SERVICE MANUAL. No, 0242-1513-4 FOR Date: 18dan05 FRAN Page: 1 CARGO PUMPING SYSTEM Rev. 2.0 GENERAL DESCRIPTION OF THE INSTALLATION 2.1 System description (design/operation) 24.4 DESCRIPTION OF HYDRAULIC SYSTEM ‘The hydraulic system is built as a central hydraulic main ring line system in open loop where hydraulic pumps deliver cil to a main pressure line. From this main pressure line a number of hydraulic motors can be run provided that a sufficient umber of power packs have been started. In order not to overspeed the hydraulic. motors, a speed control vaive is installed up stream of each motor. ‘The main hydraulic pumps are of axial piston type, swash plate design with variable displacement. The pump displacement (swivel angle) is hydraulically controlled via the pressure regulator on each pump, Atstar-up, the variable pump is in max. swivel angle, and a pressure is built up in the pressure line. This pressure is internally bled off through the pressure regulator and a solenoid valve, energised at start-up, causing that the swivel angle is reduced to min. After approximately 10 seconds the solenoid valve is de-energised, and pilot «il from the pump will push the swash plate to an increased swivel angle, and oils delivered into the main pressure line. However, if no ol is needed, a pressure is built up in the main pressure line. When this pressure reach the set pressure of the proportional valve, the valve will open for oil through the pressure regulator, and the swivel angle will decrease until a balance is reached between oil delivery and ci consumption If the oil consumption from the cargo pumps is increased, the system pressure will drop slightly, and the oil flow through the proportional valve will drop. Pilot oll from the pump will now push the swash plate to increased swivel angle until a new balance is reached between oil delivery and consumption. By this system the oll delivery from the hydraulic pumps will aways be the same as the oil consumption from the motors. All cargo and other pumps connected to the system may be remotely controlled from Framo control panel, vessel computer or locally at each pump via the speed control valve STC (Speed Torque Controller). This valve is designed to control the discharge from cargo- and other pumps powered by a central hydraulic ring line system, ‘The valve is set to @ maximum oil flow, limiting the oil flow to the hydraulic motor and thus limiting the motor speed and consequently prevents overspeed. The oil flow is proportional to the speed, which can be steplessly regulated. For further information about the STC-valve, see separate instruction ‘The portable pump speed is locally controlled at the pump.24.3 SERVICE MANUAL No: 024245134 FOR Date: 13Jan05 Page: 2 CARGO PUMPING SYSTEM Rev. ‘The main filter and the oil cooler with a built-in temperature controlled shut-off valve for the cooling water, are installed in the main return line to keep the oil clean and the temperature within desired range. The shut-off valve is installed by the Yard on the cooling water inlet line, but controlled from the FM system control system. For safe operation of the system, several transmitters/switches/alarms are installed. HYDRAULIC FLUIDS, FLUID CLEANLINESS Hydraulic pumps, motors and controls are devices requiring close tolerances, controlled wear surfaces, accurate finish and an adequate supply of clean hydraulic, fluid, Contaminated fluid will not provide proper lubrication and is a leading contributor to reduced efficiency, excessive downtime and increased maintenance cost. Max. recommended water content is 300 PPM (0.03 %), and must under no circumstances be above 500 PPM (0.05 %). I in doubt, please contact Framo. Recommended cleanliness level is code 16/12 according to ISO 4406 (or CETOP PR20). 16/12 means that number of particles: ‘Above 6 micron in 100 mlis between 32000 and 64000. ‘Above 14 micron in 100 mlis between 2000 and 4000. For further information, see separate instruction. BOW THRUSTER SYSTEM Refer to dedicated system drawings and separate instruction.SERVICE MANUAL No.: 0242-1513-4 &3 Date: 13Jan05 PEA FOR Page: 3 CARGO PUMPING SYSTEM Rev.: 22 ‘System description (electrical) 224 GENERAL “The Framo cargo pumping system is controlled by a Programmable Logic Control (PLC) installed inside the control panel. The PLC ts programmed by Framo and provides the loge fr safe operation ofthe system. Modifications of the Systemvprogram carried out by others may effet the warranty f the system. This section shouldbe read in conjunction with dedicated system drawings, 2.2.2 ALARM SYSTEM The alarms are divided into two groups: @) Alarms and shut down of the hydraulic system 8) Alarms for indication (pre-warning) only {ilalarm inputs, except "excessive wear” are normally closed, This means thet the system is bult up on normally closed contacts. Hence if a contact opens or there is 3 loose wire, an alarm condition occurs, ie. FAIL TO SAFE Each alarm is indicated wth a flickering ight and an acoustic signal until the “acknowledge” push button is activated. Ifthe alarm condition stil is on, the lamp wil turn info’ steady ight and buzzer wil stop o clear group a) alarms, the "system reset” button must be activated before any power pack can be restated Group b) alarms have got automatic reset. Plgase refer instrument st or applicable alarms and time delay 223 EMERGENCY STOP ARRANGEMENT Following emergency stop arrangement is provided by Framo according to class requirements: = Emergency stop push buttons located on deck are stopping the cargo pumps only, other consumers are not affected, - Emergency stop push buttons on thruster panels are stopping the thruster only ~ ‘other consumers are not affected. = Emergency stop push button located on hydraulic system control panel is stopping the hydraulic system.nia FRANO 2.24 22.5 Note! 2.26 2.27 SERVICE MANUAL No.: 0242-1513-4 FOR Date: 13Jan05 Page: 4 CARGO PUMPING SYSTEM Ree JOCKEY PUMP Start/stop of the jockey pump is manually from control panel, or from the electric starter cabinet. A running signal is provided for indication on the control panel. The jockey pump shall always be running. The following will be indicated on the control panel if the jockey pump stops when a power pack is running: ‘The protection pressure low alarm will be initiated and the jockey pump running light will start flashing. To reset the alarm, the jockey pump stop push button must be operated, MAIN POWER PACKS Start/stop of the main power packs is performed manually from control panel, or from the electric starter cabinet. ‘The power packs can be started in any sequence. Maximum 4 starts should be made during an hour. Maximum 2 following starts can be made, then 15 minutes between each, The starts are controlled by the PLC, including eventual starts from the local starter cabinet. The hydraulic pump will be disengaged for 10 seconds during start-up. The limit switches on the suction line for each power pack will stop of prevent start of the corresponding power pack only. An alarm light is provided for each power pack to indicate closed valve. If more than one power pack is loaded and the hydraulic cil temperature increases to 65°C or above, the control system will automatically unload all power packs in sequence except for one. The running light will start flashing for the unloaded power packs, and the high oil temperature alarm is re-iitiated each time a new power pack is unloaded. The power packs will automatically be reloaded in sequence ‘when the hydraulic oil temperature has decreased below 60°C. If the system is in thrusters mode, the power packs will not be unloaded. ‘The hydraulic pump will be disengaged 60 seconds after loss of run indication/stop of power pack. ‘SYSTEM PRESSURE CONTROL ‘System pressure is set by means of the potentiometer in front of the control panel, a8 a voltage input to the proportional valve driver card. This input is amplified by the proportional valve driver card to approximately 100 mA at minimum system pressure and approximately 400 mA at maximum system pressure. The set pressure is automatically set to zero until one of the power packs has been loaded. REMOTE CONTROL OF HYDRAULICALLY DRIVEN PUMPS, ‘The command signals from potentiometers in front of the control panel are fed directly into the proportional valves for speed control. The built in pressure transmitters give a 4-20 mA (0-300 bar) feedback signal to the instruments on the ‘control panel.4 SERVICE MANUAL No. 0242-1513-4 FOR Date: $8Jan05 FRAN age: 8 CARGO PUMPING SYSTEM Rev. 228 COOLING WATER VALVE The valve is automatically controlled and will receive “open” command at hydraulic cil temperature above 50°C. It will stay open until the temperature decreases 10 below 30°C when "close" command is given. "Close" signal wil also be given when the temperature is below 49°C after the last power pack is stopped. if no power packs are running and the hydraulic ol temperature is below 50°C, but higher than 30°C, the cooling water valve will close If there is a mismatch between command- and feedback signal, an alarm will be released after 1 minute. Ifa failure in the temperature monitoring loop occurs, open valve command is given. The "Flushing mode" program makes it possible to increase the cil temperature during flushing, In this mode the valve is closed below 50°C and opened at 58°C. The “Dirty fier” alarm willbe activated also below 30°C in the Flushing mode. ‘The Flushing mode is selected by pressing keys ACK and RESET keys simultaneously in 5 seconds. The mode is acknowledged by 1 second beep in the ‘audible alarm, and itis switched off in the same way, acknowledged by 2 second beep in the audible alarm, The mode is automaticaly turned off after 24 hours. 229 SYSTEM SHUT DOWN Please refer to instrument lst for applicable shut down functions. Ifa shut down function is initiated, the PLC will give shut down command to the power packs in sequence. The first power pack stops immediately. The delay between shut down command of each power pack is 0.75 seconds, 22.10 MANUAL OVERRIDE OPERATION Please refer to section 5. 2.2.11 TROUBLE SHOOTING Please refer to section 6.4 FRAMO 2.2.12 2.2.13 2.2.14 2.2.15 2.2.16 SERVICE MANUAL No. 0242-1513-4 FOR Date: 13Jan05 Page: 6 CARGO PUMPING SYSTEM nee ELECTRIC CONTROLLED BALLAST PUMP EJECTOR ‘The ejector for the priming system is automatically controlled by the PLC. The PLC receives input from a combined high- and low level switch installed in the pump casing and engages/disengages the solenoid valve for ejector pilot air contral. The ejector is started when low level is detected, and stopped at high level. Time delay for start and stop is 2 seconds. The logic contains interlock to prevent starting the ejector when no power packs are running and operator's pressure command is less than 30 bar. INTERFACE TO VESSEL CONTROL SYSTEM ‘The Framo cargo pumping system can be operated/monitored from Framo control panel or remotely from vessel control system (VCS). Mode is selected in front of the Framo control panel, Available control and monitoring signals are indicated on dedicated system drawings. INTERFACE TO POWER MANAGEMENT SYSTEM (PMS) ‘A’start request’ signal is sent from Framo system to PMS. Start is prohibited until a ‘power available’ signal is received from PMS. For detailed arrangement, refer to dedicated system drawings. BOW THRUSTER SYSTEM Refer to dedicated system drawings and separate instruction POWER SUPPLY Most hydraulic system control panels are connected to two separate power sources (feeders), ‘main’ supply and "back up’ supply. In case of failure to main supply, automatic changeover to back up supply will take place. For increased availabilty and simplified trouble shooting, the control system is electrically divided into separate sub-systems. Each sub-system has its own 24VDC power supply. Failure in one system is not likely to interfere with other systems, ‘The feeders and DC power supplies are monitored by relays provided with status lamps. The lamps are lit when the corresponding supply is in good condition. A failure on any of the supplies or short circuit at consumption line will generate a potential free (dry contact) power failure alarm to the engine control room in addition to alarm at local control panel. Refer to wiring diagrams for detailed arrangement.