INSTRUCTION MANUAL

INERTGAS GENERATOR

GENERAL INFORMATION

Series Gln

© 2012 Alfa Laval Aalborg Nijmegen B.V.

All rights reserved.

No part of this publication may be copied or published by means of printing, photocopying, microfilm or oth-
erwise without prior written consent of Alfa Laval Aalborg Nijmegen B.V.. This restriction also applies to the
corresponding drawings and diagrams.

The information given in this document has been collected for the general convenience of our clients. It has
been based on general data pertaining to construction material properties and working methods known to us
at the time of issue of the document and is therefore subject at any time to change or amendment. The right
to change or amend is hereby expressly reserved. The instructions in this publication only serve as a guide-
line for installation, use and maintenance of the machine mentioned on the cover page of this document.

This publication is to be used for the standard model of the machine of the type given on the cover page.
Thus Alfa Laval Aalborg Nijmegen B.V. cannot be held responsible for any damage resulting from the appli-
cation of this publication to the version actually delivered to you.

This publication has been written with great care. However, Alfa Laval Aalborg Nijmegen B.V. cannot be held
responsible, either for any errors occurring in this publication or for their consequences.
 ORDER NR: 19599

INSTRUCTION MANUAL

INERTGAS GENERATOR Series Gln

Type: Smit Gas™ Gln 4125 - 0.15 FU

Order number: 072.10.1.9599 .............................................................................

Manufacturing number: 07899 ............................................................................................

Year of construction: 2012 ............................................................................................

Customer: Guangzhou Shipyard .......................................................................

Ref. Customer: POMEGH060710 .............................................................................

Yard number: H06130023 .....................................................................................

Alfa Laval Aalborg Nijmegen BV Pagina 2 van 42


TABLE OF CONTENTS
1 GENERAL INFORMATION ....................... 4
1.1 SCOPE ............................................................... 4
1.2 LIABILITY ......................................................... 4
1.3 GUARANTEE ..................................................... 4
1.4 ABBREVIATIONS USED IN THIS MANUAL............ 4
2 SAFETY ......................................................... 5
2.1 GENERAL SAFETY INSTRUCTIONS ..................... 5
2.2 SAFETY INSTRUCTIONS FOR OPERATING &
MAINTENANCE .................................................. 6
3 INSTALLATION ........................................... 8
3.1 INSTALLATION INSTRUCTIONS........................... 8
4 STORAGE INSTRUCTIONS..................... 10
4.1 GENERAL STORAGE INSTRUCTIONS ................. 10
4.2 STORAGE INSTRUCTIONS FOR THE
CONSTRUCTION PERIOD .................................. 10
5 TECHNICAL DESCRIPTION................... 11
5.1 GENERAL........................................................ 11
5.2 PROCESS PRINCIPLE ........................................ 11
5.3 DETAILED PROCESS DESCRIPTION ................... 12
5.3.1 General ................................................. 12
5.3.2 Combustion air supply .......................... 12
5.3.3 Capacity control .................................... 12
5.3.4 Fuel oil supply ....................................... 13
5.3.5 Pilot burner ........................................... 13
5.3.6 Main burner .......................................... 13
5.3.7 Combustion chamber and scrubbing
section ................................................... 13
5.3.8 Effluent waterseal.................................. 14
5.3.9 Generator pressure control system ....... 14
5.3.10 Generator delivery pressure.................. 15
5.3.11 Purge / excess vent valve and delivery
valve ...................................................... 15
5.3.12 Excess gas vent system - deck main
pressure ................................................. 15
5.3.13 Deck main pressure control .................. 16
5.3.14 Measurement and safeguarding of the
oxygen content ...................................... 17
5.3.15 Fuel to air ratio / oxygen content .......... 17
6 TECHNICAL SPECIFICATION ............... 19
6.1 DESIGN BASIS ................................................. 19
6.2 INERT GAS SPECIFICATION .............................. 19
6.3 UTILITIES ........................................................ 19
7 OPERATING INSTRUCTIONS ................ 21
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7.1 GENERAL ....................................................... 21
7.2 CONTROL PANELS ........................................... 21
7.3 SWITCHING ON ............................................... 21
7.3.1 Inert gas production.............................. 21
7.3.2 Air production ....................................... 23
7.4 SWITCHING OFF .............................................. 23
7.4.1 Normal switch off .................................. 23
7.4.2 In case of a longer standstill ................. 24
7.5 CHECKS DURING OPERATION .......................... 24
7.6 ADJUSTMENTS................................................ 25
7.6.1 Adjustments of the generator delivery
pressure................................................. 25
7.6.2 Adjustments on the oxygen analyser ..... 25
7.6.3 Adjustments of the deck main pressure . 25
7.6.4 Adjustments to the pilot burner ............. 25
7.6.5 Adjustments of the fuel-oil pump delivery
pressure................................................. 25
8 TROUBLE SHOOTING ............................. 26
8.1 FAILURES ....................................................... 26
8.2 CONSEQUENCES OF FAILURES EXPLANATION .. 26
8.3 TROUBLE SHOOTING CHARTS......................... 27
8.3.1 General trouble shooting chart ............. 27
8.3.2 Consequences of failures trouble shooting
chart ...................................................... 28
9 MAINTENANCE ........................................ 32
9.1 GENERAL MAINTENANCE INSTRUCTIONS ........ 32
9.1.1 Rinsing the combustion chamber .......... 32
9.2 MAIN BURNER ................................................ 32
9.3 PILOT BURNER ................................................ 33
9.4 FREEZING PREVENTION .................................. 33
9.5 MAINTENANCE TABLES .................................. 33
9.5.1 Before every start .................................. 33
9.5.2 Every 250-hrs........................................ 33
9.5.3 Annually ................................................ 34
9.5.4 After every stop ..................................... 34
9.6 REPLACING THE PLC BATTERY ...................... 34
9.7 LUBRICATING SCHEDULE ................................ 35
9.7.1 Lubricating table................................... 36
10 TEST PROTOCOL ..................................... 37
11 PROCESS DOCUMENTATION ............... 38
12 DIMENSIONAL DRAWINGS ................... 39
13 ELECTRICAL DOCUMENTATION ....... 40
14 DOCUMENTATION .................................. 41
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 ORDER NR: 19599

1 GENERAL INFORMATION 1.3 Guarantee

1.1 Scope
This manual contains information for the
proper functioning and maintenance of the
inert gas generator. It also contains important
instructions to prevent accidents and serious
damage prior to and during operation of the
inert gas generator.
Read this manual carefully before using the
inert gas generator, familiarise yourself with
the functioning and operation of the inert gas
generator and strictly observe the instructions
given.
If you have any questions or need more de-
tails on specific aspects relating to the inert
gas generator, please contact:
The guarantee conditions that are stated in the
'General conditions of Sale and Delivery of Alfa
Laval Aalborg Nijmegen B.V.' are applicable to
this product. The guarantee will become null and
void if:
− service and maintenance are not carried
out strictly in accordance with the
instructions given,
− repair work is not carried out by authorised
personnel or has been performed without
prior written consent;
− the equipment has been modified without
prior written consent;
− non-original parts are used;
− the equipment is used incorrectly or not in
accordance with its intended use.
Wearing parts are not covered by the guarantee.

Alfa Laval Aalborg Nijmegen B.V. 1.4 Abbreviations used in this

St. Hubertusstraat 10 manual
6531 LB Nijmegen
The Netherlands BP Bridge panel
P.O. Box 6664
CCRP Cargo control room panel
6503 GD Nijmegen
CoF Consequences of Failures
The Netherlands
DWS Deck water seal
Tel.: +31 24 35 23 200 ERP Engine Room Panel
Fax: +31 24 35 23 177 FOP Fuel oil pump
E-mail:
inertgasaftersales.nijmegen@alfalaval.com LCRP Local Control Room Panel

P/V- Pressure / Vacuum breaker

1.2 Liability breaker
The data published in this manual are based PVB Pressure / Vacuum breaker
on the latest information available. They are
subject to future modification.

We reserve the right to change the construction

and/or design of the product, without being
obliged to adapt earlier supplies accordingly.

Alfa Laval Aalborg Nijmegen BV Pagina 4 van 42

 ORDER NR: 19599

2 SAFETY • Before entering an enclosed or poorly ven-

2.1 General Safety instructions
This plant is designed to produce inert gas, with
low oxygen content. Inert gas is an asphyxiating
gas and contains nitrogen (N2), carbon dioxide
(CO2) and little or no oxygen (O2). Furthermore
carbon monoxide (CO) and other toxic gasses
that may be present.
Exposure to or inhalation of the product gas
should be avoided; the more so as no oxygen is
present. Leakage or venting of product gas into
closed or confined areas, or at places where
personnel may be present, must be avoided.
Any violation of these warnings may result in
accidents causing personal injuries. A general
indication about the effects and symptoms in
case of low oxygen content is given below:
tilated area containing an inert gas gener-
ator or transmission equipment and pip-
ing, follow all established local safety pre-
cautions and procedures.
• Product gas should not be vented or oth-
erwise discharged except through the
normal piping system. Appropriate signs
should be placed in the area of the nitro-
gen system warning of the hazard.
• Piping of the inert gas flow to areas of
high air circulation is recommended. Con-
sult your own safety personnel for local,
state and federal procedures or regula-
tions.
• All electrical installation should be in ac-
cordance with the recognised electrical
codes.

Oxygen content Effects and symptoms

15-19% Decreased ability to work strenuously. May impair the co-ordination.
12-14% Respiration increase with exertion, increase of pulse rate, impaired co-
ordination, reception and judgement affected.
10-12% Respiration further increases in rate and depth, poor judgement, blueness of lips.
8-10% Mental failure, fainting, unconsciousness, ashen face, blueness of lips,
nausea and vomit.
9- 8% 8 minutes exposure: fatal; 6 minutes exposure: 50% fatal; 4-5 minutes
exposure recovery with treatment.
4- 6% Coma in 40 seconds, convulsions, respiration ceased or death.
Note: oxygen contents are indicated by volume percentage at atmospheric pressure.

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 ORDER NR: 19599

2.2 Safety instructions for Op-

erating & maintenance
Operating the equipment in excess of the
conditions set forth in the Sales Contract
and the Technical Specification will
subject it to stresses and strains that it
was not designed to withstand.
If ventilation is insufficient this can cause
under-pressure in the room. The result
may be that doors cannot be opened any-
more.

Carefully read the cautions and instructions Do not enter any cargo space
before starting the equipment or doing any and/or tank before the oxygen
maintenance. content in these spaces is
measured and found sufficient to
1. Before doing any maintenance to the guarantee that these places are
electrical installation, be certain that the not filled with inert gasses or
electrical supply has been switched off by other gasses then air!
the main switch.

2. Before doing any maintenance to the

equipment, be sure that all pressures of
the entire system have been vented.

3. When operating the equipment, do not

exceed the rated capacities, speeds,
pressures or temperatures or act
otherwise than laid down in these
instructions and the sub-contractors
manuals.

4. Do not remove any covers from rotating

units, such as blowers, fuel pumps, fans
etc. while the unit is in operation.

5. At no time the unit should be energised

and started in hazardous environments.

6. Sufficient ventilation air is obligatory in the

ig generator room.

7. Before any operation do test the alarms

and calibrate the O2 analyser.

8. The O2 content should not exceed 5%

when the inert gas is supplied to the tanks

9. Spilling oil (fuel or lubrication) may cause

slipperiness or fire damages.

10. The mode selection Inert Gas/ Air should

be made by the responsible person.

11. For detail about operations see chapter 7.

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 ORDER NR: 19599

Fig 1 shows the safety triangle that need be

used all the time for safe operation during
inerting- gas freeing.

Never the area indicated as “flammable or

explosive region” may be entered.

Alfa Laval Aalborg Nijmegen BV Pagina 7 van 42


3 INSTALLATION
3.1 Installation instructions
Carefully read the cautions and in-
structions before installing the
equipment:
1. Remove all packing material carefully.
2. The inert gas installations are delivered
on foundation frames; on behalf of
transport, the installation is divided or
parts are disassembled that are delivered
separately, depending on the dimensions.
3. The diameters of the piping, to which the
supply, vent, discharge and distribution
lines on board must be connected, are
indicated on the diagrams and drawings
(Process documentation and dimensional
drawings). In case a big pressure drop
will occur in the pipe system, these lines
should be of an extra ample design.
When choosing the pipe diameters, the
capacities and pressures mentioned in
the technical specification should be con-
sidered.
4. If more than one generator is placed on a
ship, each generator must be provided
with its own fittings, such as shut-off
valves, filters, reducing valves etc in the
various supply and discharge lines. This
in order to be able to guarantee an inde-
pendent operation of each generator.
5. No rain or water from the outside may
find its way into the venting and aerating
pipes.
6. The seawater supply pressure should
remain as constant as possible (+/- 20%).
If big pressure fluctuations in the sea-
water are to be expected, it is recom-
mended to fit a dedicated seawater sup-
ply pump.
6B The sea water supply to the gas genera-
tor must be stopped when a failure in the
seawater discharge of the generator oc-
curs either by closing an automatic valve
(to be fitted in the sea water supply line),
or by stopping the sea water supply
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pump. For that purpose an electrical con-
tact is made available.
In case seawater is supplied from another
source (not a dedicated seawater supply
pump), an automatic valve must always
be fitted in the supply line to the gas gen-
erator.
7. For free discharge of the seawater (con-
sequently pressure-less), the piping must
not have a great resistance (see dimen-
sions on the dimensional drawings). In
order to be able to discharge the cooling
water pressure-less during swinging (roll-
ing) of the ship, the water discharge lines
must have a slope of at least 20°. This
applies to the connection line between the
washing tower and the water seal and to
the discharge line of the water seal to
overboard.
8. When fitting the water seal and its supply
and discharge lines, attention should be
paid to the fact that during operation no
air bubbles can arise in this line. Bubbles
can block the water passage; at possible
air collecting places a venting pipe must
be made, e.g. in bends, high fitted piping
parts, under the lid of the water seal etc.
9. Inert gas generator must be installed
above highest waterline. For more details
see the flow diagrams in the "Process
documentation". If the generator is placed
near or below water level, special ar-
rangements for the generator and the wa-
ter seal are required.
10. Seawater pipes must be protected
against corrosion;
11. The temperature of the combustion air
may not be subjected to a sudden strong
variation. It is recommended to suck in
the combustion air from "inside" the ship.
12. There should be a constant fuel quality
and viscosity, this being important for the
fuel air ratio.
13. The compressed air supply may not con-
tain rests of lubricating oil and must be
free of condense.
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 ORDER NR: 19599

14. All blow-off piping indicated on the draw-

ings must be led to the "outside".

15. When the generator is erected in a room

specially meant for it, there has to be a
forced purge of air to discharge the heat
developed; a fan must be fitted in the dis-
charge canal.

16. The I.G. generator is equipped with a

Zirconia type of O2-analyser. This item
contains no moving or rotating parts and
ship movements or vibrations will have no
effect. The O2 measurement and the O2-
sensor will last for many years. The only
attention this analyser requires is regular
calibration. Calibration requires a calibra-
tion nitrogen gas bottle including pressure
reducing set. A nitrogen cylinder with ox-
ygen must be on board of the ship, close
to the O2-analyser.

17. The wiring of the auxiliary (control) cur-

rent part is performed according to the X-
wiring principle, which means that the
wires are running at the rear side of the
mounting plates. The internal wiring is of
the required flexible type for shipboard
use. All connections are made with wire
connectors.

18. The entrance of the main supply cables

can be made on a suitable place on the
starter panel. The electrical connections
(cables) between the terminal boxes, oth-
er electrical parts and the panels must be
laid alongside the ship's steel structure.
These cables should be laid during erec-
tion on board.

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4 STORAGE INSTRUCTIONS
4.1 General storage instructions
The equipment must be stored at a clean and
dry place, protected against weather and
moisture. Ambient temperature should not be
below 0 °C and above +50 °C.
During transportation, severe shocks or vibra-
tions should be prevented.
All equipment is packed by Alfa Laval Aalborg
Nijmegen B.V. and suitable for storage under
above-mentioned conditions. If equipment,
such as blowers, is stored for a period longer
than
12 months, it may be required to check the
lubrication. If necessary, it must be replaced.
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ORDER NR: 19599
4.2 Storage instructions for the
construction period
With the construction period Alfa Laval Aal-
borg Nijmegen BV means:
”The period between removing the packaging
material, the installation of the equipment into
the ship (or into a segment of the ship) and
the commissioning of the complete ship”.
During this construction period of the ship the
equipment must be stored according to the
General storage instructions mentioned
above.
Great care must be taken to protect the
equipment against damages while working in
the surrounding area of the equipment.
Special care must be taken to protect the
equipment from sparks when welding near to
the equipment.
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5 TECHNICAL DESCRIPTION The combustion is a chemical reaction be-

tween the hydrocarbon and the oxygen, main-
5.1 General ly giving carbon dioxide and water. Some little
An inert gas system contains the following rest quantities of oxygen, carbon monoxide
standard equipment: and hydrogen also remain. The nitrogen
leaves the generator unchanged.
1) 2 (two) x 100% centrifugal fan. The burner is not ignited at air production.
Each equipped with local control panel
and motor starters A good combustion process is the first re-
quirement of a reliable inert gas generator.
2) 1 (one) generator, consisting of: The burner is of our special design, in accord-
- Combustion chamber and washing ance with the Alfa Laval Aalborg Nijmegen
tower B.V. Ultra-mizing Combustion System.
- Burner
- Local control panel The combustion air is supplied to the burner
- Oxygen analyser under pressure. In the burner, the fuel oil is
- Other valves and instrumentation atomised in such a way that a perfect mixing of
fuel and air is achieved. In this way, the behav-
3) 2 Fuel Oil Pumps (FOP) both connected iour of the flame is identical to that of a gas/air
including motor starter panel. mixture.

4) Valves at main line. Consequently, a bright blue flame is seen,

- Pressure control valve. that will not create any soot. Soot cannot be
- Delivery valve. tolerated in the plant, neither in the ship’s car-
- Purge valve. go tanks nor in piping system. Prevention of
- Bleed valve. soot is only possible in an extremely stable
- Check valve. and well-balanced combustion process as
used by Alfa Laval Aalborg Nijmegen B.V..
5) Cargo Control Room Panel (CCRP):
- Recorder / Deck pressure and oxygen The hot inert gas produced mainly consists out
contents of nitrogen and carbon dioxide. The hot com-
- Several alarms, indicators and opera- bustion gases are cooled directly and indirectly
tors for the best results.

6) Deck Water Seal (DWS) The first indirectly cooling occurs in the com-
bustion chamber by a cooling-water jacket. The
7) Pressure/Vacuum breaker (P/V-breaker) main cooling of the combustion gases occurs
(PVB) in the cooling / washing section of the com-
bustion chamber.
8) Bridge Panel (BP)
During the main cooling the inert gas is direct-
5.2 Process principle ly cooled with seawater. At the same time, the
The I.G. generator is capable of producing sulphur oxides are washed out. The sulphur is
inert gas or air. See chapter 14 for operation present in the fuel and is oxidised during
guidelines. combustion. The inert gas is cooled down to a
few degrees over seawater inlet temperature
Inert gas is produced by stoichiometric com- and saturated with water of that temperature.
bustion of fuel oil with air.
At the end of the cooling section, the water
The fuel oil is a hydrocarbon and the air a mix- droplets are separated, as the gas passes
ture of mainly 79% nitrogen and 21% oxygen. through a demister.

The required final pressure of the generator is

achieved by a fan installed in front of the
combustion chamber and a pressure control

Alfa Laval Aalborg Nijmegen BV Pagina 11 van 42


valve in the inert gas line. This causes an
overpressure inside the combustion chamber
and the gas cooling section. A water seal un-
der the cooling section discharges the water,
while at the same time maintaining the re-
quired pressure and avoiding the escape of
inert gas.
5.3 Detailed process description
5.3.1 General
The process descriptions and tag numbers
refer to the flow diagrams, which you will find
in the chapter "Process documentation"
5.3.2 Combustion air supply
The combustion air is supplied to the main
burner (2001) by a centrifugal fan (2202 or
2222).
The quantity of combustion air to the burner is
adjusted via the burner lance.
The air pressure is monitored by a pressure
switch for ‘pressure too low’ (PZA-2011).
I.G. generator is equipped with two combustion
air fans according the classification require-
ments. Both fans/blowers have block valves
(2205 and 2225) at the outlet
The block valves are equipped with limit
switches for safe operation and protection of
the fans. The operator will not be able to start
the generator without having these valves in
the correct position.
5.3.3 Capacity control
The capacity of the inert gas generator can be
adjusted by the hand wheel on the main burn-
er. With this the burner gun (lance) can be
moved forward and backward in its casing.
The passages of the slots in the atomising
ring round the burner head will consequently
get smaller or bigger.
Because the supply pressure of the blower is
almost constant, less or more combustion air
will flow through the slots.
By means of a linkage, the fuel-regulating
valve (2032) is coupled to the burner gun.
This results in a simultaneously controlled
supply of fuel and of combustion air.
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If the fuel-oil/air ratio is not correct over a part
of the capacity range, then the fuel-oil/air
ratio can be changed by the pressure control
valve (2032).
Only the first time after installation the oil reg-
ulating valve (2032) has to be adjusted step-
wise. This fuel-regulating valve used has an
adjustable gradient. See the sub-suppliers
documentation of Maxon (the valve normally
is set by the commissioning engineer of Alfa
Laval Aalborg Nijmegen BV and this need be
done only once and is complicated; it is advice
not to change if not needed)
This means that with the aid of several ad-
justment screws, the right quantity of fuel oil
can be supplied to the main burner, to match
the combustion airflow at any position of the
burner gun.
By applying these kinds of valves a reliable
and repeatable adjustment of the O2 content
can be obtained. The capacity will be auto-
matically adjusted via a hand wheel or cylin-
der (option) at the main burner.
If the fuel-oil/air ratio is not correct over the
whole of the capacity range, then the fuel-
oil/air ratio can be changed by the pressure
regulating valve (1071).
This change is advised if the O2 content is too
high/low over the whole range.
If the fuel oil pressure is high, the O2 content
will be low. If the pressure is low the O2 content
will be high.
To start the generator, the burner gun has to
be in its start position, safeguarded by a limit
switch (2001a) and indicated on the mimic
panel.
During inert gas or air production the capacity
must be adjusted in such a way that the deck
main pressure can be maintained at the set
value without blowing-off a too great quantity
of gas via the purge/excess gas valve (6021).
Note:
− After re-adjustment of the capacity during
inert gas production, especially with larger
changes, the system (pressure and
temperatures) may require some time to
stabilise, before the oxygen content is
between the set limits again. Small steps
are to be advised.
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− The minimum and maximum capacity
positions, the stroke of the burner gun, are
fixed by mechanical stops on the burner
mounting slides. These may never be
changed.
5.3.4 Fuel oil supply
Fuel oil is sucked in and supplied at a con-
stant pressure by a fuel oil pump (1012). The
fuel oil pump has a built in pressure safety
relief valve.
Prior to starting the ignition, and while the
pump is already running (pre-purge time); all
the fuel oil is pumped back via the overflow
valve (1071). By means of this valve, the oper-
ating pressure of the pump is adjusted as well.
The fuel oil flows to the nozzle of the main
burner via two valves (1059, 2040) and a fuel-
oil-regulating valve (2032).
During ignition, a small quantity of fuel oil is
supplied at the set pressure to the pilot burner
(2101) via two solenoid valves (2103, 2105).
A switch (1053) safeguards the fuel oil pres-
sure.
5.3.5 Pilot burner
During a certain interval of the ignition se-
quence, the pilot burner is supplied with fuel
oil at the set pump pressure and instrument
air for atomisation and combustion.
The pilot burner is ignited with the aid of a spark
generated by means of a spark plug. An ignition
transformer (2131) is supplying the high voltage
for the spark plug.
The burning of the flame is monitored by an UV-
flame detector (2121), in conjunction with the
flame safeguard relay in the electric system.
5.3.6 Main burner
The main burner (2001) is ignited by the pilot
burner. The burning of the flame is monitored
by an U.V.-flame detector (2021), in conjunc-
tion with the flame safeguarding relay in the
electric system.
The fuel oil is atomised in two steps. First a
spray nozzle disperses the fuel oil. Then it is
subjected to the inside a tangential impulse
flow of combustion air, which added to the
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ORDER NR: 19599
mainly axially orientated impulse flow of the
liquid itself, results in an ultra-fine dispersion of
the liquid.
The tangential impulse flow is created by sup-
plying the air through slots in a ring fitted
around the spray nozzle.
The optimum gas quality is achieved by:
- the correct atomization by combustion
air
- The burner cone that concentrates the
heat, resulting in a complete chemical
reaction of fuel and air
An optimal atomisation of the fuel is achieved if
the differential pressure over the slots of the
atomising ring is minimum 0.1 bar. This means
the difference between the combustion pres-
sure (on gauge 2012) and the pressure inside
the combustion chamber (= pressure indicator
mounted on controller 8005 in the control pan-
el).
At a lower atomising pressure, the quality of
combustion will grow worse and soot could be
formed.
The burner cone is a part of wear and tear.
Therefore this cone must be checked periodi-
cally for damage, (see the chapter "Mainte-
nance"), and replaced as soon as necessary
(see drw P-X00047). The life of the burner
cone is strongly influenced by the quality of
the fuel oil (DMA, DMB or DMC) and the cor-
rect adjustment of the system (setting of O2
content, above mentioned atomizing pressure,
water pressure, etc). Alfa Laval Aalborg Nij-
megen B.V. experienced based on this, life
times of less than 1000 hours and more than
3500 hours. So the correct operation is most
important.
5.3.7 Combustion chamber and
scrubbing section
Main and pilot burners are mounted on the
combustion chamber (2301). A cooling-water
jacket surrounds the combustion chamber to
discharge the generated heat as much as
possible. The cooling water jacket has a spi-
ral, so the cooling water flows round the com-
bustion chamber wall and an optimum cooling
effect is achieved.
Pagina 13 van 42

The hot inert gas flows through the cool-
ing/washing tower, where it is directly cooled
with seawater to a few degrees above sea-
water inlet temperature.
At the same time, the sulphur oxides are
washed out of the inert gas. These sulphur
oxides are formed during combustion of the
fuel oil, as the fuel oil always contains sulphur.
The seawater is supplied to the sprayers and
the combustion chamber jacket via orifices
(2314 and 2316), which distribute the cooling
water in the correct quantities. Orifice 2316
has been adjusted during commissioning to
meet a water inlet pressure of approx 1.8
bar(g).
The seawater leaving the sprayers flows out
via the water seal. Low- and high-alarm pres-
sure switches (2320, 2321) safeguard the
seawater supply.
Sufficient cooling of the combustion chamber
wall is safeguarded by high temperature
switch (2312). Sufficient cooling of the inert
gas is safeguarded by high temperature
switch (2335).
A demister (2307) on top of the scrubbing
tower prevents a mist from being carried away
with the inert gas. The mist is condensed and
re-supplied as water droplets, which are car-
ried off via the water seal.
5.3.8 Effluent water seal
A water seal mounted under the cooling sec-
tion discharges the cooling water and the
condensate from the generator, at the same
time maintaining the required overpressure in
the generator and avoiding the escape of gas
or air.
Level controller 2418 controls the height of the
water seal. This controller becomes its input
signal from differential pressure transmitter
2415, which is fitted in front of control valve
(2419). As soon as the cooling water pump
has been started the level control will be acti-
vated. Because the level control is operated
by a differential pressure transmitter, this con-
trol is independent from the pressure inside of
the combustion chamber. Therefore, in con-
Alfa Laval Aalborg Nijmegen BV
ORDER NR: 19599
junction with the pressure control system of
the generator a constant and stable pressure
can be maintained. The consequence is a
constant combustion air supply, thus a con-
stant oxygen percentage.
For a proper functioning of the water seal, the
discharge line must have a slope of minimal
20° to overboard. In case of less slope aera-
tion connections back to inert gas main must
be made.
A level switch (2322) safeguards a proper
discharge of water to the effluent water seal.
For draining a pneumatic valve (2410) is
mounted in front of the control valve. The
drain valve is normally closed and can be
opened via a solenoid valve. Draining will take
place in case of a burner failure at start-up.
The water, with some fuel oil, is discharged to
the bilge.
As long as this draining valve is opened, the
generator cannot be (re)started as the limit
switch (GSb) of the valve is connected to the
starting circuit of the generator.
5.3.9 Generator pressure control
system
The pressure inside the generator should be
kept constant at 0.15 bar (g). This insures a
proper combustion with a constant quantity of
combustion air at a given capacity.
The pressure is held constant by the pressure
control valve (6001). The valve is controlled in the
manner described below.
The generator pressure is measured and
amplified by a pressure transmitter (6006).
The output signal is fed to a pressure
controller (8005) where it is compared with the
set value (150 mbar).
Depending on the difference between the
measured and the set values, a proportionally
integrated signal is generated, which is
passed through to a positioner (6003) of the
control valve.
At the start up the control valve will be opened
completely. Direct after the start, the pressure
control system will be activated automatically.
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 ORDER NR: 19599

The generator pressure will increase to the
set working pressure.
As the main burner starts on low capacity, the
expansion of the gasses during ignition of this
burner has no effect on the ignition of the
burner or effluent water seal of the generator.
5.3.10 Generator delivery pressure
The delivery pressure is one of the most im-
portant characteristics of the generator, which
always has to be looked at very sharply.
In case of the mode 'INERT GAS
PRODUCTION', the purge air and (after
ignition) the initially produced inert gas, are
blown off to the outside air for about 5
minutes until the inert gas quality has
stabilised.
Provided no alarms are indicated the inert gas
can be led to the cargo tanks. On the LCRP,
the operator must operate the ‘GENERATOR
STAND-BY’ switch. The inert gas delivery
valve can now be opened via the CCRP.

The air quantity delivered by the blower de-
pends both on the difference between the
blower pressure and the generator back pres-
sure and on the passage of the slots in the
atomising ring of the main burner.
If the back pressure deviates from the set
value the quantity of combustion air at the
adjusted capacity position will be too high or
too low to match the fuel supply adjusted and
thus the oxygen content will be influenced.
The quality of combustion depends on the
pressure difference (about 0.1 bar) over the
atomising ring of the main burner.
5.3.12 Excess gas vent system - deck
main pressure
Through the purge valve / excess gas vent
valve (6021) the overcapacity of inert gas is
blown-off and the pressure in the inert gas
deck main line is adjusted in accordance with
the pre-set pressure.
The pressure transmitter (6306, 0 - 0.25
bar(g)) measures the deck main pressure.
The 4 - 20 mA signal is led to a controller
(8008). The set value for the deck main
pressure has to be determined during the first
start-up on board.

If this pressure becomes too low, the quality

of combustion will decrease with the risk that
soot is being formed.

5.3.11 Purge / excess vent valve and

delivery valve
The delivery valve (6041) is a pneumatic stop
valve in the delivery line of the generator. The
delivery valve is closed by a spring in fail safe
position. It is controlled via a solenoid valve
(6044) in the instrument airline to the valve
actuator (6042).

The purge/excess gas valve (6021) is a

pneumatic valve in the purge line. The purge
valve is normally opened by a spring in fail safe
position. The function of the purge valve is to
purge air to the outside during the start-up and
to control the deck main pressure.

When the delivery valve is opened, the purge

valve will automatically start controlling the
deck main pressure.

Alfa Laval Aalborg Nijmegen BV Pagina 15 van 42


Note:
The purge valve only controls the deck main
line pressure if the inert gas generator is
running and delivering inert gas to the tanks.
5.3.13 Deck main pressure control
The deck main pressure is controlled and pro-
tected by several protections.
1. The purge / excess gas vent valve pro-
tects the tanks against overpressure dur-
ing inerting of the tanks. If the capacity of
the generator is larger than the capacity
of the cargo pumps, a part of the inert
gas will be blown to the atmosphere.
2. Alfa Laval Aalborg Nijmegen B.V. delivers
a deck main pressure monitoring set
standard with the installation. This set
comprises of two pressure transmitters
(6306, 6304), and a pressure indicator
(6302).
The signal from pressure transmitter
(6306) is used by controller (8008) for the
control of the purge valve during inerting
and indicating and recording the deck
main pressure at the CCRP.
The signal from the pressure transmitter
also provides a signal for the deck main
pressure alarms (high or low).
The high and low alarms are also
available when the generator is not in
operation. The high alarm will put the
generator in purge mode. The low deck
main pressure alarm is a pre-alarm. In
case of a low alarm the generator must
be started or the capacity of the generator
must be increased or the cargo pumps
capacity should be decreased etc.
In case of low alarm, there is still a safe
situation, but immediate action should be
taken.
3. Low-low deck main pressure alarm formed
by pressure transmitter (6304) in
combination with a switching module
(8010). Potential free contacts are provided
by Alfa Laval Aalborg Nijmegen B.V. to stop
Alfa Laval Aalborg Nijmegen BV
ORDER NR: 19599
cargo pumps. The generator keeps running
when this alarm is activated.
4. Other protections which are not part of
the Alfa Laval Aalborg Nijmegen B.V.
scope of supply are:
- PV-valves
- Ship's tank pressure monitoring system
5. Alfa Laval Aalborg Nijmegen B.V. delivers
standard a liquid filled P/V-breaker. In case
of vacuum or too high pressure, the liquid
in the P/V-valve will break through. This is
an absolute emergency action which will
only happen if all other systems or actions
have failed. The liquid level of P/V-breaker
must be checked regularly and must be re-
filled if necessary. Unlike the deck water
seal the P/V-breaker will not be filled
automatically but has a permanent
glycol/water mixture as filling.
The standard sequence for the safety of the
tanks is:
1. Pre-alarm at CCRP or ship's systems.
Personnel will act to prevent the alarms
and or the shutdowns.
2. The low-low alarm from the generator will
shutdown the cargo-pumps.
3. P/V-valves will open at a too low or too
high tank pressure when actions 1 and 2
did not have any effect.
4. P/V-breaker will break through at a too
low or too high tank pressure. This is an
absolute emergency situation; the P/V-
valves do not have enough capacity (i.e.
blocked P/V-valve as result of corrosion).
The P/V-breaker cannot be blocked since
it has no mechanical moving parts. The
P/V-breaker will always assure that the
tank pressure will be within the safe
range!
The set value for the inert gas main line pres-
sure has to be determinate during the start up
of the installation on board of the ship (for
automatic control keep tension on the CCRP
all the time)
Note:
Pagina 16 van 42

The ship may have additional safety devices,
but this is outside the scope of supply and
responsibility of Alfa Laval Aalborg Nijmegen
B.V..
5.3.14 Measurement and safeguarding
of the oxygen content
The oxygen analyser (7001) constantly
measures the oxygen content in the inert gas
and will effect an alarm if a set maximum or
minimum quantity of oxygen is exceeded.
The maximum value is fixed by the application
of the inert gas (normally about. 4 vol. % O2).
The minimum value protects against under-
stoichiometric combustion (a too high content
of combustibles CO + H2 with the risk of soot),
normally set at 2 vol. % O2.
The generator will not stop at an O2 HIGH or
an O2 LOW alarm condition. A visible and
audible alarm will occur. If such a failure
remains for more than 60 seconds, purge
valve (6021) will open; delivery valve (6041)
will close.
The inert gas produced will be blown off now
and not discharged to the cargo tanks. This
enables the operator to change the adjustment
of the equipment and to see the result.
In case of an O2 alarm the O2 content can be
changed by supplying either more or less fuel
oil to the main burner. This has to be controlled
manually by the pressure-regulating valve
(1071) in the fuel oil supply line. This can be
necessary e.g. at temperature variations of the
combustion air.
When the oxygen content in the inert gas
produced is in the correct range the product
can be led to the deck again.
The analyser has to be calibrated regularly,
with the aid of a 'span' gas (instrument air)
and with the aid of a calibration gas
(N2 + 1.5% O2).
Registration of the oxygen content
The oxygen content of the inert gas is
constantly measured by an O2 -analyser
(7001). This analyser gives a 4 - 20 mA
signal, which corresponds linearly with the
analyser range.
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ORDER NR: 19599
The output (4 - 20 mA) is supplied to a
recorder (8009) in the cargo control room
panel.
5.3.15 Fuel to air ratio / oxygen con-
tent
The fuel to air ratio, (and with this the oxygen
content of the inert gas produced), has been
set over the whole capacity range by means
of the adjustable screws in the fuel oil regulat-
ing valve (2032).
This setting is permanent and should not be
changed!
In case of large changes in air temperature,
air humidity or quality of the fuel oil, the O2-
content becomes too high or too low.
In this event, the fuel-oil pressure before the
fuel-oil regulating valve (2032) must be in-
creased or decreased by means of a pressure
control valve (1071) in the fuel-oil return line.
In case of a re-adjustment take care of the
following:
• BE SURE, THAT THE FUEL OIL PUMP
DELIVERY PRESSURE, INDICATED ON
THE MANOMETER (1003), DOES NOT
EXCEED A PRESSURE OF 20 bar (g)!
This to prevent a back flow of oil in the
pump via a built-in overflow valve.
• Adjust with small steps, this due to the
response time of the measuring system.
• In case an excess of fuel is supplied in
proportion to the combustion air (O2-
content measured below minimum setting)
or the atomising pressure is too low, the
risk exists that soot is being formed. Soot
can foul and damage the equipment. An
indication for this phenomenon is the
flame becoming yellow.
• The fuel pressure on the main burner will
not always have the same value for cer-
tain oxygen contents this depends on the
fuel temperature, the viscosity and the
quality (see technical specifications).
• The fan takes in a constant volume of
combustion air. The quantity of kilograms
of oxygen in that air depends on the ambi-
ent temperature and humidity.
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 ORDER NR: 19599

• Prior to re-adjusting check the generator

delivery pressure; it has to be exactly 0.15
bar.
• After re-adjustment of the capacity during
inert gas production, (especially with larg-
er changes), the oxygen measuring sys-
tem may require some time to stabilise,
before the oxygen content is between the
set limits again.

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 ORDER NR: 19599

6 TECHNICAL SPECIFICATION Dew point

Saturated (at gas temperature)
6.1 Design basis

The layout of the installation has been 6.3 Utilities

calculated and based upon the following
criteria. Fuel:
Marine Diesel Oil (MDO) according to:
− The unit is designed and will be built in ISO 8217 (1987) or BSMA 100 (1989), grade
accordance with the regulations of IMO DMA, DMB or DMC
and the rules of the applicable
classification society. Inlet pressure: 0 – 0.4 bar(g)
− Shipboard use, indoor erection. Consumption (at
− The inert gas capacity and composition is design capacity): approx. 323 kg/h
calculated with combustion air of + 25 °C
and 100% relative humidity at atmospheric Electricity:
pressure. The average cooling water has a Main supply system
temperature of + 25 °C. 440V / 3Ph / 60Hz
− Pressures mentioned are effective working 220V / 1Ph / 60Hz
pressures (± 5% tolerance). 24V DC
− Temperature tolerances ± 1 °C.
− Quantities tolerance ± 3%; Combustion air blower motor
− Electrical supply voltage tolerance Rating: 62 kW
+10% / -15%. Consumption: 56 kWh/h
− The combustion chamber cooling water
FOP motor
jacket is designed for a maximum of 1 bar
Rating: 0.9 kW
overpressure.
Consumption: 0.7 kWh/h
6.2 Inert gas specification Auxiliaries
Rating: 3 kW
Capacity: Consumption: 2 kWh/h
Adjustable 4125 m3/h
Turndown ratio 1:4 Cooling water:
Discharge pressure max. 0.15 bar (g) Seawater consumption
Generator: 350 m3/h
Gas composition (based on dry gas): Deck water seal:
3
3 m /h
Oxygen O2 2 - 4 vol. % Quality: filtered seawater
Carbon monoxide CO max 500 ppm (mesh size 4 mm)
Carbon dioxide CO2 max 14.0 vol. % Inlet pressure: 2 - 4 bar
Sulphur oxides SOx max. 50 ppm Outlet pressure: atmospheric
Nitrogen N2 balance Inlet temperature: max. 32 °C
Soot 0 (on scale Temperature rises: about. 10 °C average
Bacharach)
Rinsing water
Note:
-Bacharach 0 = complete absence; Fresh water
-at lower O2-content, CO-content will increase. consumption 4 m3/h
Temperature: Instrument air:
About 6 °C above cooling water inlet Quality: free from dust, oil and
temperature. condensed water
Supply pressure: 6-9 bar
Consumption for

Alfa Laval Aalborg Nijmegen BV Pagina 19 van 42

 ORDER NR: 19599

pneumatic valves: 2 Nm3/h Ambient air:

Consumption for pilot Temperature: between 0 and 50 °C
burner per start: 170 litres Consumption for
combustion: about 4685 Nm3/h
Pressure atmospheric
Humidity 100%

Sufficient ventilation in the ig generator

room is obligatory!

If ventilation is insufficient this can cause

under-pressure in the room. The result
may be that doors cannot be opened any-
more.

Noise level:
Noise produced
by blower*: max. abt 100 dB (A)
* Measured at 1m distance (in free field)

Alfa Laval Aalborg Nijmegen BV Pagina 20 van 42


7 OPERATING INSTRUCTIONS
Before operating the unit, read the
SAFETY INSTRUCTIONS.
7.1 General
The complete generator is controlled by the
PLC. The PLC program is not a part of this
manual since the program details are not
required for installation or operation of this
system. However in case of problems or
questions, please contact ALFA LAVAL
AALBORG NIJMEGEN B.V., for further
assistance.
Soot can foul and damage the system.
To prevent soot from being formed, always
make sure that:
• The correct fuel quality is used (see the
chapter Technical specifications).
• The differential air pressure over the main
burner is correct, about 0.1 bar (g); this is
the atomising pressure.
• No excess of fuel is supplied; i.e. oxygen
content indicated on the O2-analyser must
always be more than 1%.
• The oxygen analyser is regularly calibrat-
ed;
7.2 Control panels
An inert gas system comprises several control
panels which are described below.
• The Local Control Room Panel (LCRP).
This is the main panel of the generator
from which the generator can be operated.
• The Cargo Control Room Panel (CCRP).
From this panel the inert gas delivery
valve can be operated and the deck line
main pressure is controlled. This panel is
the interface between the inert gas gener-
ator and the cargo tanks.
• The Bridge panel (BP).
This is a small panel with only a few ele-
mentary functions, which are required by
the classification.
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ORDER NR: 19599
• The Engine room panel (ERP).
This is an optional panel. The panel con-
tains information useful for engine room
personnel, such as generator status and
supply of utilities. Depending on the user's
requirements Alfa Laval Aalborg Nijmegen
B.V. can supply this panel. However this is
not required by classification.
• Other panels:
Equipment such as the blowers and fuel
oil pump are equipped with starter panels
comprising of motor starters and some
basic indicators.
For more details about the control panels,
please refer to the electrical diagrams
collected in the “Electrical documentation”
7.3 Switching on
7.3.1 Inert gas production
1. Turn the main supply switches ‘ON’. Keep
‘ON’ normally for the analyser (for pro-
longing the lifetime of the sensor) and for
the deck equipment/alarms.
Switching ‘ON’ has to be done at least 1
hour before the generator is started. This
in conjunction with the warm-up time for
the oxygen analyser.
2. Before starting.
- Open the instrument air shut off valve
(1501).
- Calibrate the oxygen analyser accord-
ing to the instructions given in the O2-
analyser manual (see the Sub-
suppliers documentation).
3. Checks.
- Check if the instrumentation valves for
the pressure indicators and transmit-
ters are opened
- Check if the drain plug on the main
burner and the rinsing valve (2313) on
the combustion chamber are closed.
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4. Starting up the seawater supply:
- Open the valves in cooling water sup-
ply and the discharge lines of the
combustion chamber and the water
seal.
- Open the valves in the water supply
and the discharge lines of the deck
water seal.
- Start the cooling water supply pump.
- Check pressure: approx 1.8 barg
- Start the deck water seal water supply
pump.
5. Open the main fuel oil shut off valve
(1001).
6. Check that the fuel oil control valve
(1071), in the oil return line to the tank, is
opened.
7. Open isolating valves (1015 and 1005) of
the fuel oil pump. Rotate the handle of the
fuel oil filter (1002) twice.
8. Open the fuel oil shut-off valve (1051) on
the generator.
9. Put the main burner in the starting posi-
tion (optional: automatic). If the burner is
in the start position this is indicated on the
LCRP, the indicator light turns on. If the
light is blinking this indicates that it is not
in the starting position.
10. Select the production mode 'INERT GAS
PRODUCTION'.
11. Check that the deck seal and the P/V
breaker are correctly filled.
12. If the indication 'SYSTEM READY TO
START' on the mimic panel lights up,
start the inert gas generator by pushing
the START button of switch S4 on the
LCRP. If the indication light does not light
up consult "Trouble shooting".
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13. The burner start up sequence is start-
ed now:
0 sec. Blower starts running (pre-purge
time of 60 seconds).
30 sec. Fuel oil pump starts running.
60 sec. Ignition pilot burner.
Solenoid valves (2103, 2105,
2114) for fuel oil and instrument
air to the pilot burner open; The
ignition transformer (2131) and
the spark plug are energised.
70 sec. Ignition transformer de-energised.
UV-flame detector (2121) must
have detected the flame of the
pilot burner, otherwise the genera-
tor shuts down and an alarm is
given.
85 sec. Ignition of the main burner.
The two valves for fuel to main
burner open (1056 and 2040).
The pilot burner ignites the main
burner.
90 sec. The solenoid valves (2103, 2105,
and 2114) for the fuel oil and the
instrument air to the pilot burner
are closed again. The Pilot burner
extinguishes.
UV-flame detector (2021) must
have detected the flame of the
main burner, otherwise the gener-
ator shuts down and an alarm is
given.
The pressure control system is
now being activated.
The air pressure inside the gener-
ator must be checked and if nec-
essary adjusted to the set value of
0.15 bar (g).
295 sec. From this moment on, inert gas
can be delivered to the tanks, pro-
vided that the O2-content is be-
tween its limits.
14. Check:
- Pressures.
- Temperatures.
- Oxygen content of inert gas produced.
See the test protocol. Re-adjust, if neces-
sary.
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15. Adjust the burner capacity with the hand
wheel on the main burner if this is neces-
sary (optional: remote)
16. Wait for at least 5 minutes.
17. If the generator operates normally and
the composition of the gas is correct, and
then push the ‘STAND BY’ switch on the
LCRP (the stand-by lamp starts blinking).
18. On the LCRP and the CCRP the indica-
tion 'STAND BY' will light up. This means
the generator is ready to deliver the inert
gas to the tanks. The necessary charging
operations can now be controlled from
the Cargo Control Room Panel.
19. Push the 'INERTGAS OR AIR TO DECK'
switch (on the CCRP)
20. Provided the O2-content of the inert gas
produced is between the limits set on the
alarm set points of the oxygen analyser
the following will happen.
- The delivery valve (6041) of the gen-
erator opens.
- The purge/excess gas vent valve
(6021) is slowly controlled to the
working position.
- Check if bleed valve 6051 is closed.
If the required deck main pressure cannot
be obtained then the capacity of the
burner has to be increased by the hand
wheel on the burner (optional: remote).
7.3.2 Air production
1. Turn the main supply switches ‘ON’, (and
keep ‘ON’ normally).
2. Open the instrument-air shut-off valve
(1501).
3. Start up the seawater supply.
- Open the valves in the cooling water
supply and discharge lines of combus-
tion chamber and water seal.
- Open the valves in the water supply
and discharge lines of the deck seal.
- Start the seawater supply pump.
- Start the deck seal supply pump.
4. Put production mode selector, into posi-
tion 'AIR PRODUCTION'.
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5. Adjust the main burner into its highest
capacity position with its hand wheel.
6. If the indication “SYSTEM READY TO
START” lights-up then start the generator
with the START button S4. The blower
starts and the pressure control system is
operative.
If the indication “SYSTEM READY TO
START” does not lights-up then consult
the additional operation notes.
7. Check pressures and temperatures.
8. If the generator operates normally then
turn the ‘STAND BY’ switch or the push
button on the
10. On the LCRP and the CCRP the indica-
tion 'STAND BY' will light up. This means
the generator is ready to deliver the air to
the tanks.
11. Turn the 'INERTGAS OR AIR TO DECK'
switch (on the CCRP) into position
'START'. And release to ‘ON’. This will
have the following effect.
- The delivery valve (6041) of the gen-
erator opens.
- The purge/excess valve (6021) is slow-
ly controlled to its closed position or to
a controlled working position if the
deck main pressure increases.
7.4 Switching off
7.4.1 Normal switch off
1. Switch off 'INERT GAS OR AIR TO
DECK' (on the CCRP), so the delivery of
air/inert gas to the tanks is stopped.
This will open purge valve 6021 and close
delivery valve 6041
The indication 'INERTGAS OR AIR TO
DECK' extinguishes.
2. Push the stop button on the local control
panel for stopping inert gas or air produc-
tion (the blower keeps running for some
time). The combustion room is purged
with air now to remove the oil vapour and
the gasses with sulphur.
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7.5 Checks during operation

3. The blowers will be automatically
switched off after about 3 minutes. Checks after every start and further every
4 hours' operating time:
5. Switch off the cooling water pump only • Check the O2-content (inert gas produc-
after approx 2 hours. tion only).
This enables the combustion • Check the pressures and temperatures
chamber to cool down (see test protocol). Record these values to
properly and reduce corrosion observe any irregularity as quickly as pos-
sible.
5. Close the fuel oil shut off valves (1001 • Check whether an equal flow of inert gas
and 1051). is indicated on the flow indicator on the
oxygen analyser panel (inert gas produc-
6. Rinse the combustion chamber with fresh tion only).
water as described in the maintenance • Check the fuel oil pump delivery pressure.
chapter. This is only applicable if the
• Check the fuel oil pump discharge pres-
generator will be turned of for longer than
sure after start; the oil must return to the
a day.
tank via pressure control valve (1071) in
fuel oil return line; IF NOT, STOP THE
DO NOT use salt water when rinsing the
SYSTEM and RE-ADJUST valve (1071);
combustion chamber.
see Sub-suppliers documentation.
• Check the filter in the oxygen sample line
7. In case of a long period of standstill, han-
(7022).
dle as described in “In case of a longer
standstill” below. • Check the temperature and smooth run-
ning of the combustion air fan.
7.4.2 In case of a longer standstill
Checks every week:
• Check the calibration of the O2-analyser.
1. Close the cooling water supply valves.
An exactly calibrated O2-analyser is very
2. Drain the water seal. important (correct gas quality, prevention
of soot formation)!
3. Close the drain when the water seal is • Lamp test.
empty. • Alarm test.

4. Open valve (2340) in the fresh water line Checks every month:
to the jacket of the combustion chamber. • Open drain plug at the bottom of the burn-
Rinse with fresh water for 1 hour and er housing to drain possible collected oil
close valve (2340).

5. Close the cooling water discharge valves

of the combustion chamber and the water
seal if installed.

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7.6 Adjustments The fuel-oil pump delivery pressure can be

7.6.1 Adjustments of the generator
delivery pressure
The generator delivery pressure can be ad-
justed via the set point adjustment on the
pressure controller (8005) which is mounted in
the LCRP.
The controller is adjusted in the Alfa Laval
Aalborg Nijmegen B.V. workshop, but it is
possible that some adjustments have to be
changed during the test run on board.
For more detailed information and adjustment
see the controller instructions in "Sub-
suppliers documentation".
adjusted with the pressure regulating valve
(1071) built on the fuel-oil return line. The
pump pressure, indicted on the manometer
(1003) at the pump discharge line, must al-
ways be the same.
The pump pressure must be checked at
every start and further regularly.
The fuel-oil pump delivery pressure is safe-
guarded by means of a built-in overflow valve.
This valve is adjusted on 25 bar(g).

7.6.2 Adjustments on the oxygen

analyser
Following values are set on the oxygen ana-
lyser for wet inert gas:
Oxygen alarm low: 2.0 %
Oxygen alarm high: 4.0 %
Analyser range: 0 - 5 % with an output of
4 - 20 mA.

For calibration a gas with a content of 1.5 %

oxygen must be used at the measuring range
of 0 - 5% oxygen.

Note:
The correct analyser range is essential for the
delivery valve (6041) to open.

7.6.3 Adjustments of the deck main

pressure
The deck main pressure can be adjusted on
the controller (PIC8008) in the CCRP.

The settings for the controller are indicated in

the test protocol (see Test protocol).

7.6.4 Adjustments to the pilot burner

A pressure regulator (PIC 2112) can adjust
the instrument air to the pilot burner (approx.
0.8 bar with valve open)

Adjustment has to be carried out in such a

way that a stable non-flickering flame of suffi-
cient length is obtained.

7.6.5 Adjustments of the fuel-oil

pump delivery pressure

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 ORDER NR: 19599

8 TROUBLE SHOOTING 8.2 Consequences of failures ex-

planation
8.1 Failures See column 'C.o.F.' in 'Consequences of fail-
ures table'
• In case of a failure, an audible alarm is
given and a failure indicating signal lamp 1. a. Blower and cooling water pump are
lights up (blinking). switched off after an after purge time
of 180 seconds.
• After pushing the ACKNOWLEDGEMENT b. Fuel oil pump is switched off.
button on the panels, the audible alarm is c. Fuel oil valves close. Burner extin-
switched off, but the signal lamp remains guishes.
lightened (steady). d. Purge valve opens.
e. Delivery valve closes.
• After eliminating the cause of the failure, f. Visible and audible alarm.
the installation has to be reset by pushing
the RESET button on the local control 2. a. Blower switched off immediately.
panel. b. Same as 1b up to 1f incl.
After this the generator can be restarted.
3. a. Blower switched off immediately.
• The setting of all safety devices is given in b. Cooling water supply pump switched
the test-protocol. off.
c. Same as 1b up to 1f incl.
• The “Trouble Shooting Chart” is a chart in
which all failures that are indicated on the 4. a. Purge valve opens.
control panels, also some general genera- b. Delivery valve closes.
tor failures are mentioned. c. Audible and visible alarm.

• For specific failures in operation of the 5. a. Cargo pumps stop.

various accessories belonging to the in- b. Audible and visible alarm.
stallation, the manufacturer’s instructions
in the Sub-suppliers documentation have 6. a. Audible and visible alarm.
to be consulted.

• In the trouble shooting chart, one column

is named 'C.o.F.', which means 'Conse-
quences of failures'. The figures indicated
are explained in Consequences of failures.

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8.3 Trouble Shooting Charts
8.3.1 General trouble shooting chart
Failure
Generator doesn't start, while
no failure is indicated and indi-
cating light 'SYSTEM READY
TO START' doesn't light up on
control panel:
System does not change over
to 'charging' (inert gas/air to
deck):
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ORDER NR: 19599
Possible causes Remedies
Purge gas valve (6021) not If one of these valves is not in
completely open. its correct position, the valve
Delivery valve (6041) not com- may be jammed, or its actuator
pletely closed. or solenoid valve may be defec-
Drain bilge valve (2410) not tive. Un-jam, clean, replace.
closed.
Emergency stop button Release the emergency stop
pressed. button.
Main burner not in its starting Reposition the main burner.
position.
Seawater pump not started yet Start the seawater pump.
First failure circuit generator Push 'RESET' button.
energised.
No power supply (any). See Apply power.
Mimic diagram
Loose electrical connection. Reconnect.
Delivery is interlocked. Wait for 5 minutes after starting
the generator.
The O2-content of the produced Change the O2-content.
inert gas is not between the
limits set on the high and low
alarm units of the oxygen ana-
lyser
Switch not operated correctly. Push the button (INERT GAS
OR AIR TO DECK) again
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 ORDER NR: 19599

8.3.2 Consequences of failures trouble shooting chart

Failure CoF Safety Possible causes Remedies

Fuel oil pump motor 1 1013 Motor overloaded. Check and repair.
failure: Heavy run of the fuel oil
pump.
Adjustment of the over- Re-adjust (see specification
load relay is incorrect. plate on the motor).
Fuel oil pressure low: 1 PZA-L 1053 Pump isolating valves Open it.
closed.
Pump not running. Check fuses, isolating
switch, etc.
Air in fuel oil lines. Vent.
Setting overflow valve Check and re-adjust.
(1071) incorrect.
Filters (1002, 1052) Clean them.
clogged.
Instrument air pres- 1 PZA-L 1505 Shut off valve (1501) Open it
sure low: closed.
Filter (1502) clogged. Clean them.
Leaks in system. Check for leaks and repair.
Supply system defect. Repair.
Combustion air pres- 1 PZA-L 2011 Fan not running. Check fuses, isolating
sure low: switch, etc.
Flexible joint in blower Repair/replace.
outlet defective.
No flame: The main 1 (3, XZA 2021 Main burner flame de- Check main burner flame
burner does not ignite see tector (2021). Window detector. Clean or replace.
or extinguishes during note) may be dirty or the de-
operation tector may be defective.
Flame safeguard relay in Repair/replace.
Note: generator control panel
Situation is true for defective.
bilge drain valve se- Oil pressure low. Check fuel oil pressure be-
lection in “cancel” fore regulating valves.
mode. Oil nozzle main burner Clean or replace it.
dirty.
If the drain valve se- Solenoid valves (1059 Check functioning
lection mode is “au- and 2040) in fuel line to
tomatic”, then the main burner not func-
c.o.f. 3 is true with tioning correctly.
extra opening of bilge
drain valve 2410 (this
happens only during
30 seconds of flame
failure)
No flame The pilot 1 XZA 2121 Check instrument air Adjust with pressure regula-
burner does not ignite: pressure to pilot burner. tor PIC 2112 (see Pilot
burner).
Oil atomiser of pilot Replace.
burner dirty.

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 ORDER NR: 19599

Failure CoF Safety Possible causes Remedies

No flame The pilot 1 XZA 2121 Delivery pressure of Check pressure. Adjusta-
burner does not ig- the fuel oil pump incor- ble with built in return
nite (continued): rect. valve of fuel oil pump
and/or pressure regulating
valve (1071) in fuel oil
return line (see Sub-
suppliers documentation).
Pilot burner flame de- Clean or replace it.
tector (2121) not func-
tioning correctly. The
window may be dirty or
the detector may be
defective.
The flush airline of Un-block it.
detector (2121) is
blocked
Flame safeguard relay Replace
in generator control
panel defective
Solenoid valves for Check and or replace.
instrument air and fuel
oil to pilot burner not
functioning correctly
Spark plug not func- Check, replace or adjust.
tioning correctly. Distance between elec-
Insufficient contact of trodes should be approx. 2
sparkplugs cap. Elec- mm.
trodes worn out or
wet?
Fan motor failure: 2 2203 Motor overloaded
2223 Adjustment of the Re-adjust (see specifica-
overload relay incor- tion plate on motor).
rect.
Blower is switched off Switch on.
(no source supply).
Cooling water outlet 1 TZA-H 2312 No free discharge of Check free discharge of
temperature high: cooling water from cooling water.
combustion chamber. Check that the discharge
valves are open.
Orifice in cooling water Clean it.
line to combustion
chamber may be
clogged.
Cooling water inlet 1 PZA-L 2320 Cooling water supply Check fuses, duty switch-
pressure low: pump not running. es etc.
Pump isolation valve Open it.
closed
Filter clogged. Clean it

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 ORDER NR: 19599

Failure CoF Safety Possible causes Remedies

Cooling water supply 3 PZA-H 2321 Stoppage in combus- Clean it
pressure combustion tion chamber cooling
chamber high: water discharge line.
Excessive supply of Reduce.
cooling water.
Cooling water level 3 LZA-H 2322 Check free discharges Clean it.
high: of cooling water from Open the discharge valve.
water seal.
Air vent clogged. Open it (them).
Inert gas tempera- 1 TZA-H 2335 Supply cooling water Check pressure.
ture behind the low.
scrubber high: Sprayer pipes in Clean them.
scrubber clogged.
Orifice(s) clogged. Clean them.
Inert gas delivery 1 PZA-H 2336 Some of the valves in Open or clean them.
pressure high: the inert gas delivery
or main line are closed
or blocked.
Controller 8005 not set Set at 0.15 bar.
correctly.
The purge excess gas Check it.
vent valve (6121) is
not working correctly.
O2 analyser defect: 1 7002 Consult the Sub-suppliers
documentation manual in
Sub-suppliers documenta-
tion
O2 content low: 4 QIA-L 7001 Change in oxygen con- Re-adjust pressure by
tent may be the result means of pressure control
of changes in condi- valve (1071) in fuel oil
tions of ambient air return line.
(pressure, tempera-
ture, humidity) or a
result of a change in
fuel quality.
If generator delivery Re-adjust the generator
pressure is too high, delivery pressure
the air capacity supply
by the fan will be too
low to match the fuel
supply at the given
capacity position; as a
result the oxygen con-
tent will be too low.

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Failure CoF
O2 content high: 4 QIA-H 7001
Deck main pressure 6 PA-H 8008
high:
Deck main pressure 6 PA-L 8008
low:
Deck main pressure 5 PA-LL 80120
low-low:
Deck water seal wa- 6
ter level low:
Deck water seal wa- 1
ter pressure low:
Alfa Laval Aalborg Nijmegen BV
ORDER NR: 19599
Safety Possible causes Remedies
Change in oxygen con- Re-adjust pressure by
tent may be the result means of pressure control
of changes in condi- valve (1071) in fuel oil
tions of ambient air return line.
(temperature, humidi-
ty) or a result of a
change in fuel quality.
If generator delivery Re-adjust the generator
pressure is too low, the delivery pressure
air capacity supply by
the fan will be too high
to match the fuel sup-
ply at the given capaci-
ty position; as a result
the oxygen content will
be too high.
Oil nozzle dirty. Clean.
Generator capacity to Decrease capacity.
high.
The excess gas vent Check correct functioning
system (6021) is not and setting.
functioning correctly.
Generator capacity to Increase capacity.
low.
Bleed valve (6051) Close it.
open.
The excess gas vent Check correct functioning
system (6021) is not and setting.
functioning correctly.
Capacity of generator Increase capacity.
insufficient to follow
cargo unloading. Gen-
erator capacity to low.
The excess gas vent Check correct functioning
system (6021) is not and setting.
functioning correctly.
Bleed valve (6051) not Close it.
closed.
LA-L 6104 Water supply too low. Check and increase.
Drain valve open. Close it.
PZA-L 6125 Deck water seal water Check fuses, duty switch-
supply pump not run- es etc.
ning.
Pump isolating Open it (them).
valve(s) closed.
Filter clogged. Clean it
Pagina 31 van 42

9 MAINTENANCE
Before operating the unit, read the
SAFETY INSTRUCTIONS.
9.1 General maintenance
instructions
Next pages include the maintenance schedule
for the installation. The detailed instructions
for maintenance and repair of equipment can
be found in the instruction manuals of the
sub-suppliers. Consult the Sub-suppliers doc-
umentation.
Because maintenance greatly depends on the
operating conditions, the maintenance inter-
vals might have to be shortened or extended
due to these conditions.
This is to the operator's experience.
In case of a longer stand still the instal-
lation must be switched on each month
for approximately half an hour. To avoid
corrosion, valves being jammed, etc.
IMPORTANT:
• In the lower side of the internal wall of the
jacket of the combustion chamber there is
a valve with a small hole attached to a
flange (2351). Through this valve, the
jacket of the combustion chamber is
drained during standstill. This draining is
quick when valve is full open and slow in
case of failure of this valve (true small
hole in disc). Check this valve and hole in
disc for. The jacket part for the sprayer
does also need to be drained. This done
via filter 2350. Also see “Rinsing the com-
bustion chamber” below.
KEEP THE VALVE + FILTER
CLEAN AT ALL TIMES
• Even stainless steel (especially welds) can
corrode if it is exposed to non-flowing
seawater for longer periods for clearance
• Keep the electric power to the local control
panel turned on to prolong the lifetime of
the O2-sensor.
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ORDER NR: 19599
9.1.1 Rinsing the combustion cham-
ber
NEVER USE SALT WATER.
The combustion chamber of the generator
must be rinsed with fresh water after each stop
after stop the combustion is draining (automati-
cally) the sea water, and then starts the rinsing
with fresh water.
The fresh water is entered into the combus-
tion chamber through valve 2340.
Fig. 9.1 Flange 2350
Always check that the filter attached to flange
2350, (fig 9.1) and the hole in the disc of valve
2351 is clean. If this is not clean the combus-
tion chamber will not be drained correctly.
9.2 Main burner
The burner cone is a wear and tear part.
Therefore this cone must be checked periodi-
cally on damage to determine if replacement
is necessary see drawing P-X00047
The life of the burner cone is strongly influ-
enced by:
− The quality of the fuel that is used
− The correct adjustment of the burner (no
soot production).
To replace the cone the upper cover of the
combustion chamber must be removed:
− Depressurise the combustion chamber and
all supplies.
− Disconnect all pipes to the main burner.
− Remove the cover by loosening the bolts.
− Take out the cone.
− Place the new cone.
− Reassemble in reverse order.
Note:
Mind the correct position for the hole for the
pilot burner.
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 ORDER NR: 19599

9.5 Maintenance tables

9.3 Pilot burner 9.5.1 Before every start

Component: Maintenance Remarks:

description
O2-analyser Check calibra- OEM manual
QIA-7001 tion
Fuel oil filter Rotate handle
1002 twice
Filter in O2 Clean
measuring
line (7022)
Filters in air Clean
pressure con-
1
trol system
(6004) and O2
Fig. 9.2 Purge nozzle instrument air.
analyser lines
(7050)
Always keep the 1.5 mm hole in the purge
Filter in in- Clean
nozzle (fig. 9.2-1) clean and open. This hole is
strument air
used for purging the UV detector (2121) and
lines (1502)
the ignition transformer (2131).
Use a needle to un-block the hole.
9.5.2 Every 250-hrs

9.4 Freezing prevention Component: Maintenance Remarks:

In case the ambient temperature for the Inert description
gas installation becomes below 0 °C and the Pilot burner Check and Distance be-
installation is out of service, attention must be 2101 clean spark tween elec-
paid to the draining of the below mentioned plug. trodes approx.
items. 2 mm.
Main burner Dismount and
From all these items the water (condense, 2001 clean oil noz-
fresh water from rinsing) must be removed zle.
and or drained. Check cone Replace if
on damage. necessary
• The combustion chamber and the scrub- Fuel oil filter Drain sump
ber jacket. Normally these jackets will 1002, 1052
drain automatically and if the maintenance Instrument air Disassemble
is carried out as indicated in the Mainte- filter 1502 and clean
nance tables below, the jackets will be Filters of Clean filter
empty. pressure element
regulators
• Cooling water supply and discharge pipes, 6004,6024,
7050
Remark: Filters 7022 Clean filter
CLOSE ALL DRAIN VALVES AGAIN! element

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 ORDER NR: 19599

9.5.3 Annually FX2N for local panel: battery and EEPROM

memory backup.
Component: Maintenance Remarks:
description The battery is maintenance free. It must be
Combustion Remove the replaced every 3 years. So make sure there
chamber 2301 inspection lid is a spare battery on board of the ship for
on the cooling each CPU FX2N unit.
tower and
clean with Actions:
solvent
Demister Inspect from - Replacement battery of FX1N
2307 bottom side
Water spray- Inspect and Nothing to do, because there is no battery to
ers, pipes clean if nec- replace.
2303 – 2306 essary.
Deck water Check internal - Replacement battery of FX2N PLC.
seal coating
Deck pres- Test alarm for Class re- Replacement to be done in 20 seconds, to
sure low/low proper func- quirement: keep the ram memory intact. Some status
(8010) tioning clean sample values can be lost, but will not effect the nor-
line mal working of the PLC. The ram memory will
Temperature Check the be reloaded from EEPROM, when the power
& pressure calibration is back on.
gauges The PLC starts then from the beginning with a
Safety devic- Check correct See the set- cold start and starts at the correct point in the
es adjustment tings in the program.
and functional test protocol.
operation 1. Turn off the power supply to the PLC.
2. Remove left top cover of the PLC.
3. Remove battery form holder.
9.5.4 After every stop
4. Disconnect the connector of battery.
5. Replace the new battery.
Component: Maintenance Remarks:
6. Connect the connector of battery.
description
7. Refit the cover.
Combustion Rinse with DO NOT USE
8. Turn on the power supply to the PLC.
chamber 2301 fresh water. SALT WA- 9. Power and Run led should light up.
TER! 10. Check? Try lamp test. If all led light’s
Filter Clean. up, then the program runs and the unit
2350+2351 can be started.
Batt.V led should be off. CPU led
should be off.

9.6 Replacing the PLC battery

The PLC is almost maintenance free. There

are only a few points for maintenance.

Replacement battery of Mitsubishi PLC.

There are two plc types used with different
backup systems.

FX1N for cargo control room: no battery, only

EEPROM memory backup.

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 ORDER NR: 19599

9.7 Lubricating schedule

For lubricating instructions of the E-motors,

consult the instructions in the Sub-suppliers
documentation

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 ORDER NR: 19599

9.7.1 Lubricating table

Motor side
Interval Component Qty. Bearing type Lifetime Lubricant Reference
Driven end E-motors …Grams …hrs Shell ALVA- Sub-suppliers
Every…hrs 2203/2223 NIA or equiva- documenta-
Non driven E-motors …Grams …hrs lent (lithium tion
end Eve- 2203/2223 based grease)
ry…hrs

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 ORDER NR: 19599

10 TEST PROTOCOL

List of documentation:

No. Doc. no. Title

1. BGS19599/3-1E Test protocol

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 ORDER NR: 19599

11 PROCESS DOCUMENTATION

List of documentation:

No. Dwg. no. Title

1) 19599-PLR02 Parts list

2) 19599001R00 Schematic diagram I.G. generator
3) 19599002R00 Schematic diagram I.G. delivery line
4) 65000A024R01 Codes/Symbols

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 ORDER NR: 19599

12 DIMENSIONAL DRAWINGS

List of documentation:

No. Dwg. no. Title

1) 19599299R02 Dimensions IG generator

2) 19599309R01 Dimensions Fan
3) 19599319R01 Dimensions FOP
4) 19599449R01 P/V breaker
5) 19599474R01 Deck seal
6) P-G00042 Maintenance Main Burner
7) P-000588 Maintenance Pilot Burner
8) P-X00082 Pilot burner Purge nozzle instrument air
9) P-X00047 Status burner cone
10) P-000599 Burner cone (only applicable if not welded to burner housing)
11) P-000594 Demister holder

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 ORDER NR: 19599

13 ELECTRICAL DOCUMENTATION

List of documentation:

No. Dwg. no. Title

1) E19599R03 Electrical drawings

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 ORDER NR: 19599

14 DOCUMENTATION

List of documentation:

Supplier Description

01. ROTODYNE - Operating instructions for centrifugal blowers (rev. 00)

02. AALBORG - Oxygen Analyser AAL 7000_Rev 0.2

03. FESTO - DAPS Conformity report (april 2007)

- DAPS Operating instructions (0703b)
- DAPS_EN (2008-06)
- DAPS_EN_pneumatic_actuator (2007-08)

04. FUELMASTER - Nozzle art. 144 (rev. 00)

05. HONEYWELL - Minipeeper Ultraviolet flame detectors C7027A, C7035A, C7044A

(60-2026-10)
- Flame detector relay R 4343 D,E. (MU2C-0028Z20 R0604)

06. GIULIANI ANELLO - Strainers, turners (rev. 00)

07. MAXON - Control valves (11-90)

08. PHILIPS - Industrial controller KS90 (rev. 00)

- Recorder KS 3930B (rev. 00)

09. ROTOR - Maintenance and installation procedures and re-greasing periods

(DOC_E-232-0999)

10. ALFA LAVAL AALBORG - Operation Guidelines 65010A052R04

NIJMEGEN B.V.

11. HP TECHNIK - Series B-VB-VBR-NV (11-2004)

12. SIEMENS - Sipart PS2 (09-2008)

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 ORDER NR: 19599

Alfa Laval Aalborg Nijmegen B.V.

St. Hubertusstraat 10
6531 LB Nijmegen
P.O. Box 6664
6503 GD Nijmegen
The Netherlands
tel.: +31 (0)24 35 23 100
fax: +31 (0)24 35 23 995
E-mail: info.nijmegen@alfalaval.com
http://www.alfalaval.com

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