. reset level. program.

Lever Position RPM controller starts operating with (W/H)

Reset Level set point at reset level.
Time
Actual Revolution
Overspeed preventer
Control Lamp on
Racing Trip Level Shaft revolutions reaches
at reset level. ON
Reset Level

Time
Indication Lamp
Illustration 5.2.1i Control Pattern of Overspeed Preventer Control
(W/H) (MCB)
Lamp off

Shaft revolution / valve lift returns to Normal operation by

lever position according to time program. telegraph is available.

Illustration 5.2.1j Block Diagram of Rough Sea Control

Final draft / 2007. 12. 28 5-9 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

5.2.2 ECR Manoeuvring 4. Warming through Individual causes are indicated on the manoeuvring control box in the ECR.

1. Lever Manoeuvring When the following conditions are satisfied and the operator pushes the a) Main condenser hotwell water level high high
“WARMING THROUGH” push button. b) Stern tube bearing temperature high high
In the ECR, similar automatic control to the W/H operations can be performed c) One boiler trip
by operating the lever of the telegraph receiver. The time program control, the This time “WARMING THROUGH” indicator turns on. d) Main condenser vacuum low low Automatic slow down (I)
RPM feedback control, the manoeuvring valve lift feedback control, and auto e) Main steam temperature high
spinning are available in the same manner as W/H control, and the program by- f) Main steam pressure low low
1) Control position is ECS or M/S
pass can be performed as well. g) Main thrust pad high temperature
The rough sea control is also available during lever manoeuvring in the ECR,
2) Control mode is DIRECT h) Main boiler steam drum level high
but selection of the rough sea control is limited only in W/H. Automatic slow down (II)
i) Main boiler steam drum level low
2. Direct Control Manoeuvring 3) Not trip condition

The manoeuvring valve lift can be controlled by operating the direct control
switch (AHEAD, ASTERN), referring to the revolution indicator provided in
the ECR. The time program control, the RPM feedback control and the
manoeuvring valve lift feedback control are not available under this direct
control.
4) “WARMING THROUGH” indicator lamp turned-off 1. In Case Condition a), b), c), d), e), f) or g) – Automatic Slow Down (I)
5) Telegraph handle position is set at “STOP” position 1) If the lever position is higher than AH. DEAD SLOW, and one of the
conditions continues for longer than the time set for each condition,
6) Propeller speed less than the warming through overspeed level then the revolutions are reduced to AH. DEAD SLOW.

3. Control Method Change-over
Change-over of the control method between lever control and direct control is
performed as described in the following paragraphs.
Change-over is not possible if the manoeuvring duty is not set to ECR, or is in
the process of being transferred.
When the manoeuvring duty is transferred to another position, the control
method is automatically changed to the permitted method for each position as
shown in Table 1-1.
Effective method is indicated by lamps on the ECR console.
1) Lever Control to Direct Control
When the control method select switch provided on the ECR console is
turned from LEVER to DIRECT, the servo motor actuates the
manoeuvring valve lift to increase/decrease according to the movement
of the direct control switch.
During direct control, the lever control circuit is not effective but
follows the valve lift feedback, preparing for return of the control
method to the lever control.
2) Direct Control to Lever Control
When the control method select switch provided on the ECR console is
turned from DIRECT to LEVER, the lever control becomes effective.
Because the lever control circuit follows the valve lift feedback during
direct control, the change over can be done without bumping.
If the lever position is not coincident with the propeller revolutions at
the time of this change over, the revolutions are controlled according to
the time program as described in the Time Program paragraph, whether
the time program is by-passed or not.
If the program by-pass operation is desired in this case, it can be
effected by operating the lever as described in the paragraph for
program by-pass.
In this mode if the propeller speed exceed the same level as the auto spinning 2) When the lever is operated to AH. DEAD SLOW or lower, this slow
down can be reset.
overspeed level, the turbine trips. And then “AUTO SPINNING
(Even if the condition recovers to normal, unless the above reset
OVERSPEED” alarm is outputted to each panel and “AUTO SPINNING
action is carried out, the control system keeps AH. DEAD SLOW on.)
OVERSPEED” LED on manoeuvring control box turns on. This trip is reset
when manoeuvring valve becomes neutral position.
Condition
When any of the following condition occurs, Warming Through Mode is
released and the indicator turns off. Occurs
1) Control mode is changed over to LEVER Not Occurs Time
Revolution Time for delay of starting action is
2) Turbine trip
adjustable for each conditions
Lever Position
3) Push the “WARMING THROUGH” push button with the indicator lamp
turned-on
AH Dead Slow
4) Telegraph handle position is reset except the “STOP” position Time
5.2.3 Machine Handle Manoeuvring
Illustration 5.2.2a Control Pattern in Condition a), b), c), d), e), f), g)
Pressure gauges, vacuum gauge and revolution indicator is provided for
reference during operation with the mechanical handle.
When the mechanical handle is operated to other than the neutral position, the
remote control system shuts down control oil to the servo motor for the
manoeuvring valve as described in the paragraph on Automatic Trip. It cannot
be reset until the handle returns to the neutral position.
5.2.4 Automatic Slow Down
When one of the following conditions occurs during lever control, the propeller
revolutions are automatically reduced according to the following paragraphs
and the AUTO SLOW DOWN alarm sounds in the W/H, ECR and M/S.

Final draft / 2007. 12. 28 5 - 10 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

2. Condition h) or i) – Automatic Slow Down (II)

1) 12 sec after the condition occurs, the manoeuvring valve lift is Drum Level
controlled to decrease at the ratio of 100% per 11 minutes until it
reaches a set value of valve lift. This ratio will be adjusted onboard. Valve Lift
2) When the normal condition is recovered, decreasing of the valve lift
stops. The valve lift is controlled by the lever position according to the Valve lift increases at the ratio
time program after a reset action by operating the lever to a lower
position. Drum Level according to time program. Valve Lift
Ratio : 100%-11 min (*)
3. Cancel of Automatic Slow Down 100%
(refer to figure 1-15) 12sec 12sec
The function of automatic slow down can be cancelled by pressing the “AUTO Lever
SLOW DOWN BY-PASS” push button provided on W/H, both wings and ECR
console.
Position
During the condition of Automatic Slow Down, if cancel is selected, “SLOW
DOWN BY-PASS” indication lamp on the W/H and ECR console is lighting on,
and normal telegraph operation can be continued. Normal
4. Prewarning of Automatic Slow Down Low-Low
“PREWARNING SLOW DOWN” alarm is given to W/H for a preset time Set Level
before automatic slow down operation.

“PREWARNING SLOW DOWN” alarm is given to W/H regardless of control

position.

(*) This ratio will be adjusted on board.

The Same Operation is performed in condition of drum level high.

Illustration 5.2.2b Control Pattern In Condition of Main Boiler Steam Drum Level High or Low

Final draft / 2007. 12. 28 5 - 11 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

Telegraph lever on duty is set at A Telegraph Lever Control A

“AH DEAD SLOW” or higher
N N
D D
Main Condenser Hotwell
Timer No.1 Boiler Drum Level
Water Level High Timer
High
O
LED No.2 Boiler Drum Level R
Timer
Stern Tube Bearing High LED
Timer O
Temperature High High
No.1 Boiler Drum Level R
Timer
LED Low
O
R Auto
One Boiler Trip Timer No.2 Boiler Drum Level Slow Down
Timer
Low LED By-pass
LED
Main Condenser O
Timer Auto Maneuvering valve lift is
Vacuum Low Low Slow Down (W/H)
R decreased to full-close, (ECR)
By-pass with a ratio of 100% per
LED 11 min.
Main steam temperature
Timer (This ratio will be adjusted
high Auto Slow Down
(W/H) onboard.)
(ECR)
LED Indication Lamp (W/H) (ECR)
Normal operation by
Main steam pressure telegraph is available.
Timer
low
Slow Down By-pass
LED
Indication Lamp (W/H) (ECR)
Main Thrust Pad
Timer Note
Temperature High High
Cause indication LED is prepared on cause indication panel.
LED

Propeller Revolutions Figure 1-15 Block Diagram for Automatic Slow Down (II)
Automatically Reduced to
“AH DEAD SLOW”

Auto Slow Down

Indication Lamp (W/H) (ECR)

Normal operation by
telegraph is available.

Slow Down By-pass

Indication Lamp (W/H) (ECR)

Note
Cause indication LED is prepared on cause indication panel.

Figure 1-15 Block Diagram for Automatic Slow Down (I)

Final draft / 2007. 12. 28 5 - 12 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

5.2.5 Program Interlock 5.2.6 Control System Monitoring Function

Acceleration of the main turbine is stopped and “PROGRAM INTERLOCK”
alarm sounds in the W/H and ECR, when either of the following conditions
occurs. Individual causes are indicated on the manoeuvring control box in ECR.
- Main Steam Pressure Low
1. M/T Remote Control System Failure
When one of the following conditions occurs, “M/T REMOTE CONTROL SYSTEM FAIL” alarm sounds in the W/H and
ECR, and individual status is indicated on the mimic panel of the manoeuvring control box. In these cases the following action
is carried out automatically or is required to be carried out by manual operation.

The function of the program interlock can be cancelled by the “PROGRAM Table 1-3 M/T Remote Control System Failure
INTERLOCK BY-PASS” switch provided on the ECR console. During the
cancel operation, “PROGRAM INTERLOCK BYPASS” indication lamp in the
Item of Failure Action
W/H and ECR console is lighting on.
In case both CPU/MEMORY systems fail, the valve lift is kept at the current position, unless operator manoeuvres by
(A) Microcomputer Abnormal
direct control or mechanical handle.
Telegraph Lever Control A
N 1) In case of circuit disconnection in manoeuvring duty position, the valve lift is kept at current position unless duty
(B) W/H telegraph transmitter potentiometer disconnection
D position is changed over to another position or changed to direct control/mechanical handle control.
(C) ECR telegraph receiver potentiometer disconnection
Main Steam Press Low ime
Time 2) In case of circuit disconnection in other than manoeuvring duty position, only the alarm sounds.

1) In case only No. 1 signal is abnormal at the signal select switch position “NO.1 WORKING NO.2 S/B “ in the
LED manoeuvring control box, control signal for revolution automatically changes to No. 2 signal, and RPM feedback
control continues.
2) In case only one signal selected as RPM feedback signal is abnormal, control is automatically changed to valve lift
PROGRAM (D) No.1 revolution signal abnormal
INTERLOCK control. Manual change to remaining normal signal as feedback signal by selector switch is necessary to retain
(E) No.2 revolution signal abnormal
By-pass RPM feedback control.
3) In case only one signal not selected as RPM feedback signal is abnormal, RPM feedback control is still available.
4) In case both signal abnormal RPM feedback controls are not available, but valve lift feedback control in the lever
control is still available.
(ECR)
1) In case No.1 signal is abnormal at the signal select switch position “NO.1 WORKING NO.2 S/B” in the manoeuvring
Main turbine Stops control box, control signal for valve lift automatically changes to No.2 signal. Valve lift feedback control is still
to Accelerating
available.
Program Interlock 2) At the time that only one signal selected as valve lift feedback signal is abnormal, valve lift is kept at current position
(F) No.1 manoeuvring valve lift feedback signal abnormal until handle control is carried out, or the valve lift feedback signal is manually changed to remaining normal signal
Indication Lamp (W/H) (ECR) (G)No.2 manoeuvring valve lift feedback signal abnormal by selector switch on the manoeuvring control box.
Normal operation by 3) In case only one signal not selected as valve lift feedback signal is abnormal, valve lift feedback control is still
telegraph is available. available
Program Interlock
4) In case of both signals abnormal, the valve lift feedback control is not available, and valve lift is kept at current
By-pass
position. No control function of the lever control is available, but direct control or the mechanical handle control still
Indication Lamp (W/H) (ECR) remains.
Note Auto slow down cannot be carried out by the remote control system if the signal is disconnected, and it is necessary to
(H) Auto Slow Down Signal Abnormal
Cause indication LED is prepared on cause indication panel. carry out a manual slow down by the operator with reference to control instrumentation.

(I) Auto Slow Down By-pass Push Button Circuit 1) Auto slow down cannot be bypassed during the lever control, when it occurs in manoeuvring duty position.
Figure 1-16 Block Diagram for Program Interlock Disconnection 2) Auto slow down override is effective during the lever control, when it occurs in other than manoeuvring duty position

(J) Overspeed preventer switch circuit Overspeed preventer is not available.

Turning Gear Interlock
(L) LEVER DRIVER abnormal Control changed to the direct control or mechanical handle control.
When the turning gear is engaged, both a mechanical interlock and an
(M) DIRECT DRIVER abnormal Control changed to the lever control or mechanical handle control.
emergency trip circuit shut off the control oil to the servo motor of the
manoeuvring valve, and the valve closes to trip. When the gear is disengaged,
reset can be accepted in accordance with the procedure in the paragraph “Reset
of Emergency Trip”

Final draft / 2007. 12. 28 5 - 13 Part 5 Main Turbine Remote Control System
CLEAN FORCE
2. M/T Control System Power Failure
When one of the following conditions take place, M/T CONTROL SYSTEM
POWER FAIL alarm sounds in the W/H and ECR, and individual status is
indicated on the mimic panel of the manoeuvring control box ;
(1) Main electric source failure (AC)
(2) Emergency electric source failure (DC)
(3) Direct control electric power source failure
In case of (1) and (2) during lever control, or in case of (2) and (3) during direct
control, the valve lift is kept at the current position and cannot be controlled
unless the control method (lever/direct) is changed to another. (Change over of
control method and transfer of duty position are still available under these
conditions.)
3. Engine Telegraph Power Failure
In this case, main and sub telegraph functions described in the Engine
Telegraph paragraph are not available, but the lever control is still available.
“Telegraph Power Fail” alarm is annunciated in W/H, ECR and IAS.
4. Wrong Way
If the following conditions occur, the WRONG WAY alarm sounds in the W/H
and ECR:
1) When there is a difference in direction (Ahead/Astern) between the
W/H telegraph transmitter and opening of the manoeuvring valve in
direct mode control, and this condition is kept for longer than the
preset time.
2) When there is difference in direction (Ahead/Astern) between W/H
telegraph transmitter and ECR telegraph receiver during the ECR
control and this condition is kept for longer than preset time.
5. Mimic Board for ECR
The mimic board is provided on the manoeuvring control box in the ECR to
indicate the status of the manoeuvring system by means of LED indicators.
5.2.7 Safety System
1. Manual Trip
Manual trip switches are provided at the following places ;
(1) W/H console : Push button
(2) ECR console : Push button
Final draft / 2007. 12. 28
Machinery Operating Manual
(3) Local : Selector switch (1) The above trip conditions except (9) are eliminated.
When the manual trip switch is operated, the main turbine is tripped by closing (2) The telegraph transmitter/receiver lever in the manoeuvring duty
the manoeuvring valve. At the same time, the EMERG. TRIP alarm sounds in position is placed at the STOP position.
the W/H, ECR and M/S, and the switch operated position is indicated on the
cause indication panel in the ECR. (3) The actuator for the servo motor of the manoeuvring valve is at the
stop position (Manoeuvring valves for both ahead and astern are
2. Automatic Trip closed.)
Reset can then be effected after the RESET pushbutton provided in the
The main turbine is automatically tripped by closing the manoeuvring valve W/H, both wings, ECR and M/S is pushed for confirmation. The
when one of the following conditions occurs ; TURBINE RESET lamp changes to continuous lighting.
(1) Over speed
5. Prewarning of Automatic Trip
(2) LO pressure low low
* (3) HP turbine rotor excessive vibration (H-H) In case of the conditions marked with “PREWARNING TRIP” alarm is given
* (4) LP turbine rotor excessive vibration (H-H) for preset time before automatic trip operation.
* (5) HP turbine rotor excessive axial displacement (H-H) “PREWARNING TRIP” alarm is given to W/H regardless of control position.
* (6) LP turbine rotor excessive axial displacement (H-H)
1) EMERGENCY TRIP BY-PASS lamp is off
* (7) Main condenser vacuum low low (V-L) 2) A condition marked with “*” is occurred
* (8) Steam drum level very high
(9) Control oil pressure low-low
(10) Two boilers trip
(11) Manual trip
(12) Emergency manoeuvring handle not in neutral position
(13) Auto spinning over speed
(14) Turning gear engaged
*(15) Main thrust pad excessive axial displacement (H-H)
In the event of a trip, EMERG. TRIP alarm sounds in the W/H, ECR and M/S,
and the above individual causes are indicated on the manoeuvring control box
in the ECR.
3. Cancel of Automatic Trip
For the conditions marked with “*”, the automatic trip is cancelled when the
EMERG. TRIP BY-PASS selector switch is set at the BY-PASS position on
W/H, bridge wings and ECR consoles and on the emergency control panel in
the machine side.
Under this override operation, the main turbine can be started even under these
abnormal conditions. In this case, the TRIP BY-PASS indication lamp on W/H,
bridge wings and ECR console and on the local emergency control panel lights,
and individual abnormal causes are indicated on the cause indication panel in
the ECR.
4. Reset of Emergency Trip
After all the following conditions are satisfied, the TURBINE RESET
indication lamp provided in the W/H, ECR and M/S starts flickering ;
5 - 14 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

5.2.8 Safety System Monitoring Function

W/H Indication Lamp
Manual trip from W/H (Switch) "EM'CY TRIP" ON NOT "EM'CY TRIP" OFF
1. Main Turbine Safety System Failure

M/T SAFETY SYSTEM FAIL alarm sounds in the W/H and ECR, and the ECR
Manual trip from ECR (Switch) "EM'CY TRIP" ON NOT "EM'CY TRIP" OFF
individual cause is indicated on the cause indication panel in the event of the
Manual trip from M/S (Switch) M/S
following conditions ; "EM'CY TRIP" ON NOT "EM'CY TRIP" OFF

(1) Trip solenoid valve circuit disconnection

Timer HP turbine rotor excessive vibration HP turbine rotor vibration NORMAL
Timer LP turbine rotor excessive vibration LP turbine rotor vibration NORMAL
(2) Trip sensor circuit disconnection
Timer HP turbine rotor excessive axial displacement HP turbine rotor axial displacement NORMAL
Timer LP turbine rotor excessive axial displacement LP turbine rotor axial displacement NORMAL
(3) Manual trip switch circuit disconnection
Timer Main condenser vacuum low-low Main condenser vacuum NORMAL
Timer Main thrust bearing vibration Main thrust bearing vibration NORMAL
(4) M/T trip override switch circuit disconnection
Timer Steam drum level very high Steam drum level NORMAL

(5) Micro-computer abnormal (safety)

Prewarning Shut Down

(6) Safety rev. signal abnormal

Even if the safety system has failed, the manoeuvring valve keeps the current M/T TRIP CANCEL
M/T TRIP CANCEL
position and can be controlled by the control lever.

2. Main Turbine Safety System Power Failure

In case of trip due electric source failure, the SAFETY SYSTEM FAIL alarm Both boiler trip Both boilers NORMAL
sounds in the W/H and ECR. Over speed Over speed NORMAL
Even if the Safety system has failed, the manoeuvring valve keep the current LO pressure low-low LO pressure NORMAL
position and can be controlled by the control lever. Em'cy manoeuvring handle not in neutral position Em'cy maneuvering handle in neutral position
Hard Wire Relay

Auto spinning over speed Auto spinning NORMAL

Logic Circuit
Turning gear engaged Turning gear not engaged Telegraph Level in Duty
Control oil pressure low-low Position is at Stop
Lamp changes to Position & Actuator is at
Trip when energized continuous lighting Stop Position
Control oil pressure
Solenoid Valve for is raised
Manoeuv. System
Hard Wire Relay (TRIP-RESET) Reset when deenergized "TURBINE RESET"
Operating oil
is energized lndication Lamp flickers
pressure stop Solenoid Valve for
acting on servo Manoeuv. System
Over speed (HPT/LPT) piston. Reset is confirmed by
(TRIP-RESET)
Turning gear interlock A "RESET" PB
is deenergized
N
Mechanical device D
MANOEUVRING VALVE CLOSE Over speed NORMAL
Turning gear interlock not active
Mechanical device

Illustration 5.2.8a Block Diagram for Safety System

Final draft / 2007. 12. 28 5 - 15 Part 5 Main Turbine Remote Control System
CLEAN FORCE Machinery Operating Manual

Part 6 : Description of Critical Operation

6.1 Flooding in the Engine Room ............................................................ 6 - 1
6.2 Main Boiler Emergency Operation .................................................... 6 - 2
6.2.1 One-Boiler Operation ............................................................. 6 - 2
6.2.2 Operation of Stand by FDF ..................................................... 6 - 2
6.2.3 Emergency Operationl ............................................................ 6 - 3
6.3 H.P. and L.P. Turbine Solo Running Operation ................................. 6 - 6
6.4 Restore Engine Room Plant from Dead Ship Condition .................... 6 - 7

Illustrations
6.1a Floodable time, control position and method for valve operation.... 6 - 1
6.2.3a Boiler Emergency Operation Panel ............................................... 6 - 4
6.3a H.P. and L.P. Turbine Solo Running Operation ................................ 6 - 5

Part 6
Description of Critical Operation

Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

Part 6 : Description of Critical Operation Illustration 6.1a Floodable time, control position and method for valve operation

6.1 Flooding in the Engine Room

1. General Procedure

Is E/R bilge pump running ?

Under normal circumstances, the engine room bilges are pumped to the bilge
holding tank using the E/R bilge pump. The pump is started and stopped, and the LEVEL STILL RISING LEVEL NOT RISING

suction valves opened and closed, by level switches in the port and starboard Start bilge pump, taking Find and isolate the source of
suction from the direct bilge ingress of water.
midship bilge wells (covered by the automatic system). The bilge holding tank is suction (STBD fwd) & discharging Restrict the rate of entry by any
YES NO
pumped through the bilge water separator with the water being discharged directly overboard. means available, such as
Start E/R bilge pump, taking suction shoring, bandaging, caulking,
overboard and any oil separated out by the bilge water separator being Is E/R bilge pump pumping ?
from its bilge main and any of the associated if the source of water cannot be
discharged to the oily bilge tank. bilge wells, and ensure that it is pumping. isolated by valves.
If it does not pump immediately, investigate
in particular that no additional suction valves are
If, however, the level in the bilge well being pumped has not been lowered to the open.
LEVEL STILL RISING
pump stop level after the pump has started, and after a preset (adjustable) time,
Advise bridge. LEVEL NOT RISING
an alarm is given on the central alarm system. Stop the main engine and secure
NO YES Find and isolate the source of
it aganist the ingress of water.
Isolate equipment from the main ingress of water.
Note Check reason why E/R bilge switchboard before the equipment Restrict the rate of entry by any
pump is not pumping. means available, such as shoring,
Flooding in the engine room may be due to collision, running aground, Check the position of all valves,
is flooded.
bandaging, caulking, if the source
Before the sea water pumps are
corrosion of water pipes, broken rubber expansion bellows, etc. and the particularly that extra suction flooded, it will be necessary to shut of water cannot be isolated by
valves are not open. down the boilers, stop the turbine valves.
immediate action will depend upon the nature and severity of the
Generators, and start the
flooding. LEVEL STILL RISING LEVEL NOT RISING emergency diesel.
Secure the boilers against the
Find and isolate the source ingress of water. Secure the main
The first priority in any case of flooding must be to control the rise in water level, of ingress of water. Feed pumps, turbine generators
The inflow of water is exeeding Restrict the rate of entry by and diesel generator against the
either by controlling the inflow or pumping the water out. Pipework damage can the capacity of the reciprocating any means available, such as ingress of water
be relatively easily controlled by isolating sections, whereas hull damage is not bilge pump. shoring, bandaging, caulking,
if the source of water cannot
so easily checked. be isolated by valves.
Start No.1 Ballast pump for
Summon assistance using
Discharging from emergency bilge
Isolating sections of pipework will of necessity involve shutting down items of the engineer's call bell.
suction.
plant served by that section of pipework. To help avoid this, a fibre rope
wrapped around a sea water pipe is often effective in reducing the flow and also
Advise Bridge for further action.
acts to reinforce the pipe.

If the flow can be effectively reduced, use the large diameter bent welding rods
with the flux removed.

If the main circulating system is damaged and cannot be repaired in service, the
main engine and turbine generators will have to be shut down and the boilers
secured until repairs have been effected. If the sea water service system is
damaged and cannot be repaired in service, all engine room services will have to
be shut down and the emergency diesel generator started.

If plastic steel or other proprietary compound is used to repair a section of pipe,

follow the manufacturer’s instructions, and allow at least 24 hours after
application for the compound to dry before pressurising the pipe.

Final draft / 2007. 12. 28 6-1 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

6.2 Main Boiler Emergency Operation Note 9) Remove atomizer.

6.2.1 Dead Ship Starting
When neither shore power nor shore steam is available, a diesel generator is used
to start a boiler from dead ship conditions.
The diesel generator will provide power for fuel oil service pump, forced draft
fan, and necessary lighting in the machinery space.
Fuel oil service pump serve for supplying fuel oil to the burners using diesel oil
and air atomising until steam are available enough to heat heavy fuel oil to the
temperature required for burning.
1) Prepare a boiler for starting
Note
In accordance with “Inspections and setting prior to putting boiler in
service” 4.2.1 putting Boiler in Service
Watch the fuel oil temperature closely and, if necessary, stop the burner
and circulate the fuel oil until it reaches to suitable temperature.
12) Confirm that steam press, reaches about 18bar.
13) Start the main feed water pump and use main feed line.
14) Close superheater drain valves and leave open superheater air vent
valve(start up valve).
Note
Confirm the superheater outlet steam temperature.
15) Steam press. rises to approx. 50 bar and start the turbo generator.
16) Pressure rise to working steam press.
10) Maintain normal water level, as the boiler cools down, the water level
will drop.
11) Boiler press. drops to approx. 15bar.
12) Fully open the superheater drain valves and desuperheater drain valves.
Note
It is very important that all drains and vents in the superheater outlet are
kept open when there is no normal steam flow in the superheater.
Caution
1. Since sudden cooling of the furnace promotes uneven expansion and
may damage refractory and parts subkected to pressure, avoid
opening the access door until the furnace temperature has fallen.

2) Fill the boiler with distilled water until 100mm in the gauge glass. 17) Refer to 4.2.1.4. supply steam 2. Do not use cold feed water to cool a boiler.

3) Fully open the superheater and desuperheter drain and air vent valves. 6.2.2 Taking Boiler Out of Service 3. Empty the boiler gradually to avoid subjecting press. parts to sudden
changes in temperature.
Note 1) Carry out soot blowing and change fuel oil from heavy oil to diesel oil
Atomising air is used for nor. Tip at continuous fire before stopping the boiler.

4) Start the forced draft fan. 2) Stop the boiler by manual trip.

5) Start the F.O service pump. 3) Keep the forced draft fan operating for a while.

6) Light the burner at BGB. 4) Twice of furnace post purge (BGB).

7) Maintain the pressure of fuel oil. Note

A furnace post purge is carried out twice by manual re-purge switch. Re-
Note purge switch in BGB inside to be turned to “ON (BY-PASS)” and push the
In accordance with the attached “Main Boiler Starting up Curve” Keep FO No.1 burner “ON” button. After post-purge, this switch to be turned to
press at min. press. (2.2bar) and atomising air press. at 3.5bar on the “NOR”.
atomising air line pressure gauge.
5) Close main steam stop valve gradually, because sudden pressure drop is
8) Take care not to produce any smoke. harmful to piping.

Caution 6) Open the SH outlet vent valve and open SH drain valve 1/4 turn, if
Do not spray more oil than is appropriate for the amount of air available. necessary.

9) Check that steam press. reaches about 10bar. Note

In case that boiler is kept at hot condition or re-start within short period,
10) Start warming up of the auxiliary steam line and supply steam to the the valves should be kept close.
fuel oil heater.
7) Change ACC to MAN. Operation.
11) After proper temperature of fuel oil is secured, turn to heavy oil.
8) Close fully the fuel oil valves.

Final draft / 2007. 12. 28 6-2 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

6.2.3 Operation Method of One Boiler Shut Down Note

(During two boilers are running No.2 boiler will be shut down)
1) No.1 & No.2 Boiler is normally running.
2) Operate the soot blower (boiler, economiser) in No.2 boiler.
3) Change the fuel mode to FO only in No.2 boiler.
1. If the boiler is kept hot and re-started within a short period (1~2day),
valves market with * is kept at boiler operation condition.
2. In case of FO/FG dual burning or FG only burning, change to FO-only
burning mode at first, then stop the boiler.
(Change-over operation is referred to “Burner Control System”)
3. If the No.1 boiler is to be shutdown instead, follow the same procedure
siren for shuttingdown the No.2 boiler.

4) Lower the output of main turbine to less than 40%.

5) Decrease the No.2 boiler load to 0% using the “Boiler Load Ratio”
setting button.

6) Burner is fired at min load with only the No.1 burner.

7) Confirm the stability of control (FWC, ACC, STC) in No.1 boiler.

8) Change over to “MANUAL”, if necessary in No.2 boiler.

9) Confirm normal drum levels in No.2 boiler.

10) Stop the boiler by pushing the No.1 burner “OFF” button in No.2 boiler.

11) Confirm closing of FO emergency shutoff valve and FO piston valves in

No.2 boiler.

12) Furnace post purging in No.2 boiler.

13) Close the FO stop valve(BV-401) and atomise steam stop valve(BV-410)
for burner in No.2 boiler.

14) Close the air register in No.2 boiler.

15) FDF stop in No.2 boiler

16) Draw out the burner atomizer gun in No.2 boiler

*17) Close the superheater outlet vent valve (BV-311, BV-3-5)

18) Close all stop valves of No.2 boiler main steam line

*19) Fully open all drain valves of No.2 boiler main steam line

20) Close all stop valves of No.2 boiler feed water line

21) One boiler shutdown operation “FINISH”

Final draft / 2007. 12. 28 6-3 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

Illustration 6.2.3a Boiler Emergency Operation Panel

BURNER
EMERGENCY OPERATION
EMERG MODE FURNACE PURGE FO EMERG V
PURGE
NOR BURN NOR CLOSE

FINISH

NO.3 BURNER NO.1 BURNER NO.2 BURNER

NOR NOR NOR
OFF ON OFF ON OFF ON

Final draft / 2007. 12. 28 6-4 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

Illustration 6.3a HP and LP Turbine Solo Running Operation

Emergency Pipe (G)

Orifice Dia. 240mm (F)

Blind Flange (C)

L.P. Turbine L.P. Turbine L.P. Turbine

H.P. Turbine H.P. Turbine H.P. Turbine

Blind Flange (C)

From Emerg.
Spectacle Flange Spectacle Flange Spectacle Flange Steam Line
(Bline Side) (I) (Bline Side) (I) (Orifice Side) (I)

Ring Flange (A) Ring Flange (B) Ring Flange (A) Blind Flange (E) Blind Flange (E) Ring Flange (B) Root Valve
Spectacle Flange (H) Spectacle Flange (H) Spectacle Flange (H) Open
(Blind Side) (J) (Blind Side) (J) (Orifice Side) (J)

H.P. Turbine H.P. Turbine H.P. Turbine

Blind Flange (C)

L.P. Turbine L.P. Turbine L.P. Turbine

Main Steam Pipe Main Steam Pipe
Blind Flange (D)

Manoeuv. Valve Manoeuv. Valve Manoeuv. Valve

Normal Operation Operation with H.P. Turbine Only Operation with L.P. Turbine Only

Final draft / 2007. 12. 28 6-5 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

6.3 H.P. and L.P. Turbine Solo Running Operation 4. Operation by Emergency Hand Operation Device
(Emergency Operation)
In case the manoeuvring valve is operated by emergency handle on the machine
1. General side, take care the followings.

During a voyage, if any problems occur with the HP, LP turbines and it seems 1) When the main turbine is astern operation, astern steam spray valve (T-
impossible to continue the voyage, apply emergency piping and carry out solo 57) is opened by manual at local
running as in the following procedure.

2. Cruising by HP Turbine Alone :

1) Draw out the ring-flange (B) from the cross-over pipe and insert a
blind-flange (E) instead.

2) Draw out the blind-flange (C) from the cross-over pipe, and the blind-
flange (D) from the lower exhaust casing.

3) Connect the HP turbine exhaust directly to LP turbine exhaust casing

using the emergency piping (G).
For this connection, insert an orifice (F) between the cross-over pipe
and the emergency piping.

4) Disconnect the LP turbine coupling to avoid turning the LP turbine.

3. Cruising by LP Turbine Alone :

1) Draw out the ring-flange (A) from the cross-over pipe and insert a
blind-flange (E) instead.

2) Move the spectacle flange (I), (J) in the emergency piping (H) from
blind to orifice.

3) Disconnect the HP turbine coupling.

4) Ahead running can be carried out by operation of the root valve.

HP Turbine LP Turbine
Solo Running Solo Running
Steam Press. 39bar 3.2bar
Condition
Temp. 500°C 189°C
at Steam Chest
Output abt. 11,610 PS abt. 12,164PS

Propeller Revolution abt. 58.8 rpm. abt. 59.7rpm.

Final draft / 2007. 12. 28 6-6 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

6.4 Restore Engine Room Plant from Dead Ship Condition

Dead
DeadShip
ShipCondition
Condition

Shore
ShoreSupply
SupplyAvailable No Fill
FillThe
Thecondensate
condensatesystem
system atmos. draindrains
feed water tank, tank,
Available NoShore
ShoreSupply
SupplyAvailable
Available
deaerator,
deaerator,1LP
st stage heater and gland condenser.
feed heater and gland condenser.
Establish
Establishshore
shoresupply.
supply. Using emergency air compressor, bring emergency
ItDGnecessary
starting fill
air emergency
reservoir to diesel generator fuel
pressure.
tank from IGGfillGO
It necessary serv. tank.
emergency diesel generator fuel
Start
StartFO
FOservice
servicepump
pumpwith
withaaburner
burnerinin aaboiler,
boiler,
tank from drums.
Supply
Supplydiesel
diesel oil
oilto
tothe
theburner
burner with atomising air.
withatomising air.

Start
Startthe
theemergency
emergencygenerator,
generator,and
andsupply
supply
emergency
emergencyandandmain
mainswitchboards
switchboardsthrough
throughthe
the Start
Startboiler
boilerforced
forced draft
draftfan.
fan.
respective
respectivebreakers.
breakers. With
Withall
allrequired
required vents
vents and
anddrains
drains open,
open,commence
commence
to
toflash
flashthe
theboiler.
boiler.
Ensure
Ensurethatthatthe
thefurnace
furnaceisis adequately
adequatelypurged
purged prior
prior
to
toignition.
ignition.
Supply
Supplymain
main and
andemergency
emergencylighting
lightingthroughout
throughout the
the (Note
(NoteThe
Theboiler
boilershould
shouldbe
beflashed
flashed up
upmanually
manually
vessel.
vessel. from
fromthe
thelocal
localstation.)
station.)

IfIfthe
theboiler
boilerhas
has been
beenshut
shutdown
downfor
foraalong
longperiod,
period,
allow
allowfor
forlow
lowfuel
fuel pressure
pressureto
toenable
enableheat
heatand
and boiler
boiler
Put
Putthe
thefire
firedetection
detectionsystem
systeminto
intooperation.
operation. pressure
pressureto torise
riseslowly.
slowly.
Start
Startengine
engineroom
roomfans.
fans.

Put
Put the
the instrument
instrument air
air system
system into
into operation
operation
Put
Putthe
thegeneral
generalservice
serviceairairsystem
systeminto
intooperation.
operation. Open
Openboiler
boilerstop
stop valves
valvesto:to:
Put
Putthe
theDG
DG starting
starting air
airsystem
systeminto
intooperation.
operation. The
Thesuperheated
superheatedsteamsteamsystem.
system.
.. The
Thedesuperheated
desuperheatedsteam steamsystem.
system.
The
Theexhaust
exhauststeam
steamsystem.
system.
Put The
The6bar heatingsteam
LP heating steamsystem
system
Putthe
thefresh
freshwater
watercooling
coolingsystem
systeminto
intooperation.
operation.
DO Start-up
Start-upvalve
valve
DOsupply
supply
Start Ensure
Ensureallallsteam
steamline
linedrains
drains are
areopen.
Start Pre.
Pre.LO
LO pump.
pump. open.
Open
Openthethevalves
valvestotothe
theheating
heatingcoils
coils of
of one
oneFO
FO
settling
settlingtank,
tank,placing
placingthethecoil
coildrains
drainsto
tothe
the
Start up the main diesel generator and shift contaminated
contaminated drains
drainssystem.
system.
Start upload
electric the to
main
thediesel generator
main diesel and shift
generator and
electric load to the main
stop emergency generator. diesel generator and

Shut
Shutdrum
drumvent
vent when
whensteam
steamissues
issuesfrom
fromit,it, at
at
approximately
approximately2.0
2.0bar.
bar.
Put
Putthe
thesea
seawater
waterservice
servicesystem
systeminto
intooperation.
operation. Close
Closesuperheater
superheater and
and desuperheater
desuperheater drain
drain valves
valves
except
exceptsuperheater
superheateroutlet
outlet valve
valveand
and open
open main
mainstopstop
valve
valveat
at approximately
approximately2.5
2.5bar.
bar.

Fill
Fill aaboiler
boiler to
to100
100mmmm above
abovegauge
gaugebottom,
bottom,using
using
the
thedrain
drainpumps
pumps(or(or direct
directdrop
dropfrom
from deaerator).
deaerator). To Next Page

Final draft / 2007. 12. 28 6-7 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

From Previous Page

By
Bymanual
manualoperation
operationofofthe
theburner
burnerregisters,
registers,place
place With
Withthe
theboiler
boilersuperheater
superheaterbeing
beingcirculated,
circulated,as
as
the No.1 unit in use.
the No.1 unit in use. steam
steam being supplied to the feed pumpand
being supplied to the feed pump andturbine
turbine
When
Whenthe thefuel
fueltemperature
temperatureisisapproximately
approximately9090 ˚˚CC generator,
generator,allallthe
theboiler
boilerdrains
drainsand
andvents
ventscan
cannow
now
open settling tank outlet valve and close the diesel
open settling tank outlet valve and close the diesel be closed.
be closed.
oil
oilsupply.
supply. Continue
Continueto toraise
raisesteam
steampressure,
pressure,with
withfuel
fuelcontrol
control
Allow
AllowthetheNo.1
No.1burner
burnerto
tooperate,
operate,and
andcontinue
continuetoto on manual.
on manual.
raise
raise the steam pressure in the boiler, onheavy
the steam pressure in the boiler, on heavyfuel
fuel Check
Checkeach
eachsystem
systemnow nowin inuse,
use,and
andgradually
gradually
oil.
oil. change
changeover
overallallcontrol
controlsystems
systemsto toautomatic
automaticand/or
and/or
remote.
remote.
Ensure
Ensuresystems
systemsand andcomponents
componentsthat thathave
havebeen
been
used
usedareareplaced
placedbackbackononstand
stand -by
-bycondition
conditionor
or
isolated
isolatede.g.
e.g.cold start feed
emergency pump,
feed pump,emergency
emergency
As
Asthe
thesteam
steampressure
pressurerises,
rises,use
usethe
thecold start
emergency diesel
dieselgenerator
generatoretc.etc.
feed pump to maintain the boiler water
feed pump to maintain the boiler water level. level.
With
Withboiler
boilernow
nowbeing
beingfired
firedononheavy
heavyfuel
fueloil,
oil,the
the
fuel pressure will require adjusting to maintain
fuel pressure will require adjusting to maintain
pressure
pressurerise.
rise.
At
Ataaboiler
boilerpressure
pressureof
of60
60bar,
bar,close
closethe
theboiler
boilerstart
start --
up valve and ensure the boiler ACC steam
up valve and ensure the boiler ACC steam
flow/pressure
flow/pressurevalves
valvesare
areopen,
open,and
andchange
changeover
overthe
the
boiler master/fuel and air controllers to automatic.
boiler master/fuel and air controllers to automatic.
Start
Startauxiliary
auxiliarysea
seawater
watercirculating
circulatingpump
pumpto tosupply
supply The
Theboiler
boilershould
shouldnow
nowbe
beproviding
providingnormal
normalsteam
steam
Aux. condenser. When boiler at pressure
atmospheric condenser. When boiler at pressure to turbo generator/main feedpump/and
to turbo generator/main feed pump/and
approximately
approximately18 18bar
barpressure,
pressure,ensure
ensurethe
thedrains fuel
drains fueloil
oilheating
heatingetc.
etc.
pump system is operating to the deaerator.
pump system is operating to the deaerator.
Put
Putone
onemain
mainfeed
feedpump
pumpintointooperation
operationto
tomaintain
maintain
the boiler level.
the boiler level.
The
Theturbine
turbineexhaust
exhaustwill
willbe
betotothe
thedeaerator,
deaerator,steam
steam Start
Startup
upall
allremaining
remainingauxiliaries
auxiliaries -refrigeration
-refrigeration
air heater to aux. condenser.
air heater and HP dump to atmospheric condenser. units/air
units/aircondition
conditionunits/not
units/notininuse
usefans/galley
fans/galleyand
and
accommodation
accommodationsupplies
suppliesetc.
etc.

(Note!! IfIfthe
(Note thevessel
vesselisisinindry
drydock,
dock,or or alongside
alongsideaa
At
At20
20bar,
bar,start
startwarming
warmingof ofmain
mainturbine
turbinegenerator.
generator. shore
shore installation, electric power maybesupplied
installation, electric power maybe supplied
At
At approximately 50 bar, start up onmain
approximately 50 bar, start up on mainturbo
turbo through
throughthetheshore
shorebreaker.)
breaker.)
generator.
generator. However,
However,this thisisisnormally
normallyused
usedfor fordry
drydock
dock
The
Theelectrical
electricalload
loadfor
fordiesel
dieselgenerator
generatorshifts
shiftsto
to purposes
purposeswhen whenseparate
separatearrangements
arrangementsare aremade
made
main
mainturbo
turbogenerator.
generator. for
forcooling
coolingwater
watersupplies
suppliesto toair
air
Shut
Shutdown
downthethediesel
dieselgenerator
generatorand
andplace
placeonon compressors/refrigeration
compressors/refrigerationand andairairconditioning
conditioningunits.
units.
standby.
standby.

Vessel
Vessel in
inLive
LiveCondition
Condition

Final draft / 2007. 12. 28 6-8 Part 6 Description of Critical Operation

CLEAN FORCE Machinery Operating Manual

Part 7 : Steam Plant Heat Balance System

7.1 100% MCR FO Burning Condition ................................................... 7 - 1

7.2 100% MCR DUAL Burning Condition ............................................. 7 - 2
7.3 100% MCR BOIL OFF GAS Burning Condition .............................. 7 - 3
7.4 90% MCR FO Burning Condition (Guarantee Condition) ................ 7 - 4
7.5 90% MCR FO Burning Condition ..................................................... 7 - 5
7.6 90% MCR DUAL Burning Condition ............................................... 7 - 6
7.7 90% MCR BOIL OFF GAS Burning Condition ................................ 7 - 7
7.8 80% MCR FO Burning Condition ..................................................... 7 - 8
7.9 50% MCR FO Burning Condition ..................................................... 7 - 9
7.10 30% MCR FO Burning Condition ................................................. 7 - 10
7.11 Cargo Unloading Condition (FO) .................................................. 7 - 11
7.12 Cargo Loading Condition (FO) ...................................................... 7 - 12
7.13 Hotel Load Condition (FO)............................................................ 7 - 13

Part 7
Steam Plant Heat Balance System
Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

Part 7 : Steam Plant Heat Balance System

7.1 100% MCR FO Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 470 Loss
Q 470 62.5/15.7
Steam to Burners

Q 995
H.P Turbine
Q 2200 720 mmHg Main Pump
F.O. Tank Heating Q 114682 Q 102847 Q 90856 L.P Q 79753 Vacuum Q 86466
P 62.5 E 823.6 Turbine E 546 Main T 33.6
T 515 P 61
T 510 Condenser

M
Q 545
Boiler F.O. Heater

MQ 2526
P 20.3
Q 100

E 758

Q 9180
20.3/11.5

Q 285
E 687

E 699
L.O. Purifier Heater

P 6.5

Q 11103

E 644
P 1.5
Q 7929
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q0 62.5/5.5
Q 6783 Turbo Q 6663 No.2
E 823.6 Generator E 582.2 Distilled
Q0 Plant

Q 1251
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q0
6.5/2.8
Q 7929

Low Duty Heater Boiler Feed Water

E 699

Q 1251
Q0
Pump Turbine Q 30
Q 115152

E 732.3 No.1
Q 4377
Q0

Q0
E0

T 145

Air Conditioning Unit Q 4057 Q 4027 Q0

Distilled
E 823.6 E 732.1 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 724.4
Q 5278
Q 3552

T 510

E 649
Q 50
62.5/11

Exhaust
Q 4377
11.5/7

Q 2526 Vent
Deoiler E 758 Q 86466 T 52.5 T 49.1
Drain T 70 Q0 T 103.3
Cooler
1st Stage Gland Steam Ship Condition - 100% MCR (F.O Burning)
Deaerator
E 668.5
Q 2945

Q 115571
Feed Water Condenser Main Turbine Shaft Horse Power - 39,000 SHP(PS) 88 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.35 kg/PS.H
Feed Water
Heater Boiler Efficiency : 88.5 %

Q 3552
Q 419

Q 12400
E 138
Inspection

Q 3030
E 129 Q 3552 Q0 Turbo Generator Load : 1,680 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 2526
Sea Water Temperature : 27 ℃
E 758 Air Temperature : 38 ℃
Q 1465 Q 15430 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 87.3
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2845 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100.0 Q 20325 E : kcal/kg
T 100.1 T 81.2
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7-1 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.2 100% MCR DUAL Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 470 Loss
Q 470 62.5/11
Steam to Burners

Q 1007
H.P Turbine
Q 2200 720 mmHg Main Pump
F.O. Tank Heating Q 116513 Q 103778 Q 90554 L.P Q 79389 Vacuum Q 86943
P 62.5 E 823.6 Turbine E 546 Main T 33.6
T 515 P 61
T 510 Condenser

M
Q 260
Boiler F.O. Heater

MQ 3620
P 20.3
Q 100

E 758

Q 9319
20.3/11.5

Q 285
E 687

E 699
L.O. Purifier Heater

P 6.5

Q 11165

E 644
P 1.5
Q 8001
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q0 62.5/5.5
Q 7624 Turbo Q 7504 No.2
E 823.6 Generator E 584 Distilled
Q0 Plant

Q 1318
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q 1560
Q 8001 6.5/2.8
Low Duty Heater Boiler Feed Water
E 699

Q 1318
Q0
Pump Turbine Q 30
Q 116983

E 732.1 No.1
Q 4392
Q0

Q0
E0

T 145

Air Conditioning Unit Q 4104 Q 4074 Q0

Distilled
E 823.6 E 732.1 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 649.1
Q 5392
Q 3609

T 510

E 724

Q 50
62.5/11

Exhaust
Q 4392
11.5/7

Q 3620 Vent
Deoiler E 758 Q 86943 T 52.4 T 49
Drain T 70 Q0 T 103.3
Cooler
1st Stage Gland Steam Ship Condition - 100% MCR (Dual Burning)
Deaerator
E 668.5
Q 4220

Q 117583
Feed Water Condenser Main Turbine Shaft Horse Power - 39,000 SHP(PS) 88 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.35 kg/PS.H
Feed Water
Heater Boiler Efficiency : 86 %

Q 3609
Q 600

Q 12477
E 138
Inspection

Q 3030
E 129 Q 3609 Q0 Turbo Generator Load : 1,890 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 3620
Sea Water Temperature : 27 ℃
E 758 Air Temperature : 38 ℃
Q 1477 Q 15507 Key F.G/F.O High Heat Value : 13,280/10,280 kcal/kg
Make-up
T 35 T 87.3
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2560 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 1660 Q 21689 E : kcal/kg
T 90.7 T 82.0
Low Pressure Steam Boil-off Rate : 0.15 %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : 470 kg/m3
T:℃

Final draft / 2007. 12. 28 7-2 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.3 100% MCR BOIL OFF GAS Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 280 Loss
Q 280 62.5/11
Steam to Burners

Q 1020
H.P Turbine
Q 2200 720 mmHg Main Pump
F.O. Tank Heating Q 118737 Q 105522 Q 89958 L.P Q 78814 Vacuum Q 86784
P 62.5 E 823.6 Turbine E 546 Main T 33.6
T 515 P 61
T 510 Condenser

M
Q0
Boiler F.O. Heater

MQ 5785
P 20.3
Q 100

E 758

Q 9494
20.3/11.5

Q 285
E 687

E 699
L.O. Purifier Heater

P 6.5

Q 11144

E 644
P 1.5
Q 8084
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q0 62.5/5.5
Q 8040 Turbo Q 7920 No.2
E 823.6 Generator E 585 Distilled
Q 2785 Plant

Q 1410
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q 1560
Q 8084 6.5/2.8
Low Duty Heater Boiler Feed Water
E 699

Q 1410
Q0
Pump Turbine Q 30
Q 119017

E 731.9 No.1
Q 4413
Q0

Q0
E0

T 145

Air Conditioning Unit Q 4155 Q 4125 Q0

Distilled
E 823.6 E 731.9 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 723.5

E 649.1
Q 5535
Q 3671

T 510

Q 50
62.5/11

Exhaust
Q 4413
11.5/7

Q 5785 Vent
Deoiler E 758 Q 86784 T 52.5 T 49.1
Drain T 70 Q0 T 103.3
Cooler
1st Stage Gland Steam Ship Condition - 100% MCR (B.O.G. Burning)
Deaerator
E 668.5
Q 6745

Q 119977
Feed Water Condenser Main Turbine Shaft Horse Power - 39,000 SHP(PS) 88 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.35 kg/PS.H
Feed Water
Heater Boiler Efficiency : 83.8 %

E 138.7
Q 3671
Q 960

Q 12477
Inspection

Q 3030
E 129 Q 3671 Q0 Turbo Generator Load : 1,991 kW

T 90

T 76
Tank
E 138.7 Evaporator Load : 60 Ton/Day

Q 5785
Sea Water Temperature : 27 ℃
E 758 Air Temperature : 38 ℃
Q 1301 Q 15507 Key F.G High Heat Value : 13,280 kcal/kg
Make-up
T 35 T 87.3
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2300 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 4445 Q 24037 E : kcal/kg
T 90.3 T 83.4
Low Pressure Steam Boil-off Rate : 0.15 %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : 470 kg/m3
T:℃

Final draft / 2007. 12. 28 7-3 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.4 90% MCR FO Burning Condition (Guarantee Condition)

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 510 Loss
Q 510 62.5/11
Steam to Burners

Q 905
H.P Turbine
Q 380 720 mmHg Main Pump
F.O. Tank Heating Q 100280 Q 90833 Q 81191 L.P Q 71956 Vacuum Q 76709
P 62.5 E 823.6 Turbine E 545 Main T 32.6
T 515 P 61
T 510 Condenser

M
Q 475
Boiler F.O. Heater

P 18.5
Q 911
Q 100

E 754

Q 8446
18.5/11.5

Q 285
E 687

E 695
L.O. Purifier Heater

P 5.8

Q 9235

E 641
P 1.3
Q 7000
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q0 62.5/5.5
Q 4823 Turbo Q 4703 No.2
E 823.6 Generator E 585.7 Distilled
Q0 Plant

Q 1446
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q0
Q 7000 5.8/2.8
Low Duty Heater Boiler Feed Water
E 695

Q 1446
Q0
Pump Turbine Q 30
Q 100790

E 733.6 No.1
Q 3868
Q0

Q0
E0

T 145

Air Conditioning Unit Q 3719 Q 3689 Q0

Distilled
E 823.6 E 733.6 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 722.7

E 649.1
Q 5135
Q 3132

T 510

Q 50
62.5/11

Exhaust
Q 3868
11.5/7

Q 911 Vent
Deoiler E 754 Q 76709 T 55.1 T 51.2
Drain T 70 Q0 T 98.8
Cooler
1st Stage Gland Steam Ship Condition - 90% MCR (F.O Burning), Guarantee Condition
Deaerator
E 668.5
Q 1055

Q 100934
Feed Water Condenser Main Turbine Shaft Horse Power - 35,100 SHP(PS) 85 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.34 kg/PS.H
Feed Water
Heater Boiler Efficiency : 88.5 %

Q 3132
Q 144

Q 10023
E 138
Inspection

Q 3030
E 129 Q 3132 Q0 Turbo Generator Load : 1,150 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 911
Sea Water Temperature : 27 ℃
E 754 Air Temperature : 38 ℃
Q 1415 Q 13053 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 86.8
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 955 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 16008 E : kcal/kg
T 100.1 T 81.4
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7-4 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.5 90% MCR FO Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 510 Loss
Q 510 62.5/11
Steam to Burners

Q 926
H.P Turbine
Q 2220 720 mmHg Main Pump
F.O. Tank Heating Q 103653 Q 92308 Q 80647 L.P Q 71276 Vacuum Q 77832
P 62.5 E 823.6 Turbine E 545 Main T 32.6
T 515 P 61
T 510 Condenser

M
Q 490
Boiler F.O. Heater

MQ 2512
P 18.5
Q 100

E 754

Q 8864
18.5/11.5

Q 285
E 687

E 695
L.O. Purifier Heater

P 5.8

Q 9371

E 641
P 1.3
Q 7224
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q0 62.5/5.5
Q 6626 Turbo Q 6506 No.2
E 823.6 Generator E 585.7 Distilled
Q0 Plant

Q 1640
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q0
Q 7224 5.8/2.8
Low Duty Heater Boiler Feed Water
E 695

Q 1640
Q0
Pump Turbine Q 30
Q 104163

E 733.6 No.1
Q 3988
Q0

Q0
E0

T 145

Air Conditioning Unit Q 3793 Q 3763 Q0

Distilled
E 823.6 E 733.6 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 721.7

E 649.1
Q 5403
Q 3236

T 510

Q 50
62.5/11

Exhaust
Q 3988
11.5/7

Q 2512 Vent
Deoiler E 754 Q 77832 T 54.8 T 51.0
Drain T 70 Q0 T 98.8
Cooler
1st Stage Gland Steam Ship Condition - 90% MCR (F.O Burning)
Deaerator
E 668.5
Q 2910

Q 104561
Feed Water Condenser Main Turbine Shaft Horse Power - 35,100 SHP(PS) 85 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.34 kg/PS.H
Feed Water
Heater Boiler Efficiency : 88.5 %

Q 3236
Q 398

Q 10279
E 138
Inspection

Q 3030
E 129 Q 3236 Q0 Turbo Generator Load : 1,640 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 2512
Sea Water Temperature : 27 ℃
E 754 Air Temperature : 38 ℃
Q 1436 Q 13309 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 86.8
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2810 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 18140 E : kcal/kg
T 100.1 T 80.3
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7-5 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.6 90% MCR DUAL Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 510 Loss
Q 510 62.5/11
Steam to Burners

Q 936
H.P Turbine
Q 2200 720 mmHg Main Pump
F.O. Tank Heating Q 105197 Q 93192 Q 80331 L.P Q 70928 Vacuum Q 78098
P 62.5 E 823.6 Turbine E 545 Main T 32.6
T 515 P 61
T 510 Condenser

M
Q 200
Boiler F.O. Heater

MQ 3591
P 18.5
Q 100

E 754

Q 8985
18.5/11.5

Q 285
E 687

E 695
L.O. Purifier Heater

P 5.8

Q 9403

E 641
P 1.3
Q 7278
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q0 62.5/5.5
Q 7240 Turbo Q 7120 No.2
E 823.6 Generator E 583.1 Distilled
Q0 Plant

Q 1707
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q 1560
5.8/2.8
Q 7278

Low Duty Heater Boiler Feed Water

E 695

Q 1707
Q0
Pump Turbine Q 30
Q 105707

E 733.1 No.1
Q 3994
Q0

Q0
E0

T 145

Air Conditioning Unit Q 3829 Q 3799 Q0

Distilled
E 823.6 E 733.1 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 721.3

E 649.1
Q 5506
Q 3284

T 510

Q 50
62.5/11

Exhaust
Q 3994
11.5/7

Q 3591 Vent
Deoiler E 754 Q 78098 T 54.7 T 50.9
Drain T 70 Q0 T 98.8
Cooler
1st Stage Gland Steam Ship Condition - 90% MCR (Dual Burning)
Deaerator
E 668.5
Q 4160

Q 106276
Feed Water Condenser Main Turbine Shaft Horse Power - 35,100 SHP(PS) 85 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.34 kg/PS.H
Feed Water
Heater Boiler Efficiency : 86.3 %

Q 3284
Q 569

Q 10317
E 138
Inspection

Q 3030
E 129 Q 3284 Q0 Turbo Generator Load : 1,795 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 3591
Sea Water Temperature : 27 ℃
E 754 Air Temperature : 38 ℃
Q 1446 Q 13347 Key F.G/F.O High Heat Value : 13,280/10,280 kcal/kg
Make-up
T 35 T 86.8
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2500 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 1660 Q 19438 E : kcal/kg
T 90.7 T 81.2
Low Pressure Steam Boil-off Rate : 0.15 %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : 470 kg/m3
T:℃

Final draft / 2007. 12. 28 7-6 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.7 90% MCR BOIL OFF GAS Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 280 Loss
Q 280 62.5/11
Steam to Burners

Q 948
H.P Turbine
Q 2200 720 mmHg Main Pump
F.O. Tank Heating Q 107403 Q 94952 Q 79685 L.P Q 70310 Vacuum Q 77868
P 62.5 E 823.6 Turbine E 545 Main T 32.6
T 515 P 61
T 510 Condenser

M
Q0
Boiler F.O. Heater

MQ 5822
P 18.5
Q 100

E 754

Q 9160
18.5/11.5

Q 285
E 687

E 695
L.O. Purifier Heater

P 5.8

Q 9375

E 641
P 1.3
Q 7361
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q0 62.5/5.5
Q 7628 Turbo Q 7508 No.2
E 823.6 Generator E 584 Distilled
Q 2785 Plant

Q 1799
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q 1560
Q 7361 5.8/2.8
Low Duty Heater Boiler Feed Water
E 695

Q 1799
Q0
Pump Turbine Q 30
Q 107683

E 732.9 No.1
Q 4015
Q0

Q0
E0

T 145

Air Conditioning Unit Q 3875 Q 3845 Q0

Distilled
E 823.6 E 732.9 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 720.8

E 649.1
Q 5644
Q 3346

T 510

Q 50
62.5/11

Exhaust
Q 4015
11.5/7

Q 5822 Vent
Deoiler E 754 Q 77868 T 54.7 T 50.9
Drain T 70 Q0 T 98.8
Cooler
1st Stage Gland Steam Ship Condition - 90% MCR (B.O.G. Burning)
Deaerator
E 668.5
Q 6745

Q 108606
Feed Water Condenser Main Turbine Shaft Horse Power - 35,100 SHP(PS) 85 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.34 kg/PS.H
Feed Water
Heater Boiler Efficiency : 84 %

Q 3346
Q 923

Q 10310
E 138
Inspection

Q 3030
E 129 Q 3346 Q0 Turbo Generator Load : 1,891 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 5822
Sea Water Temperature : 27 ℃
E 754 Air Temperature : 38 ℃
Q 1228 Q 13340 Key F.G High Heat Value : 13,280 kcal/kg
Make-up
T 35 T 86.8
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2300 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 4445 Q 21798 E : kcal/kg
T 90.3 T 82.9
Low Pressure Steam Boil-off Rate : 0.15 %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : 470 kg/m3
T:℃

Final draft / 2007. 12. 28 7-7 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.8 80% MCR FO Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 10223 Loss
Q 550 62.5/11
Steam to Burners

Q 895
H.P Turbine
Q 2220 720 mmHg Main Pump
F.O. Tank Heating Q 88980 Q 77793 Q 75739 L.P Q 67188 Vacuum Q 73725
P 62.5 E 823.6 Turbine E 547.5 Main T 32.6
T 515 P 61
T 510 Condenser

M
Q 460
Boiler F.O. Heater

M
Q 100

Q 1769
Q 285
E 687

E 696
L.O. Purifier Heater

Q0

P 5.1
E0
P0

Q 8551

E 642
P 1.2
Q0
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q 6912 62.5/5.5
Q 6607 Turbo Q 6487 No.2
E 823.6 Generator E 582.1 Distilled
Q0 Plant

Q 1769
P 61
Forcing Vaporizer T 510
62.5/4.2
Q0 Q0

Q 3030
Q0
5.1/2.8
E 691.8
Q 6912
Low Duty Heater Boiler Feed Water

Q 1769
Q0
Pump Turbine Q 30
E 691.8
Q 2761

Q 99203

E 733.7 No.1
Q 3812

Q0
T 145

Air Conditioning Unit Q 3685 Q 3655 Q0

Distilled
E 823.6 E 733.7 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 721.4

E 649.1
Q 5424
Q 3100

T 510

Q 50
62.5/11

Exhaust
Q 3812
11/7

Q0 Vent
Deoiler E0 Q 73725 T 56 T 52
Drain T 70 Q0 T 96.5
Cooler
1st Stage Gland Steam Ship Condition - 80% MCR (F.O Burning)
Deaerator
E 668.5
Q 2880

Q 99322
Feed Water Condenser Main Turbine Shaft Horse Power - 31,200 SHP(PS) 81.7 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.36 kg/PS.H
Feed Water
Heater Boiler Efficiency : 88.4 %

Q 3100
Q 119

E 138
Inspection

Q 9283

Q 3030
E 129 Q 3100 Q0 Turbo Generator Load : 1,635 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 2761
Sea Water Temperature : 27 ℃
E 691.8 Air Temperature : 38 ℃
Q 1445 Q 12313 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 86.6
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2780 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 17123 E : kcal/kg
T 100.1 T 79.7
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7-8 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.9 50% MCR FO Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 9583 Loss
Q 720 62.5/11
Steam to Burners

Q 718
H.P Turbine
Q 2220 720 mmHg Main Pump
F.O. Tank Heating Q 61515 Q 51208 Q 50923 L.P Q 45388 Vacuum Q 51731
P 62.5 E 823.6 Turbine E 564.5 Main T 32.6
T 515 P 61
T 510 Condenser

M
Q 330
Boiler F.O. Heater

M
Q 100

Q 285
E 687
L.O. Purifier Heater

Q0

E0
P0

Q0

E0
P0

Q 5535

E 648
P 1.0
Q0
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q 5041 62.5/5.5
Q 6413 Turbo Q 6293 No.2
E 823.6 Generator E 581.9 Distilled
Q0 P 61 Plant
Forcing Vaporizer T 510
62.5/4.2

Q0
Q 1182 Q 1182

Q 3030
Q0
Q 5041 4.2/2.8
Low Duty Heater Boiler Feed Water
E 691

Q 1182
Q0
Pump Turbine Q 30
Q 2640
E 691

Q 71098

E 736.3 No.1
Q 2816

Q0
T 145

Air Conditioning Unit Q 3176 Q 3146 Q0

Distilled
E 823.6 E 736.3 3.1/722
P 61 P 2.8 mmHg Q 50 Plant

E 723.9

E 649.1
Q 4328
Q 2225

T 510

Q 50
62.5/11

Exhaust
Q 2816
11/7

Q0 Vent
Deoiler E0 Q 51731 T 65.9 T 60.2
Drain T 70 Q0 T 92.3
Cooler
1st Stage Gland Steam Ship Condition - 50% MCR (F.O Burning)
Deaerator
E 668.5
Q 2750

Q 71208
Feed Water Condenser Main Turbine Shaft Horse Power - 19,500 SHP(PS) 69.8 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.52 kg/PS.H
Feed Water
Heater Boiler Efficiency : 87.6 %

Q 2225
Q 110

E 138
Inspection

Q 5271

Q 3030
E 129 Q 2225 Q0 Turbo Generator Load : 1,585 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 2640
Sea Water Temperature : 27 ℃
E 691 Air Temperature : 38 ℃
Q 1438 Q 8301 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 84.9
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2650 Drain Tank Q 485
Feed and Condensate Main Condenser : Scoop Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 12974 E : kcal/kg
T 100.1 T 76.6
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7-9 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.10 30% MCR FO Burning Condition

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 11786 Loss
Q 780 62.5/11
Steam to Burners

Q 614
H.P Turbine
Q 2220 720 mmHg Main Pump
F.O. Tank Heating Q 42878 Q 33045 Q 32760 L.P Q 32760 Vacuum Q 38950
P 62.5 E 822 Turbine E 588 Main T 32.6
T 507.2 P 61
T 507.2 Condenser

M
Q 255
Boiler F.O. Heater

M
Q 100

Q 285
E 687
L.O. Purifier Heater

Q0

E0
P0

Q0

E0
P0

Q0
Q0

E0
P0
Q 100
Q 120 Q 3030 Q0
Calorifier
E 820
Q 3936 62.5/5.5
Q 6310 Turbo Q 6190 No.2
E 822 Generator E 581.8 Distilled
Q0 P 61 Plant
Forcing Vaporizer T 507.2
62.5/4.2

Q0
Q 4514 Q 4514

Q 3030
Q0 E 693.7 4.2/2.8
Q 3936

Low Duty Heater Boiler Feed Water

Q 4514
Q 3030
Pump Turbine Q 30
E 693.7
Q 2556

Q 54664

E 735.8 No.1
Q 2234

Q0
T 145

Air Conditioning Unit Q 2909 Q 2879 Q0

Distilled
E 822 E 735.8 3.1/722
P 61 P 2.8 mmHg Q0 Plant

E 721.5

E 649.1
Q 4363
Q 1702

T 507.2

Q 50
62.5/11

Exhaust
Q 2234
11/7

Q0 Vent
Deoiler E0 Q 38950 T 76.9 T 69.3
Drain T 70 Q0 T 77.3
Cooler
1st Stage Gland Steam Ship Condition - 30% MCR (F.O Burning)
Deaerator
E 668.5
Q 2675

Q 54783
Feed Water Condenser Main Turbine Shaft Horse Power - 11,700 SHP(PS) 58.9 rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : 2.8 kg/PS.H
Feed Water
Heater Boiler Efficiency : 86 %

Q 1702
Q 119

E 138
Inspection

Q 2234

Q 3030
E 129 Q 1702 Q0 Turbo Generator Load : 1,545 kW

T 90

T 76
Tank
E 138 Evaporator Load : 60 Ton/Day

Q 2556
Sea Water Temperature : 27 ℃
E 693.7 Air Temperature : 38 ℃
Q 1394 Q 5264 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 81.9
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2575 Drain Tank Q 485
Feed and Condensate Main Condenser : Pump Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 9818 E : kcal/kg
T 100.1 T 72.7
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7 - 10 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.11 Cargo Unloading Condition (FO)

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 7955 Loss
Q 720 62.5/11
Steam to Burners

Q 507
H.P Turbine
Q 2220 720 mmHg Main Pump
F.O. Tank Heating Q 29642 Q0 Q0 L.P Q0 Vacuum Q 26202
P 62.5 E0 Turbine E0 Main T 32.6
T 485.9 P0
T0 Condenser

M
Q 170
Boiler F.O. Heater

M
Q 100
L.O. Purifier Heater

Q0

E0
P0

Q0

Q0
E0

E0
P0

Q0
Q0

E0
P0
Q 100
Q 240 Q0 Q0
Calorifier
E 820
Q 2811 62.5/5.5
Q 26442 Turbo Q 26202 No.2
E 810.0 Generator E 597.6 Distilled
Q0 P 61 Plant
Forcing Vaporizer T 485.9
62.5/4.2

Q0
Q 1928 Q 1928

Q0

Q0
4.2/2.8
E 688.9
Q 2811
Low Duty Heater Boiler Feed Water

Q 1928
Q0
Pump Turbine Q 30
E 688.9
Q 2496

Q 37597

E 729.7 No.1
Q 1630

Q0
T 145

Air Conditioning Unit Q 2693 Q 2663 Q0

Distilled
E 810.0 E 729.7 3.1/722
P 61 P 2.8 mmHg Q0 Plant

E 712.6

E 649.1
Q 4591
Q 1181

T 485.9

Q 50
62.5/11

Exhaust
Q 1630
11/7

Q0 Vent
Deoiler E0 Q 26202 T 40.8 T 32.6
Drain T 70 Q0 T 41.3
Cooler
1st Stage Gland Steam Ship Condition - Unloading (F.O Burning)
Deaerator
E 668.5
Q 2590

Q 37691
Feed Water Condenser Main Turbine Shaft Horse Power - - SHP(PS) - rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : - kg/PS.H
Feed Water
Heater Boiler Efficiency : 86.9 %

Q 1181
Q 94

E 138
Inspection

Q 1630
E 129 Q 1181 Q0 Turbo Generator Load : 6,125 kW

T 90
Tank

Q0
T0
E 138 Evaporator Load : - Ton/Day

Q 2496
Sea Water Temperature : 27 ℃
E 688.9 Air Temperature : 38 ℃
Q 1227 Q 1630 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 90
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2490 Drain Tank Q 320
Feed and Condensate Main Condenser : Pump Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 5767 E : kcal/kg
T 100.1 T 69.8
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7 - 11 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.12 Cargo Loading Condition (FO)

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 6033 Loss
Q 780 62.5/11
Steam to Burners

Q 444
H.P Turbine
Q 2220 720 mmHg Main Pump
F.O. Tank Heating Q 21588 Q0 Q0 L.P Q0 Vacuum Q 18296
P 62.5 E0 Turbine E0 Main T 32.6
T 473.1 P0
T0 Condenser

M
Q 125
Boiler F.O. Heater

M
Q 100
L.O. Purifier Heater

Q0

E0
P0

Q0

Q0
E0

E0
P0

Q0
Q0

E0
P0
Q 100
Q 240 Q0 Q0
Calorifier
E 820
Q 2148 62.5/5.5
Q 18536 Turbo Q 18296 No.2
E 802.8 Generator E 586.7 Distilled
Q0 P 61 Plant
Forcing Vaporizer T 473.1
62.5/4.2

Q0
Q 640 Q 640

Q0

Q0
4.2/2.8
Q 2148

Low Duty Heater Boiler Feed Water

E 686
Q0

Q 640
Pump Turbine Q 30
Q 2465
E 686

Q 27621

E 726.9 No.1
Q 1276

Q0
T 145

Air Conditioning Unit Q 2608 Q 2578 Q0

Distilled
E 802.8 E 726.9 3.1/722
P 61 P 2.8 mmHg Q0 Plant

E 718.8

E 649.1
Q 3218
T 473.1
Q 872

Q 50
62.5/11

Exhaust
Q 1276
11/7

Q0 Vent
Deoiler E0 Q 18296 T 44.4 T 32.6
Drain T 70 Q 1299 T 44.9
Cooler
1st Stage Gland Steam Ship Condition - Loading (F.O Burning)
Deaerator
E 663.8
Q 2545

Q 27701
Feed Water Condenser Main Turbine Shaft Horse Power - - SHP(PS) - rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : - kg/PS.H
Feed Water
Q 80 Heater Boiler Efficiency : 86 %

Q 872
E 138
Inspection

Q 1276
E 129 Q 872 Q0 Turbo Generator Load : 4,325 kW

T 90
Tank

Q0
T0
E 138 Evaporator Load : - Ton/Day

Q 2465
Sea Water Temperature : 27 ℃
E 686 Air Temperature : 38 ℃
Q 1224 Q 1276 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 90
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2445 Drain Tank Q 320
Feed and Condensate Main Condenser : Pump Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 5365 E : kcal/kg
T 100.1 T 68.5
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7 - 12 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

7.13 Hotel Load Condition (FO)

Q0
Q0
Soot Blowers Main Boiler
Vacuum Pump
Q 4436 Loss
Q 780 62.5/11
Steam to Burners

Q 358
H.P Turbine
Q 2220 720 mmHg Main Pump
F.O. Tank Heating Q 9570 Q0 Q0 L.P Q0 Vacuum Q 7523
P 62.5 E0 Turbine E0 Main T 32.6
T 459.8 P0
T0 Condenser

M
Q 65
Boiler F.O. Heater

M
Q 100
L.O. Purifier Heater

Q0

E0
P0

Q0

Q0
E0

E0
P0

Q0
Q0

E0
P0
Q 100
Q 120 Q0 Q0
Calorifier
E 820
Q 1238 62.5/5.5
Q 6551 Turbo Q 6431 No.2
E 795.2 Generator E 581.8 Distilled
Q0 P 61 Plant
Forcing Vaporizer T 459.8
62.5/4.2

Q0
Q0 Q0

Q0

Q0
Q 1238 4.2/2.8
Low Duty Heater Boiler Feed Water
E 683
Q0
Pump Turbine Q 120

Q0
Q 2418
E 683

Q 14006

Q0 E 719 No.1
Q 794

T 145

Air Conditioning Unit Q 2661 Q 2631 Q 1092

Distilled
E 795.2 E 719 3.1/722
P 61 P 2.8 mmHg Q0 Plant

E 649.1
Q 1539
T 459.8

E 719
Q 444

Q 50
62.5/11

Exhaust
Q 794
11/7

Q0 Vent
Deoiler E0 Q 7523 T 49.9 T 32.6
Drain T 70 Q 14927 T 50.8
Cooler
1st Stage Gland Steam Ship Condition - Hotel Load (F.O Burning)
Deaerator
E 668.5
Q 2485

Q 14073
Feed Water Condenser Main Turbine Shaft Horse Power - - SHP(PS) - rpm
P 2.5
E 129.0 Heater
E 127.3 Design Base
3rd Stage
M/T Nonextra Steam Rate : - kg/PS.H
Feed Water
Q 67 Heater Boiler Efficiency : 83 %

Q 444
E 138
Inspection

Q 794
E 129 Q 444 Q0 Turbo Generator Load : 1,495 kW

T 90
Tank

Q0
T0
E 138 Evaporator Load : - Ton/Day

Q 2418
Sea Water Temperature : 27 ℃
E 683 Air Temperature : 38 ℃
Q 1138 Q 794 Key F.O High Heat Value : 10,280 kcal/kg
Make-up
T 35 T 90
Superheated Steam Air Cond. Plant (Cooling) : In Use
Q 2385 Drain Tank Q 200
Feed and Condensate Main Condenser : Pump Cooling
T 70 T 90
Q : kg/h Desuperheated Steam Main F.W. Pump : 170 m3/h x 865 MTH
Q 100 Q 4617 E : kcal/kg
T 100.1 T 66.3
Low Pressure Steam Boil-off Rate : - %/Day
P : kg/cm2A
Drain Line S.G. of Cargo : - kg/m3
T:℃

Final draft / 2007. 12. 28 7 - 13 Part 7 Steam Plant Heat Balance System
CLEAN FORCE Machinery Operating Manual

Part 8 : General Information

8.1 Maker List.......................................................................................... 8 - 1

8.2 Tank Capacity Plan and List .............................................................. 8 - 6
8.3 LO Chart ............................................................................................ 8 - 8

Illustration
8.2a Tank Location Plan .......................................................................... 8 - 5

Part 8
General Information
Part 8 General Information
CLEAN FORCE Machinery Operating Manual

Part 8: General Information

8.1 Maker List

No. Equipment Q'ty Specification Maker / Supplier Model Fax /Tel No. Equipment Q'ty Specification Maker / Supplier Model Fax /Tel
Type : Two Cyl Cross Compound Type : Oil Lub.
KOBELCO
Marine steam turbine. Consisting of F) +81-78-682-5581 Stern Tube Dimension (I.D x O.D x length) : F) +81-794-45-7246
1 Main Turbine 1 KHI UA400 17 1 EAGLE MARINE
HP Turbine & LP Turbine with built- T) +81-78-682-5338 Bush Aft : 796.2 x 938 x 1,600 T) +81-794-45-7109
ENG
in Astern Turbine. Fwd : 798.2 x 938 x 550
Type : Single Pass-scoop cooled Type : Forced Lub. KOBELCO
Intermediate F) +81-794-45-7246
Vacuum : 722MMHG 18 1 Dimension (Id x length) : EAGLE MARINE KMF-660
Main F) +81-78-682-5581 Shaft Bearing T) +81-794-45-7109
2 1 C.W. Temp : 27℃ KHI 625.6 x 500 ENG
Condenser T) +81-78-682-5338
C.W.Q’TY : 17,900m3/h Shaft Intermediate Shaft : Dia 620
F) +82-32-683-3233
(By Scoop sys.) 19 Grounding 1 Slip Ring + Earthing brush CORRESTECK
T) +82-32-683-3204
Type : Water Sealed Rotary Device + Milli-Volt Meter
Vacuum Pump F) +81-78-682-5581
3 2 Vacuum level : 730mmHGV KHI(Shinko) UVT13 Type : Forged Steel Plain
Unit T) +81-78-682-5338 Propeller F) +82-52-230-7692
Pump Cap. : 12.7 m3/h 20 1 Max Stroke : 35 mm HHI-EMD
Shaft Nut T) +82-52-230-7324
Type : Water spray With Multi-Plate Working Pressure : 616 bar
Inlet Steam Press x temp : Type : Fixed Propeller Pitch
External - 1.5kg/cm2 x 289℃ Keyless F) +85-52-230-7692
Desuper heater NANSEI F) +81-3-3355-0794 21 Propeller 1 HHI-EMD
2 Cooling Water Press x temp : Pitch(Mean) : 7,440.82 MM T) +82-52-230-7324
4 for dumping (YARWAY) T) +81-3-3358-1044
- 9.5kg/cm2 x 32.6℃ Out Dia : 8.6M, No. of Blade : 6
steam line
Outlet Steam Press x temp : Type : Elec-Hyd, 2 ram-4 cyl. TONGMYUNG F) +82-55-269-5124
22 Steering Gear 1
- 1.5kg/cm2 x 160℃ Cap. : 350 Ton-M (at 35 deg.) -KHI T) +82-55-269-5142
Type : Water Spray F)+82-31-452-3203
23 Grease Pump 1 Motor Driven + Hand Pump 3K-IND
Inlet Steam Press x temp : T)+82-2-2678-3303
External - 10kg/cm2 x 353℃ Type : 4-Stroke, Trunk piston
desuper heater NANSEI F) +81-3-3355-0794 Diesel Engine F) +82-52-230-7696
5 1 Cooling Water Press x temp : 24 1 Output : ABT. 5,510 PS HHI-EMD 9L 32/40
for aux steam (YARWAY) T) +81-3-3358-1044 for Generator T) +82-85-230-7272
- 30kg/cm2 x 127℃ Revolution : 720 rpm
line
Outlet Steam Press x temp : Output : 3,850 kW
Generator HSJ7 908 F) +82-52-230-6995
- 10kg/cm2 x 191℃ 25 (D/G)
1 Voltage : AC 6,600V HHI-EES
-10P T) +82-52-230-6611
Revolution : 720 rpm
Type : Two Drum Water Tube
F) +81-3-3355-0794 Type : Multi-Stage Impulse
6 Main Boiler 2 Evaporation : 52,000kg/h(NOR) KHI UME68/52
T) +81-3-3358-1044 Turbine For Rated Output : 3,850 kW F) +81-52-508-1020
68,000kg/h(MAX) 2 SHINKO RG 92-2
26 Generator Rated Speed(turbine/output): T) +81-82-508-1000
Proof F) +81-3-3355-0794
7 Burner 3 KHI 8,145 : 1,800 rpm
Fired – Down ward firing. T) +81-3-3358-1044
Output : 3,850 kW
Steam air F) +81-3-3355-0794 Generator HSJ7 719 F) +82-52-230-6995
8 2 Tubular extended surface type KHI 27 2 Voltage : AC 6,600V HHI-EES
heater T) +81-3-3358-1044 (T/G) -4P T) +82-52-230-6611
Revolution : 1,800 rpm
Forced Draft F) +81-3-3355-0794
9 3 1,380m3/min x 70.6mbar x 3sets KHI Type : M.D. 2 stage
Fan T) +81-3-3358-1044
G/E Starting Reciprocating,
F) +81-3-3355-0794 F) +82-51-831-3772
F.O Pump 3 10.5m3/min x 30bagr x 2sets KHI 28 Air 2 Air cooled JONGHAP AHV-20
10 T) +82-51-831-3277
T) +81-3-3358-1044 Compressor Cap : 25m3/h
F) +81-3-3355-0794 Disch. Press : 25 bar
11 F.O Heater 2 100% x 2sets KHI
T) +81-3-3358-1044 Type : M.D. Rotary Screw, F.W
LONG RETRA x 2sets F) +81-3-3355-0794 Working Air Cooled GA55WP F) +82-51-518-4392
Soot Blower KHI 29 1 ATLAS COPCO
12 STAT. ROTARY x 8sets T) +81-3-3358-1044 Compressor Cap : 500m3/h -125-60 T) +82-51-518-4393
Disch. Press : 9 bar
F) +81-3-3355-0794
13 Economizer 2 Tubular x Extended Surface Type KHI Type : M.D. Rotary Screw, F.W
T) +81-3-3358-1044
Control Air Cooled GA55WP F) +82-51-518-4392
30 2 ATLAS COPCO
Material : Solid Forged Steel (SF60) F) +82-82-230-7692 Compressor Cap : 500m3/h -125-60 T) +82-51-518-4393
14 Propeller Shaft 1 HHI-EMD HHI-STD
Dia x Length (mm) : 795 x 10,913 T) +82-52-230-7324 Disch. Press : 9 bar

Intermediate Material : Solid Forged Steel (SF60) F) +82-82-230-7692 Type : Cylinderical

G/E Starting F) +82-55-269-7795
15 1 HHI-EMD HHI-STD 31 1 Volume : 1m3 KANGRIM AR11AB6V
Shatf Dia x Length (MM) : 620 x 12,000 T) +82-52-230-7324 Air Reservoir T) +82-55-269-7786
Press. : 25 barg
Aft : 3A- Type : Cylinderical
KOBELCO Working Air F) +82-55-269-7795
Stern Tube Aft : Air Seal 850 F) +81-794-45-7246 32 1 Volume : 7.5M3 KANGRIM AR27AA4V
16 1 EAGLE MARINE Reservoir T) +82-55-269-7786
Seal Fwd : Air Seal. Fwd:3A- T) +81-794-45-7109 Press. : 9 barg
ENG
850

Final Draft / 2007.12.28 8-1 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

No Equipment Q'ty Specification Maker / Supplier Model Fax /Tel No. Equipment Q'ty Specification Maker / Supplier Model Fax /Tel
Type : Cylinderical M.D.V.C-
Control Air F) +82-55-269-7795
33 1 Volume : 7.5M3 KANGRIM AR27AAAV TM
Reservoir T) +82-55-269-7786 Aux L.O. Cap : 180 m3/h x 4.5 bar F) +81-82-508-1020
Press. : 9 barg 52 2 SHINKO DEEP
Pump Motor : 55 kW x 1,800 rpm T) +81-82-508-1000
WELL
Type : Absorption KHDM F) +82-31-962-0180
34 Air Dryer 2 KYUNG-NAM (SAE150-2)
Cap : ABT 250 nm3/h Free Air -350 T) +82-31-963-0080
Aux. Cent.
Type : Refrigerated KADM F) +82-31-962-0180 Cap : 160 m3/h x 30 MTH M.D.V.C F) +81-82-508-1020
35 Air Dryer 1 KYUNG-NAM 53 Cool F.W. 2 SHINKO
Cap : ABT 250 nm3/h Free Air -300 T) +82-31-963-0080 Motor : 22 kW x 1,800 rpm (SVA150M) T) +81-82-508-1000
Boost Pump
Main Feed Type : Turbine Driven Horizontal Cold Start M.D.H.C
F) +1-210-568-4716 Cap : 6m3/h x 860 MTH F) +81-82-508-1020
36 Water Pump 2 Centrifugal COFFIN DEB-16 54 Boiler Feed 1 SHINKO Piston
T) +1-201-568-4700 Motor : 30 kW x 1,200 rpm T) +81-82-508-1000
And Turbine Cap : 170 m3/h x 865 MTH Water Pump (HLX6)
M.D.V.C M.D.V
Main S.W Cap : 9,000/4,500 m3/h x 5/8 MTH F) +81-82-508-1020 Oily Bilge Cap : 5m3/h x 45 MTH F) +81-82-508-1020
37 1 SHINKO (CVF- 55 1 SHINKO Piston
Circ. Pump Motor : 200 kW x 360 rpm T) +81-82-508-1000 Pump Motor : 1.5 kW x 1,200 rpm T) +81-82-508-1000
1000M) (VPS5)
Aux. S.W M.D.V.C M.D.V.
Cap : 9,000/4,500 m3/h x 5/8 MTH F) +81-82-508-1020 E/R Bilge Cap : 10 m3/h x 45 MTH F) +81-82-508-1020
38 Circ. 1 SHINKO (CVF- 56 1 SHINKO Piston
Motor : 200 kW x 360 rpm T) +81-82-508-1000 Pump Motor : 3.7 kW x 1,200 rpm T) +81-82-508-1000
Pump 1000LM) (VPS10)
Main Cooling Cap :1,300 m3/h x 21 MTH M.D.V.C F) +81-82-508-1020 Waste Oil
Cap : 5 m3/h x 45 MTH
M.D.V.
F) +81-82-508-1020
39 2 SHINKO 57 Transfer 1 SHINKO Piston
S.W. Pump Motor : 110 kW x 1,200 rpm (SVA400M) T) +81-82-508-1000 Motor : 1.5 kW x 1,200 rpm T) +81-82-508-1000
Pump (VPS5)
Main Central
Cap :1,200 m3/h x 30 MTH M.D.V.C F) +81-82-508-1020 Main L.O
40 Cooling F.W. 2 SHINKO Cap : 3 m3/h x 3 KDP M.D.H.G F) +81-06-6535-1884
Motor : 150 kW x 1,200 rpm (SVA400M) T) +81-82-508-1000 58 Purifier Supply 2 NANIWA
Pump Motor : 1.5 kW x 1,140 rpm (ALG-32N) T) +81-06-6541-6131
Pump
Hot Water Cap :2 m3/h x 10 MTH M.D.H.C.F F) +81-82-508-1020
41
Circ. Pump
2
Motor : 0.75 kW x 1,800 rpm
SHINKO
(HJ40-2M) T) +81-82-508-1000 L.O. Transfer Cap : 5 m3/h x 4 KDP M.D.H.G F) +81-06-6535-1884
59 1 NANIWA
Pump Motor : 2.2 kW x 1,140 rpm (ALG-40N) T) +81-06-6541-6131
Main M.D.V.C
Cap :110 m3/h x 95 MTH F) +81-82-508-1020 H.F.O. M.D.V.G
42 Condensate 2 SHINKO (EVZ Cap : 50 m3/h x 4 KDP F) +81-06-6535-1884
Motor : 55 kW x 1,800 rpm T) +81-82-508-1000 60 Transfer 1 NANIWA (ALGV-
Pump 130M) Motor : 18.5 kW x 1,140 rpm T) +81-06-6541-6131
Pump 100BSJ)
M.D.V.C
Condensate Cap : 30m3/h x 85 MTH F) +81-82-508-1020 M.D.O.
Cap : 30 m3/h x 4.5 KDP M.D.H.G F) +81-06-6535-1884
43 2 SHINKO (EVZ 61 Transfer 1 NANIWA
drain Pump Motor : 18.5 kW x 1,800 rpm T) +81-82-508-1000 Motor : 18.5 kW x 1,140 rpm (ALGP-80) T) +81-06-6541-6131
70MH) Pump
Dump Drain Cap : 80 m3/h x 85 MTH M.D.V.C F) +81-82-508-1020 Gas Oil
44 1 SHINKO Cap : 2 m3/h x 2.5 KDP M.D.H.G F) +81-06-6535-1884
Pump Motor : 37 kW x 1,800 rpm (EVZ130M) T) +81-82-508-1000 62 Transfer 1 NANIWA
Motor : 0.75 kW x 1,130 rpm (ALGP-25) T) +81-06-6541-6131
M.D.V.C-SP Pump
Bilge Fire &
Cap : 245/150 m3/h x 30/115 MTH Self priming F) +81-82-508-1020 Stern Tube Cap : 1 m3/h x 2.5 KDP M.D.H.G F) +81-06-6535-1884
45 General 2 SHINKO 63 2 NANIWA
Motor : 110 kW x 1,800 rpm (RVP200- T) +81-82-508-1000 L.O. Pump Motor : 0.75 kW x 1,130 rpm (ALG-25N) T) +81-06-6541-6131
Service Pump
2MS)
M.D.O.
Cap : 3 m3/h x 3 KDP M.D.H.G F) +81-06-6535-1884
Fire Line 3 64 Purifier 1 NANIWA
Cap : 2 m /h x 115 MTH M.D.H.C F) +81-82-508-1020 Motor : 1.5 kW x 1,140 rpm (ALGP-32) T) +81-06-6541-6131
46 Pressuring 1 SHINKO Supply Pump
Motor : 7.5 kW x 3,600 rpm (SHQ50M) T) +81-82-508-1000
Pump Type : Automatic, Self-cleaning,
Water Spray Cap : 850 m3/h x 110 MTH M.D.V.C F) +81-82-508-1020 Main L.O. Partial Disch. With Separate Supply F) +82-2-3406-0701
47 1 SHINKO 65 2 ALFALAVAL SA-830
Pump Motor : 400 kW x 1,800 rpm (KV300K) T) +81-82-508-1000 Purifier Pump T) +82-2-3406-0722
Cap : 3,000 L/H
M.D.V.C-
Cap : 3,000 m3/h x 30 MTH SP(1) F) +81-82-508-1020 Type : Automatic, Self-cleaning,
48 Ballast Pump 1 SHINKO M.D.O. Total Disch. With Separate Supply F) +82-2-3406-0701
Motor : 355 kW x 1,200 rpm (GVD500- T) +81-82-508-1000 66 1 ALFALAVAL SA-825
3MS) Purifier Pump T) +82-2-3406-0722
Cap : 3,000 L/H
M.D.V.C-
Type : S.W. Cooled
Cap : 3,000 M3/H x 30 MTH SP(2,3) F) +81-82-508-1020 Central F.W. F) +82-2-3406-0701
49 Ballast Pump 2 SHINKO 67 2 Heat Dissipation : 5,400,000 Kcal/h ALFA-LAVAL M30-FM
Motor : 355 kW x 1,200 rpm (GVD500- T) +81-82-508-1000 Cooler T) +82-2-3406-0714
Heat Transfer Area : 331.2 m2
3M)
Type : SUS Plate, F.W. Cooled
Distilling Plant M.D.V.C M/T L.O. F) +82-2-3406-0701
Cap : 90 M3/H x 43 MTH F) +81-82-508-1020 68
Cooler
2 Heat Dissipation : 760,000 Kcal/h ALFA-LAVAL M20-MFM
T) +82-2-3406-0714
50 S.W. Feed 2 SHINKO (SVA125- Heat Transfer Area : 194.6 m2
Motor : 22 kW x 1,800 rpm T) +81-82-508-1000
Pump 2M)
Type : SUS Plate, F.W. Cooled
Stern Tube F) +82-2-3406-0701
F.W Trans. Cap : 25 m3/h x 25 MTH M.D.H.C F) +81-82-508-1020 69 1 Heat Dissipation : 5,000 Kcal/h ALFA-LAVAL M6-MFM
51 1 SHINKO L.O. Cooler T) +82-2-3406-0714
Pump Motor : 3.7 kW x 3,600 rpm (GJ50-20M) T) +81-82-508-1000 Heat Transfer Area : 2.1 m2

Final Draft / 2007.12.28 8-2 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

No. Equipment Q'ty Specification Maker / Supplier Model Fax /Tel No. Equipment Q'ty Specification Maker / Supplier Model Fax /Tel
Type : S&T, F.W. Cooled Type : Sludge Oil & Solid Waste
Oil Heating F) +82-51-970-1031 MAXI150SL- F) +82-32-583-0674
70 1 Heat Dissipation : 90,000 Kcal/h DONGHWA 87 Incinerator 1 Burning HMMCO
Drain Cooler T) +82-51-970-1070 1 WS T) +82-32-583-0671
Heat Transfer Area : 3 m2 Cap : 700,000 KCAL/H
Type : S&T, S.W. Cooled Oil Bilge Type : Gravity and Filtering F) +82-52-345-1684
88 1 HAN-YOUNG HYN05000
Aux. Heat Dissipation : 47,081,750 F) +82-51-970-1031 Separator Cap. : 5m3/h T) +82-55-345-2933
71 1 DONGHWA
Condenser Kcal/h T) +82-51-970-1070 Viscorator For Type : Pneumatic control F) +31-78-617-7068
Heat Transfer Area : 405 m2 89 1 VAF
Main Boiler Flow Rate : 13m3/h T) +31-78-618-3100
Main L.O. Type : S&T, Steam Heated Type: Positive Displacement
F) +82-51-970-1031
72 Purifier 2 Heat Dissipation : 55,688 Kcal/h DONGHWA Flow Meter Flow Rate(L/H) :
T) +82-51-970-1070
Hearter Heat Transfer Area : 2.55 m2 90 For 1 Max:810, Nor:730, Min:180 VAF
F) +31-78-617-7068
T) +31-78-618-3100
1st Stage Type : S&T G/E M.D.O. Kinematic Viscosity:M.D.O. 13cst
F) +82-51-970-1031
73 Feed Water Heat Dissipation : 4,232,000 Kcal/h DONGHWA @40℃
T) +82-51-970-1070
Heater Heat Transfer Area : 100 m2
Type: Positive Displacement
3rd Stage Type : S&T Flow Rate(L/H) :
F) +82-51-970-1031 Flow Meter
74 Feed Heat Dissipation : 2,037,199 Kcal/h DONGHWA Max:9,840, Nor:7,270, F) +31-78-617-7068
T) +82-51-970-1070 91 For 1 VAF
Water Heater Heat Transfer Area : 43.1 Min:133 T) +31-78-618-3100
G/E H.F.O. Kinematic Viscosity:H.F.O. 700cst
Type : Spray Scrubber Type
Cap : 30 m3 F) +82-51-970-1031 @50℃
75 Deaerator 1 Diposed Feed W. Q’ty :117,615kg/h DONGHWA
T) +82-51-970-1070 Type : Dolomite F) +82-55-366-0129
Disposed Feed Temp : 138.2℃ 92 Mineralizer 1 SAMKUN MIN-5000
Cap : 5,000 L/H T) +82-55-366-0130
Type :Cond. Water Cooled Type : SK-LAWSON F) +81-6-6473-5540
F.W. 93 De-Oiler 1 SASAKURA 20 GPM
Generator
(VSP-C25CC)
VSP-36- F) +45-39-53-6568 Cap : 4.5 m3/h T) +81-6-6473-2134
76 2 S.W. Cooled (VSP-C125SWC) ALFA-LAVAL
(Distilling C125CC T) +45-39-53-6000 F) +49-421-537-05-
Cap : 60 ton/Day Grease Type : Filter Clote
Plant) 94 1 RWO BFG 4F 40
Max. Salinity (ppm) : 1.5 Extractor Cap : 80 m3/h
T) +49-421-53-70-50
M.D. Axial flow, Reversible.
E/R Exhaust AQ- F) +82-55-346-3501 Type : Ionizing Electrode
77 2 Cap : 1,750m3/mx 15mmaq HI-PRES Wilson Walton F) +82-51-831-0134
Vent. Fan 1400/578 T) +82-55-346-3500 95 M.G.P.S 1 Cap : 18,000 m3/h(For Scoop)
Motor : 22kW x 1,175rpm KOREA T) +82-51-831-0131
1,5000 m3/h(For General Service)
M.D Axial flow, Non-Reversible.
E/R Supply AQ- F) +82-55-346-3501 Type : Ultra Violet F) +82-55-366-0129
78 4 Cap : 1,750m3/mx 50mmaq HI-PRES 96 Sterilizer 1 SAMKUN JSA-3000
Vent. Fan 1400/578 T) +82-55-346-3500 Cap : 2,000 L/H T) +82-55-366-0130
Motor : 37kW x 1,175rpm
Silver Ion Type : Silver Ion F) +46-31-795-45-40
Boiler off leak M.D Centrifugal with Explosion 97 1 JOWA AB
Sterilizer Cap : 5,000 L/H T) +46-31-795-00-44
gas extraction proof Elec. Motor. F) +82-55-346-3501
79 2 HI-PRES SPSF-315 Type : Steam Heated with Electric
fan for fuel Cap : 60m3/mx 40mmaq T) +82-55-346-3500
gas pipe Motor : 1.7kW x 1,704rpm Heating Coil (30kW x 2)
F) +82-55-269-7795
98 Calorifier 1 Flow Rate (L/H) : 2,000 KANGRIM
Exh. Fan for M.D Axial flow. T) +82-55-269-7786
ADW- F) +82-55-346-3501 Tank Cap.(L) : 1,500
80 Welding 1 Cap : 30m3/mx 30mmaq HI-PRES
500/280 T) +82-55-346-3500 Heating Range(℃) : 10-70
Space Motor : 1.5kW x 1,710rpm
M.D Axial flow. Sewage
Exh. Fan for F) +82-55-346-3501 Type : Biological HAMWORTH F) +44-1202-668793
81 1 Cap : 150m3/mx 50mmaq HI-PRES AQ-560/380 99 Treatment 1 ST3A
Purifier Room T) +82-55-346-3500 Cap : 50 Persons / Day KSE T) +44-1202-662675
Motor : 3.7kW x 1,730rpm Plant
M.D Axial flow. Type : Vertical Centrifugal
F.W.
82
Exh. Fan for
1 Cap. : 300m3/m x 50mmaq HI-PRES AQ-710/330
F) +82-55-346-3501 Pump : 10 m3/h x 70 MTH x 2 sets F) +81-82-508-1020
D/G Room T) +82-55-346-3500 100 Hydrophore 1 SHINKO UH202M
Motor : 5.5kW x 1,740rpm Tank : 2,000 L x 1 Set T) +81-82-508-1000
Unit
Motor : 7.5 kW x 3,600 rpm
Exh. Fan for M.D Axial flow.
F) +82-55-346-3501 Type : Vertical Centrifugal
83 Chemical 1 Cap : 30m3/m x 40mmaq HI-PRES AQ-560/280 D.W.
Store Motor : 1.5kW x 1,710rpm
T) +82-55-346-3500 Pump : 6 m3/h x 65 MTH x 2 sets F) +81-82-508-1020
101 Hydrophore 1 SHINKO UH102M
Tank : 1,000 L x 1 Set T) +81-82-508-1000
Exh. Fan for M.D Axial flow. Tank
F) +82-55-346-3501 Motor : 5.5 kW x 3,600 rpm
84 L.O. Grease 1 Cap : 30m3/m x 40mmaq HI-PRES AQ-560/280
T) +82-55-346-3500 S.W.
store Motor : 1.5kW x 1,170rpm F) +81-82-508-1020
102 Hydrophore 1 Cap : 1.5 m3/h SHINKO UH150
M.D Axial flow. T) +81-82-508-1000
Boiler Seal F) +82-55-346-3501 Tank
85 2 Cap : 8m3/m x 1,100mmaq HI-PRES SPTB-105
Air Fan T) +82-55-346-3500 Type : Package
Motor : 5.3kW x 3,470rpm Unit Cooler HIP F) +82-55-346-3501
103 1 Cap : Cooling Cap : 54,000 Kcal/h HI-PRES
M.D Axial flow. For Workshop -20WGDE T) +82-55-346-3500
Exh. Fan for ADW- F) +82-55-346-3501 Heating Cap : 43,000 Kcal/h
86 1 Cap : 12M3/minx 15mmaq HI-PRESS
E/R Toilet 300/190 T) +82-55-346-3500
Motor : 0.4kW x 1,725rpm

Final Draft / 2007.12.28 8-3 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

No. Equipment Q'ty Specification Maker / Supplier Model Fax /Tel

Unit Cooler
Type : Package
For MIP F) +82-55-346-3501
104 1 Cap : Cooling Cap : 9,000 Kcal/h HI-PRES
Boiler Test -3WGE T) +82-55-346-3500
Heating Cap : 8,600 Kcal/h
Room
MSBD / ECR
Type : Condensing & Central Unit F) +82-55-346-3501
105 Air 2 HI-PRES
Cap : ABT. 144,480 Kcal/h T) +82-55-346-3500
Cond. Plant
Condensate
Type : Magnetic F)+82-51-740-5704
106 Water 1 BOLL & KIRCH
Cap. : 80 m3/h T)+82-51-740-5701
Magnetic Filter
Cap : Center Distance : 2,000 mm
NSL 580 F) +82-42-936-8105
107 Lathe 1 Swing Over Bed : 580 mm GOMT
x 2000G T) +82-42-936-8100
Motor(kW) : 7.5
Type : Up-Right
Drilling NBTG- F) +82-54-776-6455
108 1 Cap : Max. 50 mm DIa. YOUNGKWANG
Machine 540 T) +82-54-776-6456
Motor(kW) : 2.2
Bench Drilling Cap : Max. 16 mm Dia. F) +82-54-776-6455
109 1 YOUNGKWANG YKD-20
Machine Motor(kW) : 0.75 T) +82-54-776-6456
Pedestal Type : Double Wheel
YKGV F) +82-54-776-6455
110 Grinding 1 CaP : 300 mm Dia. x 1Set – Heavy YOUNGKWANG
-300 / 150 T) +82-54-776-6456
Machine 150 mm Dia. x 1 Set - Fine
Type : Hydraulic Motor Driven F) +82-54-776-6455
111 Pipe Bender 1 YOUNGKWANG TPB-4
Cap : Pipe Dia. 4 Inch T) +82-54-776-6456
Stroke : 150 mm
Hack Sawing Round Bar : 200 mm F) +82-54-776-6455
112 1 YOUNGKWANG KDBS-200
M/C Square Bar : 200 x 200 mm T) +82-54-776-6456
Tube Dia. : 4 Inch
Plasma F) +82-54-776-6455
113 1 Cap : 16 mm YOUNGKWANG TKP-90P
Cutting M/C T) +82-54-776-6456
Type : Central Installation
UNITOR F) +82-51-728-3848
114 Gas Welder 1 Oxygen Bottle : 10 EA
KOREA T) +82-51-728-4900
Acetylene Bottle : 5 EA
Ballast Type : Water Jet Stripping
F) +47-37-19-98-90
115 Stripping 2 Driving Power : 245 m3/h x 11 bar TEAMTEC
T) +47-37-19-98-00
Eductor Suction Capacity : 300 m3/h

Final Draft / 2007.12.28 8-4 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

Illustration 8.2a Tank Location Plan

G/E L.O
50.8 m A/B
Settling
Tank
Fan Vent Mast Vent Mast Vent Mast
G/E L.O Room Manifold Service Handling
Storage Crane, 10 Ton (P&S)
Cargo Gear L.P. L.P. L.P.
Tank
Locker
Motor Cargo Compressor
Room Room Dry Powder
Room (P&S)
No.4 Trunk No.3 Trunk No.2 Trunk No.1 Trunk
Trunk (Void)
Paint Deck Incinerator Pool
Store Store Room S.L.
Domestic F.W Tank

Tank (P&S) M.L.O M.L.O G/E M.D.O

B.V.H.
Storage Settling Service Bosun Store
Bunker Tank (S)
Room
2nd Deck Tank Tank Tank
AFT H.F.O

Distilled H.F.O
Water Tank M.D.O Low Settling
(P&S) Storage Sulphur FWD H.F.O Bunker
3rd Deck Tank (S) No.3 Cargo Tank No.2 Cargo Tank No.1 Cargo Tank Cargo Tank
Tank Fuel Tank (P&S)
After Peak Tank Engine Room (S) Tank (S) Fore Peak
4th Deck Tank
FWD Water Ballast
H.F.O Overflow (Void)
Tank (P&S)
Tank No.4 Cargo Tank
H.S.C Pipe
Water Ballast Tank Duct
Water Ballast Tank

C.W. Tank M.L.O Sump Tank L.S.C

Oily Bilge Tank No.5 Cofferdam No.4 Cofferdam No.3 Cofferdam No.2 Cofferdam No.1 Cofferdam Bow Thrust &
Stern Tube L.O Sump Tank Emergency Fire
Bilge Holding Tank Pump Room

No.4 Water Ballst Tank (P) No.3 Water Ballst Tank (P) No.2 Water Ballst Tank (P)
H.F.O Sett. Tank (P) No.1 Water Ballst Tank (P)
IGG G.O Serv. Tank (P) Aft Bunker Tank (P)
G.T L.O Low Sulphur Fuel Tank (P)
Stor. Tank
G.T L.O Forward Water Ballst Tank (P)
Sett. Tank
Forward H.F.O Bunker Tank

Drinking
Water
Distilled
Tank (P)
Water Tank (P)
No.5 Cofferdam

No.4 Cofferdam

No.3 Cofferdam

No.2 Cofferdam

No.1 Cofferdam
No.4 Cargo Tank No.3 Cargo Tank No.2 Cargo Tank No.1 Cargo Tank
M.L.O Stor. Tank (S) Fore Peak
Pipe Duct Pipe Duct Tank
M.L.O Sett. Tank (S) (Void)

Distilled
G/E L.O Sett. Tank
Fresh
Water Tank (S) Water G/E L.O Stor. Tank
Tank (S)

M.L.O Sump Tank

Bow Thrust &
Oily Bilge Tank Emergency Fire
Stern Tube L.O Sump Tank Aft Bunker Tank (S) Pump Room
Bilge Holding Tank H.F.O Sett. Tank (S)
G/E M.D.O Forward Water Ballst Tank (S)
No.4 Water Ballst Tank (S) No.3 Water Ballst Tank (S) No.2 Water Ballst Tank (S) No.1 Water Ballst Tank (S)
Serv. Tank (P) Low Sulphur Fuel Tank (S)

Final Draft / 2007.12.28 8-5 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

8.2 Tank Capacity Plan and List

Cargo Tanks S.G.=0.47 Water Ballast Tanks S.G.=1.025

Centre of Gravity Centre of Gravity

Capacities Capacities Free
(100% Base) Free Location (100% Base)
Location Surface
Surface Compartment Frame Volume Weight L.C.G.
Compartment Frame V.C.G. Moment
Volume Weight L.C.G. From V.C.G. Above Moment Number 100% 100% From Mid.
Number Above B.L. (m4)
100% (m3) 98% (Tons) Mid (Mid) B.L. (m4) (m3) (Tons) (m)

FWD W.B. TK (P) 130.0-154.0 2009.7 2060.0 107.08 12.198 1361

FWD W.B. TK (S) 130.0-154.0 2009.7 2060.0 107.08 12.198 1361

No. 1 Cargo Tank 118.1-128.9 24619.3 11339.6 79.57 17.797 103566 No. 1 W.B. TK (P) 117.0-130.0 6161.4 6315.5 76.63 10.769 10884
No. 1 W.B. TK (S) 117.0-130.0 6161.4 6315.5 76.63 10.769 10884
No. 2 Cargo Tank 103.1-116.9 43233.3 19913.3 38.00 16.662 206520
No. 2 W.B. TK (P) 102.0-117.0 6367.6 6526.8 36.39 8.903 27780
No. 3 Cargo Tank 88.1-101.9 43233.3 19913.3 -10.19 16.662 206520
No. 2 W.B. TK (S) 102.0-117.0 6367.6 6526.8 36.39 8.903 27780
No. 4 Cargo Tank 74.1-86.9 38644.1 17799.5 -56.01 16.662 184617
No. 3 W.B. TK (P) 87.0-102.0 6459.6 6621.1 -11.57 8.805 28957
No. 3 W.B. TK (S) 87.0-102.0 6459.6 6621.1 -11.57 8.805 28957
No. 4 W.B. TK (P) 73.0-87.0 5604.5 5744.6 -56.92 9.072 23824
Total 149730 68965.7 6.66 16.849
No. 4 W.B. TK (S) 73.0-87.0 5604.5 5744.6 -56.92 9.072 23824
A.P. TK -6.1-17 2320.6 2378.7 -131.40 14.291 44268

Total - 55526.5 56914.6 13.43 9.792

Cargo Tanks SG=0.50

Capacities Centre of Gravity Fresh Water Tanks S.G.=1.000

Free Surface
Location Frame Centre of Gravity
Compartment Weight L.C.G. Max. Inertia Capacities Free
Number Volume V.C.G. Location (100% Base)
98.0% From Mid Moment (m4) Surface
100% (m3) Above B.L. Compartment Frame Weight
(Ton) (Mid) Volume L.C.G. From V.C.G. Moment
Number 100%
100% (m3) Mid (Mid) Above B.L. (m4)
(Tons)
No. 1 Cargo Tank 118.1-128.9 24619.3 12063.4 79.57 17.797 103566
Distilled W. TK (P) -6.1-10.0 268.4 268.4 -134.77 18.943 305
No. 2 Cargo Tank 103.1-116.9 43233.3 21184.3 38.00 16.662 206520 Distilled W. TK (S) -6.1-10.0 268.4 268.4 -134.77 18.943 305
No. 3 Cargo Tank 88.1-101.9 43233.3 21184.3 -10.19 16.662 206520 Drinking W. TK (P) 10.0-17.0 197.1 197.1 -126.61 18.863 374
No. 4 Cargo Tank 74.1-86.9 38644.1 18935.6 -56.01 16.662 184617 Domestic F.W. tank(S) 10.0-17.0 197.1 197.1 -126.61 18.863 374

Total 931.1 931.1 -131.31 18.909

Total 149730.0 68965.7 6.66 16.849

Final Draft / 2007.12.28 8-6 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

MDO & Gas Oil Tanks S.G.=0.850

Fuel Oil Tanks S.G.=0.990
Centre of Gravity
Capacities Free
Centre of Gravity Location (100% Full)
Capacities Free Surface
Location (100% Base) Compartment Frame Weight
Surface Volume L.C.G. From V.C.G. Moment
Compartment Frame Volume Weight L.C.G. Number 98%
V.C.G. Moment 100% (m3) Mid (Mid) Above B.L. (m4)
Number 100% 98% From Mid (Tons)
Above B.L. (m4)
(m3) (Tons) (Mid) M.D.O. STOR. TK (S) 45.0-51.0 211.0 170.4 -99.10 15.813 31

FWD H.F.O BUNKER TK (P) 130.0-154.0 2570.1 2417.2 106.88 12.685 745 G/E M.D.O. SERV. TK (S) 45.0-53.0 134.2 108.3 -98.30 23.613 41

FWD H.F.O BUNKER TK (S) 130.0-154.0 2599.4 2444.8 106.80 12.685 758 IGG G.O SERV. TK. TK (P) 49.0-55.0 100.7 81.3 -95.90 23.613 31

AFT H.F.O BUNKER TK (P) 67.0-73.0 164.0 154.2 -80.70 17.968 9

Total 445.9 360.1 -98.14 19.922
ATF H.F.O BUNKER TK (S) 67.0-73.0 252.7 237.6 -81.55 17.968 14
HFO. SETT. TK (P) 59.0-69.0 518.1 487.3 -86.45 17.964 45
HFO SETT. TK (S) 57.0-67.0 537.8 505.8 -87.94 17.975 50
LOW SULPHUR FUEL TK (P) 53.0-59.0 288.7 271.6 -92.50 17.466 31 VOID Tanks S.G.=1.000
LOW SULPHUR FUEL TK (S) 51.0-57.0 282.6 265.8 -94.09 17.597 31
Centre of Gravity
Capacities Free
(100% Full)
Total 7213.5 6784.3 51.72 14.147 - Location Surface
Compartment Weight V.C.G. L.C.G.
Frame Number Volume Moment
100% Above B.L From Mid.
100% (m3) (m4)
(Tons) (m) (m)

F.P.TK 162.0-188.5 1992.0 1992.0 11.885 130.94 2683

Lubricating Oil Tanks S.G.=0.900 Total 1992.0 1992.0 11.885 130.94

Centre of Gravity
Capacities Free
Location (100% Base)
Surface
Compartment Frame Weight
Volume L.C.G. From V.C.G. Moment Miscellaneous Tanks S.G.=1.000
Number 95%
100% (m3) Mid (Mid) Above B.L. (m4)
(Tons) Centre of Gravity
Capacities Free
M.L.O. SUMP. TK (C) 32.0-37.0 69.9 59.8 -109.94 2.746 102 Location (100% Full)
Surface
M.L.O SETT. TK (S) 41.0-49.0 100.4 85.8 -102.04 23.610 28 Compartment Frame Weight L.C.G.
Volume V.C.G. Moment
Number 100% From Mid
M.L.O STOR. TK (S) 35.0-41.0 100.6 86.0 -107.10 23.613 31 100% (m3) Above B.L. ((m4)
(Tons) (Mid)
M.L.O GRAVITY TK (S) 41.0-43.0 28.1 24.0 -103.90 16.765 5
C.W.TK (C)
G/T L.O. SETT. TK (P) 45.0-47.0 16.7 14.3 -100.70 23.598 1 8.6-17.0 70.7 70.7 -125.80 4.916 47
BILGE HOLDI\NG TK (C)
G/T L.O. STOR. TK (P) 45.0-47.0 16.9 14.4 -100.70 23.627 1 17.0-28.0 119.2 119.2 -118.32 1.724 206
H.F.O. OVERFLOW TK
G/E L.O. SETT. TK (S) 47.0-49.0 16.9 14.4 -99.10 23.627 1 28.0-31.0 49.4 49.4 -113.86 2.630 244
(S)
G/E L.O. STOR. TK (S) 45.0-47.0 16.9 14.4 -100.70 23.627 1 57.0-73.0 87.6 87.6 -85.22 8.517 22
OILY BILLGE TK (C)
S/T L.O. SUMP TK (S) 21.0-24.0 5.4 4.6 -119.44 2.163 1 33.0-41.0 14.0 14.0 -108.12 9.356 9
SLUDGE TK (S)

Total 317.7 317.8 -104.97 18.858

Total 340.9 340.9

Final Draft / 2007.12.28 8-7 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

8.3 Lubrication Oil Chart

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

Maker : K.H.I
1 SYSTEM OIL 120 M3 REGAL R&O 66 INCL. SUMP TK +GRAV. TK
(UA 400)

SPHERICAL BEARING 0.18 L NEVER SEEZ, REGULAR GRADE INITIALLY FILLED

NO.1 & 2 NOZZLE VALVES 2 LUBRICATOR OF ACTUATOR 0.4 L REGAL R&O 32 INITIALLY FILLED

ACTUATOR 0.1 KG MULTI FAK EP 2 INITIALLY FILLED

1 MAIN TURBINE
LEVER MECHANISM BUSHING 0.25 L NEVER SEEZ, REGULAR GRADE INITIALLY FILLED
MANOEUVRING VALVE 1
CAM MECHANISM WARM GEAR 0.3 KG MULTIFAK EP 2 INITIALLY FILLED

TURNING GEAR 1 GEARS, BEARINGS & CHAIN 8.5 L MEROPA 100 INITIALLY FILLED

HAND OPERATING DEVICE 1 BUSHING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED

L.O SUMP TANK 4,216 L DELO 1000 MARINE 40

MAKER : HHI-EMD
2 D/G ENGINE 1
(PL32/40), FOUR STROKE
GOVERNOR OIL 1.9 L DELO 1000 MARINE 40 INITIALLY FILLED

GEAR COUPLING 3 L MEROPA 680

MAKER : SHINKO
GENERATOR (RG 92-2, MULTI-STAGE
3 2 L.O TANK (TURBINE BED) 4,800 L REGAL R&O 68
TURBINE IMPULSE TYPE WITH
REDUCTION)
GOVERNOR 4 L REGAL R&O 68

G/E STARTING MAKER : JONG HAP COMPRESSOR OIL EP VDL 100

4 2 BREATHER PIPE OR SIDE COVER 5.6 L
AIR COMPERSSOR (AHV-20) OR CETUS DE 100

INITIALLY FILLED

CONTROL/ NOTE ) INITIAL FILLING BY ATLAS COPCO OIL. OTHER OIL CAN
MAKER : ATLAS COPCO
5 WORKING AIR 3 GEAR AND BEARING 79.5 L CETUS PAO 46 BE USED AFTER TAKING FOLLOWING PRECAUTIONS
(GA55W-125-60)
COMPRESSOR - THE PREVIOUS USED OIL SHOULD FIRST BE DRAINED AND THE
SYSTEM FLUSHED.
- THE OIL FILTER SHOULD BE REPLACED.

MAKER : K.H.I
2 BV-101 10.4 KG MULTIFAK EP 0
FEED WATER MOTOR VALVE

12 BV-102, 103, 104, 015, 106, 107 12 KG MULTIFAK EP 2

GEAR BOX FOR VALVES 4 BV-313, 314 12 KG MULTIFAK EP 2

BOILER & 2 BV-302 7 KG MULTIFAK EP 2

6
ACCESSORIES
BC-317 (AUX. DESH INLET SDNR V.) &
HAND OPERATED VALVES 4 0.12 KG MULTIFAK EP 2
BV- 320 (AUX. STM DESH OUTLET SDNR V.)

3 BEARING HOUSING 5.7 KG MULTIFAK EP 2

FORCED DRAFT FAN
FALK COUPLING 1.3 KG MULTIFAK EP 2

Final Draft / 2007.12.28 8-8 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

INLET VALVE CONTROL LEVER 0.1 KG MULTIFAK EP 2

MOTOR BEARING 0.4 KG MULTIFAK EP 2

BOILER LEG 2 BOILER LEG 1.4 KG MULTIFAK EP 2

GEARED MOTOR 1 KG MULTIFAK EP 0 INITIALLY FILLED

LONG RETRACTABLE SOOT

4 TRIGGER PIM & GEAR 0.4 KG MULTIFAK EP 2 INITIALLY FILLED
BLOWER

TRAVELLING HEAD & FEED SCREW 1.6 KG VRATOR EP 0 INITIALLY FILLED

GEAR & CHAIN 1.6 KG MULTIFAK EP 2 INITIALLY FILLED

ROTARY SOOT BLOWER 16
REDUCTION GEAR 9.6 KG CRATOR EP 0 INITIALLY FILLED

FUEL OIL PUMP 2 GREASE NIPPLE 0.12 KG MULTIFAK EP 2 INITIALLY FILLED

MAKER : ALFA LAVAL

1 SPINDLE 2.2 L RANDO HDZ 66
M.D.O.(SA825)
7 PURIFIER
MAIN L.O.(SA830) 2 SPINDLE 4.4 L RANDO HDZ 68

W.O. PUMP GEAR BOX 0.3 L MEROPA 220 INITIALLY FILLED

MAKER : HMMCO
8 INCINERATOR 1
(MAXI 150SL-1 WS)
MILL PUMP SEAL BOX 0.75 L REGAL R&O 68 INITIALLY FILLED

BOILER F.W. MAKER : COFFIN UNIT BEARINGS, MITER GEARS & GEVERNOR
9 2 46 L REGAL R&O 66
PUMP TURBINE (DEB-16) ASSY.

MAKER : SHINKO
MAIN & AUX. S.W. CIRC. P/P 2 PUMP COUPLING SIDE BEARING 0.5 KG MULTIFAK EP 2 INITIALLY FILLED
(CVF 1000M & 1000LM)

MAIN CONDENSATE PUMP

2 PUMP COUPLING SIDE BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED
(EVZ 130M)

CONDENSATE DRAIN PUMP

2 PUMP COUPLING SIDE BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED
(EVA 70MH)

DUMP DRAIN PUMP

1 PUMP COUPLING SIDE BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED
(EVZ 130MH)

E/R CENT.
PUMP COUPLING SIDE BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED
PUMP &
10
PISTON/
WATER SPRAY PUMP
PULENGER PUMP 1 PUMP END SIDE BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED
(KV 300K)

PUMP SIDE GEAR COUPLING 0.2 L MEROPA 680

BALLAST PUMP
3 PUMP COUPLING SIDE BEARING 0.3 KG MULTIFAK EP 2 INITIALLY FILLED
(GVD 500-3MS & 3M)

COLD START BOILER F.W.

PUMP 1 CRANK CASE 50 L REGAL R&O 68
(HLX 6)

OILY BILGE PUMP

1 COUNTER/CRANK SHAFT BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED
(VPS 10)

Final Draft / 2007.12.28 8-9 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

OIL BOX OR GEAR CASE 0.3 L REGAL R&O 68

COUNTER/CRANK SHAFT BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED

E/R BILGE PUMP
1
(VPS 10)
OIL BOX OR GEAR CASE 0.3 L REGAL R&O 68

COUNTER/CRANK SHAFT BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED

WASTE OIL TRANS. PUMP
1
(VPS 5)
OIL BOX OR GEAR CASE 0.3 L REGAL R&O 66

MAKER : NANIWA TIMING GEAR & BALL BEARING 1 L REGAL R&O 68

M.D.O. TRANS. PUMP 1
(ALGP-80) BALL BEARING COUPLING SIDE 0.01 KG MULTIFAK EP 2

TIMING GEAR & BALL BEARING 0.4 L REGAL R&O 68

GAS OIL TRANSFER PUMP
11 E/R GEAR PUMP 1
(ALGP-25)
BALL BEARING COUPLING SIDE 0.01 KG MULTIFAK EP 2

TIMING GEAR & BALL BEARING 0.4 L REGAL R&O 68

M.D.O. PURI. SUPPLY PUMP
1
(ALGP-32)
BALL BEARING COUPLING SIDE 0.01 KG MULTIFAK EP 2

MAKER : HI-PRES KOREA E/R

(CLOSING DAMPER)
FAN 6 3.6 KG MULTIFAK EP 2 INITIALLY FILLED
GREASE NIPPLE FOE SHAFT BEARING
(AQ-1400/578)

12 E/R FAN PURI. ROOM EXH. FAN

1 GREASE NIPPLE FOE SHAFT BEARING 0.4 KG MULTIFAK EP 2 INITIALLY FILLED
(AQ-560/380)

D/G ROOM EXH. FAN

1 GREASE NIPPLE FOE SHAFT BEARING 0.4 KG MULTIFAK EP 2 INITIALLY FILLED
(AQ-710/330)

MSBD/ECR AIR MAKER : HI-PRES KOREA

13 2 COMPRESSOR CRANKCASE 60 L CAPELLA HFC 100
COND. PLANT (MCU28/411910 V)

MAKER : HI-PRES KOEA FOE

WORKSHOP 1 COMPRESSOR CRANKCASE 3.8 L CAPELLA HFC 32 INITIALLY FILLED
(HIP-20WGE)
14 UNIT COOLER
FOR BOILER TEST ROOM
1 COMPRESSOR CRANKCASE 1 L CAPELLA HFC 32 INITIALLY FILLED
(HIP-3WGE)

HEAD STOCK & GEAR BOX 10 L RANDO HDZ 32 INITIALLY FILLED

MAKER : GOMT
15 LATHE 1
(NSL 580 X 2000G)
APRON AND ETC. 2 L RANDO HDZ 68 INITIALLY FILLED

COLUMN SIDE, SPINDLE & TABLE/HEAD GEAR

MAKER : YOUNGKWANG 3 L RANDO HDZ 32 INITIALLY FILLED
BOX
UP-RIGHT DRILLING MACHINE 1
(NBTG-540)
COLUMN GEAR 0.2 KG MULTIFAK EP 2 INITIALLY FILLED

WORKSHOP
16 SLEEVE & SPINDLE 0.2 L RANDO HDZ 32 INITIALLY FILLED
MACHINERY BENCH DRILLING MACHINE
1
(YKD-20)
BAND GEAR BOX & COLUMN GEAR 0.2 KG MULTIFAK EP 2 INITIALLY FILLED

PIPE BENDER
1 OIL TANK 8 L RANDO HDZ 46 INITIALLY FILLED
(TPB-4)

Final Draft / 2007.12.28 8 - 10 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

GEAR OIL 1.5 L RANDO HDZ 32 INITIALLY FILLED

PIPE THREADING MACHINE
1
(KSU-50A)
GEAR BOX & SHAFT 0.2 KG MULTIFAK EP 2 INITIALLY FILLED

FRAME/GEAR COVER & ROD 0.03 L RANDO HDZ 32 INITIALLY FILLED

BAND SAWING MACHINE
1
(KDBS-200)
HYDRO. PUMP 0.2 L RANDO HDZ 46 INITIALLY FILLED

ENGINE MAIN L.O. SYSTEM 114 L URSA MARINE 15W-40 INITIALLY FILLED

EM’CY MAKER : STX

E-1 1 W/W GOVERNOR 3 L URSA MARINE 15W-40 INITIALLY FILLED
GENERATOR (KTA38DMGE)

HYDRAULIC STARTER 30 L RANDO HDZ 15 INITIALLY FILLED

MAKER : HHI-EES
2 BOTTOM SIDE / TOP SIDE 0.9/1.3 KG MULTIFAK EP 2 INITIALLY FILLED
FOE MAIN & AUX. S.W. CIRC. P/P

FOE EM’CY FIRE PUMP 1 BOTTOM SIDE / TOP SIDE 0.2/0.3 KG MULTIFAK EP 2 INITIALLY FILLED

FOR WATER SPRAY PUMP 1 BOTTOM SIDE / TOP SIDE 0.2/0.3 KG MULTIFAK EP 2 INITIALLY FILLED

FOR BALLAST PUMP 3 BOTTOM SIDE / TOP SIDE 0.5/1 KG MULTIFAK EP 2 INITIALLY FILLED

E-2 ELECTRIC MOTOR FOR MAIN COOL. S.W. PUMP 2 D.E. SIDE / N.D.E. SIDE 0.6/0.4 KG MULTIFAK EP 2 INITIALLY FILLED

FOR MAIN CENT. COOL. F.W.

2 D.E. SIDE / N.D.E. SIDE 0.6/0.4 KG MULTIFAK EP 2 INITIALLY FILLED
P/P

FOR MAIN CONDENSATE PUMP 2 D.E. SIDE / N.D.E. SIDE 0.4/0.2 KG MULTIFAK EP 2 INITIALLY FILLED

FOR FIRE, BILGE & G/S PUMP 2 D.E. SIDE / N.D.E. SIDE 0.6/0.4 KG MULTIFAK EP 2 INITIALLY FILLED

FOR AUX. L.O. PUMP 2 D.E. SIDE / N.D.E. SIDE 0.4/0.2 KG MULTIFAK EP 2 INITIALLY FILLED

PUMP, CYLINDER & PIPE 1,450 L RANDO HDZ 66

MAKER : TONGMYUNG
S-1 STEERING GEAR 1
(FE21-400-T050/340)
HYD. OIL STORAGE TANK 700 L RANDO HDZ 68

PROPELLER
S-2 MAKER : HHI-EMD 1 BONNET INSIDE 220 KG MULTIFAK EP 0
BONNET

INTER. SHAFT MAKER : KOBELCO EAGLE

S-3 2 BEARING & OIL BATH 60 L REGAL R&O 68
BEARING M.E.L.(KMF-660)

FWD/AFT SEAL CHAMBER 10 L REGAL R&O 68

MAKER : KOBELCO EAGLE
STERN TUBE SEAL M.E.L.
S-4 1 FWD SEAL TANK 20 L REGAL R&O 68
(AFT & FWD) AFT (AIR SEAL-3A, SIZE-850)
FWD (AIR SEAL-3A, SIZE-850)
PIPE LINE 20 L REGAL R&O 68

STERN TUBE STERN TUBE INSIDE 1,700 L REGAL R&O 68

S-5 BEARING MAKER : JAPAN MARINE TECH. 1
& SYSTEM S/T L.O. TANK 150 L REGAL R&O 68

Final Draft / 2007.12.28 8 - 11 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

S/T L.O. SUMP. TANK. 5,400 L REGAL R&O 68

S/T L.O. GRAVITY TANK 180 L REGAL R&O 68

PIPE LINE 170 L REGAL R&O 68

HYD. NUT FOR

S-6 MAKER : HHI-EMD 1 HYD. POWER PUMP 18 L RANDO HDZ 32 INITIALLY FILLED
PROP. SHAFT

GREASE PUMP MAKER : 3k INDUSTRIES RUDDER CARRIER BEARING, GREASE PUMP &
S-7 1 90 KG MULTIFAK EP 0
FOR R/CARRIER (MSK-602-T5M) FILLER PACK

MAIN AIR COND. MAKER : HI-PRES KOREA

A-1 2 COMPRESSOR CRANK CASE 300 L CAPELLA HFC 100
PLANT (MCU116/412702 D)

AUX. AIR COND. MAKER : HI-PRES KOREA

A-2 2 COMPRESSOR CRANK CASE 138 L CAPELLA HFC 100
PLANT (MCU28/502320 V)

PROV. REF. MAKER : HI-PRES KOREA

A-3 2 COMPRESSOR CRANK CASE 24 L CAPELLA HFC 55
PLANT (SB042/271230 V)

GEAR CASE OF MACHINE 6 L PINACLE MARINE GEAR 220 INITIALLY FILLED

BEARING PART OF TRACTION MACH. 0.3 KG MULTIFAK EP 2 INITIALLY FILLED

A-4 CREW ELEVATOR MAKER : HYUNDAI ELEVATOR 1
GUIDE RAILS, CAGE DOOR, SAFETY DEVICE,
GOVERNOR, TENSION SHEAVE & ENTRANCE 2 L REGAL R&O 68 INITIALLY FILLED
DOOR

THRUSTER PROPER 560 L MEROPA 100

GRAVITY TANK 110 L MEROPA 100

HYDRAULIC UNIT 10 L MEROPA 100

H-1 BOW THRUSTER MAKER : K.H.I. 1
PIPES 124 L MEROPA 100

SF COUPLING 3 KG MULTIFAK EP 2

MAIN MOTOR BEARING 0.5 KG MULTIFAK EP 2

AIR WINCH 3 L MEROPA 220 INITIALLY FILLED

EM/CY CARGO HOISTING ROPE 5 KG TEXCLAD 2 INITIALLY FILLED

H-2 PUMP HANDLING MAKER : SHIN MYUNG TECH. 2
UNIT BEARING 4 KG MULTIFAK EP 2 INITIALLY FILLED

FILTER & OILER UNIT 0.4 L RANDO HDZ 32 INITIALLY FILLED

OPEN GEAR 10 KG TEXCLAD 2 INITIALLY FILLED

GREASE NIPPLE 12 KG MULTIFAK EP 2 INITIALLY FILLED

MAKER : ROLLS-ROYCE
H-3 DECK MACHINERY 2
WINDLASS (W1, W2)
CLOSED GEAR 130 L PINACLE MARINE GEAR 220

HYDRAULICS & PIPES 630 L RANDO HDZ 100

Final Draft / 2007.12.28 8 - 12 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

GREASE NIPPLE 42 KG MULTIFAK EP 2 INITIALLY FILLED

MOORING WINCH (M1- M7) 7 CLOSED GEAR 1,029 L PIANCLE MARINE GEAR 220

HYDRAULICS & PIPES 1,155 L RANDO HDZ 100

SERVO PUMP UNIT 1 OIL TANK 69 L RANDO HDZ 15

WINCH GEAR BOX 1 L MEROPA 220

FALL WIRE ROPE 2 KG TEXCLAD 2

REMEDY
H-4 MAKER : HUNG-A 2
HANDLING DAVIT
MOTOR BEARING 0.4 KG MULTIFAK EP 2

OILER SET 1.4 L RANDO HDZ 32

WINCH GEAR BOX 0.5 L MEROPA 220

FALL WIRE ROPE 1 KG TEXCLAD 2

PORTABLE DAVIT
H-5 MAKER : JUNG-A 1
(TRIPOD TYPE)
MOTOR BEARING 0.2 KG MULTIFAK EP 2

OILER SET 0.7 L RANDO HDZ 32

HOISTING WINCH 6 L MEROPA 220

OILER & FILTER UNIT 0.3 L RANDO HDZ 32

ACCOMMODATION
H-6 MAKER : SAM-GONG 2
LADDER
WIRE ROPE 7.5 KG TEXCLAD 2

GREASE POINT (LADDER MOCING PART) 1 KG MULTIFAK EP 2 INITIALLY FILLED

4 REDUCTION GEAR BOX 6 L MEROPA 220

PILOT LADDER
H-7 MAKER : SAM-GONG
REEL
2 OILER & FILTER UNIT 0.3 L RANDO HDZ 32

ENCLOSED GEAR 44 L MEROPA 220

LIFE BOAT DAVIT &

H-8 MAKER : ORINTAL 2 WIRE ROPE 10 KG TEXCLAD 2
WINCH

BEARINGS 4 KG MULTIFAK EP 2 INITIALLY FILLED

EM’CY TOWING MAKER : TANKTECH

H-9 1 STORAGE DRUM (REDUCTION GEAR) 6 L MEROPA 220 INITIALLY FILLED
SYSTEM (KETSP-40A)

4 WINCH GEAR BOX 60 L MEROPA 220

H-10 CAPSTAN MAKER : JUNG-A 4 MOTOR BEARING 0.8 KG MULTIFAK EP 2

4 OILER SET 2.8 L RANDO HDZ 32

H-11 FIRE WIRE REEL MAKER : JUNG-A 4 WINCH GEAR BOX 4.6 L MEROPA 220

Final Draft / 2007.12.28 8 - 13 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

4 MOTOR BEARING 0.4 KG MULTIFAK EP 2

4 OILER SET 1.4 L RANDO HDZ 32

WINCH GEAR BOX 1.5 L MEROPA 150 INITIALLY FILLED

SLEWING REDUCER BOX 2.5 L MEROPA 150 INITIALLY FILLED

LUFFING GEAR BOX 1 L MREOPA 150 INITIALLY FILLED

CARGO
H-12 COMP./MOTOR MAKER : ILHO MARINE TECH 1 AIR MOTOR 1 KG MULTIFAK EP 2 INITIALLY FILLED
ROOM DAVIT
PLAIN BEARING 1 KG MULTIFAK EP 2 INITIALLY FILLED

WIRE ROPE & OPEN GEAR 2.5 KG TEXCLAD 2 INITIALLY FILLED

OILER 0.7 L RANDO HDZ 32 INITIALLY FILLED

(LIFTING POST)
1 0.2 KG MULTIFAK EP 2 INITIALLY FILLED
ELEC. MOTOR ROOM FAN

1 CARGO COMP. ROOM FAN 0.2 KG MULTIFAK EP 2 INITIALLY FILLED

H-13 VENT. FAN MAKER : HI-PRES KOREA
1 PIPE DUCT FAN 0.2 KG MULTIFAK EP 2 INITIALLY FILLED

2 PASSAGE WAY FAN 0.4 KG MULTIFAK EP 2 INITIALLY FILLED

2 HYDRAULIC OIL ON SYSTEM 1,800 L RANDO HDZ 32

4 SLEW. GEAR BOX 40 L MEROPA 150 INITIALLY FILLED

WINCH GEAR BOX 5 L MEROPA 150 INITIALLY FILLED

HOSE AHNDLING
H-14 MAKER : SHIN YOUNG
CRANE
WIRE ROPE & OPEN GEAR 45 KG TEXCLAD 2 INITIALLY FILLED
2
ROLLER / BALL BRONZE 40 KG MULTIFAK EP 2 INITIALLY FILLED

PLAIN BEARING BRONZE 20 KG MULTIFAK EP 2 INITIALLY FILLED

HYDRAULIC OIL ON SYSTEM 1,000 L RANDO HDZ 32

SLEW. GEAR BOX 14 L TEXTRAN TDH PREMIUM INITIALLY FILLED

WINCH GEAR BOX 3 L TEXTRAN TDH PREMIUM INITIALLY FILLED

H-15 PROVISION CRANE MAKER : SHIN YOUNG 2
WIRE ROPE & OPEN GEAR 45 KG TEXCLAD 2 INITIALLY FILLED

ROLLER / BALL BRONZE 40 KG MULTIFAK EP 2 INITIALLY FILLED

PLAIN BEARING BRONZE 20 KG MULTIFAK EP 2 INITIALLY FILLED

HD/ LD CARGO
H-16 MAKER : CRYOSTAR 4 STEAM HEATER 40 L TEXATHERM 32
COMP.

Final Draft / 2007.12.28 8 - 14 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

GEAR BOX BEARINGS 1,600 L REGAL R&O 46

CARGO 4 FOR HD CARGO COMPRESSOR 24 L CETUS PAO 68

H-17 COMPRESSOR’S MAKER : TAIYO ELECTRIC
MOTOR 4 FOR LD CARGO COMPRESSOR 18 L CETUS PAO 68

MAKER : SHINKO
H-18 EM’CY FIRE PUMP 1 PUMP COUPLING SIDE BEARING 0.1 KG MULTIFAK EP 2 INITIALLY FILLED
GVD300-3MS)

2 AIR BLOWER COMBUSTION AIR INTAKE 11 L PIANCLE MARINE GEAR 220

1 COMPRESSOR FOR I.G. CHILLER UNIT 50 L CAPELLA HFC 100

2 DRIVER FOR AIR BLOWER 0.18 KG MULTIFAK EP 2

INERT GAS
H-19 MAKER : SMIT
GENERATOR
1 DRIVER FOR FUEL OIL PUMP 0.04 KG MULTIFAK EP 2

1 GLYCOL CIRCULATING PUMP 0.04 KG MULTIFAK EP 2

1 DRIVER FOR DRYER REGENERATION FAN 0.0.4 KG MULTIFAK EP 2

NOTE ) DO NOT MIX DIFFERENT LUBRICANTS. IF OIL TYPE IS

H-20 N2 GENERATOR MAKER : TAMROTOR 2 COMPRESSOR OIL SUMP. 68 L CETUS PAO 46 CHANGED, ALSO CHANGE OIL SEPARATOR FILTER ELEMENTS
AND OIL FILTER

TRANSMITTER 6.5 L RANDO HDZ 32

5
MANUAL HYD.
H-21 MAKER : BY CONTROLS ACTUATOR 2 L RANDO HDZ 32
OPERATING UNIT

PIPE 5.8 L RANDO HDZ 32

PORTABLE PUMP
H-22 FOR BILGE MAKER : SHIN MYUNG TECH. 7 OILER 1.4 L RANDO HDZ 32 INITIALLY FILLED
DISCHARGE

8 HYD. ACTUATOR CYLINDER (HQ25) 1 L RANDO HDZ 22

CRYOGENIC BALL
H-23 MAKER : SEIL-SERES
VALVE
1 HYD. ACTUATOR CYLINDER (HQ50) 3 L RANDO HDZ 22

6 HYD. ACTUATOR CYLINDER (ACTO200) 2 L RANDO HDZ 22

19 HYD. ACTUATOR CYLINDER (ACTO400) 18.5 L RANDO HDZ 22

CRYOGENIC B/F
H-24 MAKER : KSB-AMRI
VALVE
5 HYD. ACTUATOR CYLINDER (ACTO800) 10.2 L RANDO HDZ 22

1 HYD. ACTUATOR CYLINDER (ACTO1600) 4.3 L RANDO HDZ 22

1 HYD. POWER PACK (CARGO) 980 L RANDO HDZ 22

CARGO & BALLAST 1 HYD. POWER PACK (BALLAST) 980 L RANDO HDZ 22
H-25 VALVE REMOTE MAKER : SEIL-SERES
CONTROL SYSTEM 27 ACCUMULATOR 100 L RANDO HDZ 22

9 SOLENOID VALVE BOX 55 L RANDO HDZ 22

Final Draft / 2007.12.28 8 - 15 Part 8 General Information

CLEAN FORCE Machinery Operating Manual

FILL’G Q’TY
NO. EQUIPMENT (MAKER/TYPE) Q'TY APPLICATION POINT UNIT L.O GRADE REMARK
(PER SHIP)

PIPE LINE 1,224 L RANDO HDZ 22

11 HYD. ACTUATOR CYLINDER (HQ25) 1 L RANDO HDZ 22

25 HYD. ACTUATOR CYLINDER (HQ50) 3 L RANDO HDZ 22

19 HYD. ACTUATOR CYLINDER (HQ100) 4.5 L RANDO HDZ 22

VALVE REMOTE CONTROL
SYSTEM 4 HYD. ACTUATOR CYLINDER (HQ200) 2 L RANDO HDZ 22

19 HYD. ACTUATOR CYLINDER (HQ400) 25 L RANDO HDZ 22

2 HYD. ACTUATOR CYLINDER (HQ800) 5 L RANDO HDZ 22

ENGINE 7 L URAS MARINE 15W-40 INITIALLY FILLED

H-26 LIFE BOAT MAKER : HYUNDAI LIFEBOATS 2 BW-7 MARINE GEAR 2.2 L URSA MARINE 15W-40 INITIALLY FILLED

STERN TUBE (FLEXIBLE) 0.3 L MEROPA 220 INITIALLY FILLED

Final Draft / 2007.12.28 8 - 16 Part 8 General Information