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Marine Freshwater Generators: Common

Problems And Solutions
By Sargun Sethi | May 27, 2021 | Guidelines

A freshwater generator (FWG) is a vital machinery system used

onboard ships. FWG should only be operated by an experienced
and trained person, who would carefully study the instruction
manual provided by the manufacturer to fully understand the
working of the freshwater generator, before carrying out
maintenance, repair or trying to troubleshoot the equipment.

The maintenance schedule should be followed and checked

regularly to avoid any unfortunate circumstances and ensure the
smooth
Sponsored by:operation
Andreotti of the freshwater generator.
ANDREOTTI HOMEWEEK
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SALES

Precautions to be taken while operating

Fresh Water Generators
1. While operating the freshwater distillate pump for the first time,
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 the distillate present should be discharged overboard the ship for
a minimum of 30 minutes.

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2. Fresh Water Generators should be stopped before the ship

comes close to land, port or a river mouth. This is because the
seawater in such locations may be contaminated with bacteria
which can get mixed in the distillate generated by the machinery.
There is hence a high chance that the Fresh Water Generator
malfunctions when the ship is in the dirty sea.
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 Related Read: How To Prevent Fresh Water Contamination On
Ships?

3. The bottom blow valve should not be opened to restore

atmospheric pressure in the evaporator. If this is done, seawater
being used in the heater may be blown up and damage the
deflector plates and other parts of the Fresh Water Generator.
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 4. For testing leakage in the evaporator, the vacuum gauge should
be removed, or the main valve should be fully closed.

5. Before carrying out cleaning operations, the technician should

carefully read and follow instructions as stated in the manuals
provided by the manufacturer.

6. During cleaning and rinsing of the Fresh Water Generator,

steam should not be used as the inside surface of the evaporator
is covered with a coating material which can get ruined under the
action of steam.
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 Get the Free
OpenFlows Guide

Easy tools connect 1D

network elements with 2D

7. This coating material should be handled with a lot of care and

should be washed off immediately if it comes in contact with skin.
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 Sustainable. Together. Better.
One Mobility car replaces 11
privately owned ones. Don’t own.
Drive.

8. To avoid leakages, the bolts securing the tube plates should not
be removed or loosened.

9. The FreshWater Generator should not be heated, and welding

by an open flame has to be avoided to protect the coating present
on the inside surfaces of the Fresh Water Generator.

10. To move the Fresh Water Generator from one place to another,
the lifting holes present on the top cover should be used with
wires of sufficient weight carrying capacity as specified in the
assembly outline drawings present onboard.
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 Get the Free
OpenFlows Guide

Easy tools connect 1D

network elements with 2D
11. The FreshWater Generator can be damaged if it is run with a
valve or cock in closed position installed on the steam drain outlet
line. Hence these should not be incorporated on the outlet steam
drain line.

Related Read: General Overview of Central Cooling System on

Ships
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 ANDREOTTI HOMEWEEK SALES
Andreotti

The inlet of the ejector pump should always be filled with

seawater.

Common Problems Faced in Fresh Water

Generators with Possible Causes and
:
 Solutions
Low Rate of Distillate Generation

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Andreotti

The heating tubes or the condenser piping are fouled from

the inside, and they need to be cleaned.
Hot water temperature and or flow rate is low and needs to be
increased by the operator.
The cooling water flow rate may be low and needs to be
increased according to the given specifications.
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 Dropping of Evaporation Temperature

The temperature of hot water is low and needs to be

increased to the specified level.
Hot water flow rate is low and needs to be increased to the
specified level.

Related Read: Important Points Seafarers Must Consider For

Clean Drinking Water System On Ships
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 The vacuum obtained in the evaporator has dropped

There is an air leak present in the system which should be

repaired and then tested at 0.05 MPa to make sure regular
operation has been restored.

Freshwater generator shell with vacuum gauge

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 Malfunctioning of Water Ejector

The nozzle of the ejector has closed partially or fully and

needs to be cleaned
The diffuser has worn out, or corrosion has taken place. It has
to be replaced by a new one
The nozzle has been worn out and needs to be replaced by a
spare.
The pressure at the outlet of the ejector is at 0.08 MPa or
higher.
The ejector outlet piping may be clogged and needs to be
checked and corrected. The valve opening of the overboard
discharge valve needs to be checked and repaired.
The pressure at the outlet of the ejector is negative; the
overboard discharge valve should be closed up to a certain
degree.
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 The distillate is present in the Sight Glass

This may indicate failure of the Distillate pump. It should be

repaired.
The outlet valve of the Distillate pump is in the closed position
and hence needs to be opened.
The outlet piping is clogged and needs to be cleaned
The pump is drawing in air, and the mechanical seal needs to
be replaced.
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 High Salinity of the Distillate

The rate of generation of the distillate is too high and needs

to be decreased by lowering the hot water flow rate.
The temperature of evaporation is low (50 degrees or such).
The vacuum adjusts valve needs to be closed to an extent
such that the evaporating temperature increases.
The Fresh Water Generator has been used in an area where
the feed water is dirty and needs to be stopped.
The reading of the salinity indicator is faulty and has to be
checked using the indicator test switch; the electrode needs
to be cleaned.
The piping of the condenser has been damaged and needs to
be plugged inappropriately.
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 Related Read: Reverse Osmosis: Modern Alternative for
Shipboard Water Production

Low Feed Water Rate

The opening of the feed water adjusts valve is not sufficient

and needs to be adjusted accordingly to increase the rate of
feedwater entering the system.
The feed water orifice may be clogged, and its surface needs
to be cleaned. There is insufficient internal pressure in the
condenser piping and the condenser cooling water outlet
valve needs to be closed to an extent.

High Feed Water Rate

The feed water adjusts valve has a very large opening and
needs to be closed sufficiently.
The feed water orifice has been worn and needs to be
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 replaced.

Problems Specific to Pumping Systems of

FWG
Pump fails to start
The electrical system or the motor has failed and needs to
repair after proper inspection.
The impeller has seized with the casing ring causing
problems in starting the pump. In this case, the impeller
and/or casing ring need to be repaired or replaced after
carrying out inspections. After doing so, the centring of the
pump and motor needs to be checked. The eccentricity of the
shafts should be checked. Inspection of the bearings,
balancing on the impeller and shaft coupling should be
carried out.
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 The pump does not operate at the required head or
capacity
The pump is drawing in air through the suction system and
this needs to be checked and tightened.
The strainer at the suction pipe is clogged and has to be
cleaned.
The passage at the impeller is clogged and has to be cleaned.
After carrying out the cleaning operations, the pumping
system, including the casing, impeller, etc. should be
inspected for any damage. The piping systems, including the
suction and discharge, should be cleaned and if required, the
strainer has to be replaced.
The motor has been run in the reversed direction, and the
wires need to be correctly connected.
The motor speed has dropped, and the electrical system
needs to be checked for faults.
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 The clearing ring clearance has increased and needs to be
replaced. The impeller should be inspected for damage and
replaced if required. After doing so, the centring, shaft
couplings, eccentricity and the ball bearing should be
inspected for proper operation.

Water Flows after starting the pump but stops

abruptly
Air may be trapped in the system, and the piping needs to be
corrected. The air outlet valve should hence be checked, and
the suction pipe should be inspected.
The stuffing box is drawing in air, and the mechanical seal
needs to be inspected and repaired or replaced.

Related Read: 10 Ways To Reduce Freshwater Consumption On

Ships
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 Overloaded Motor
There is damage to the bearing and it needs to be replaced.
After doing so, the centring of the motor and pump, the
lubrication, shaft couplings, eccentricity and the ball bearing
should be inspected for proper operation.
The pump and motor are misaligned; hence the centring
needs to be adjusted, followed by proper inspection.
The shaft has been deformed and needs to be replaced
followed by proper inspection of the machinery.
The motor or electric system us at fault and needs to be
repaired and checked after inspection.
The discharge volume is high and needs to be checked and
altered according to the pump specifications.
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 Related Read: Single Phasing in Electrical Motors: Causes,
Effects, and Protection Methods

The Pump begins to vibrate during operation

The impeller is not balanced correctly and needs to be
repaired or replaced.
The Bearing has been damaged and needs to be replaced
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 The motor is misaligned with the pump, and the centring has
to be adjusted.
The Shaft has been deformed and needs to be replaced.
The pump has been incorrectly installed, and this needs to be
corrected by the onboard technicians after carrying out
investigations.
If any of the above actions are performed, the centring of the
motor and pump, the lubrication, shaft couplings, eccentricity
and the ball bearing should be inspected for proper operation.

Related Read: 7 Common Problems Found in Pumps on Board

Ships

Overloaded Bearing
The bearing may be assembled incorrectly or poorly; this
needs to be checked and adjusted after which inspections
need to be carried out. Fresh lubrication should be given to
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 the system.
The thrust experienced by the bearing is more than its
specifications, and the impeller may need to be repaired or
replaced. After doing so, the casing ring needs to be
inspected. The balance hole of the impeller needs to be
checked for blockage.
The Bearing has been damaged and needs to be replaced
The motor is misaligned with the pump and the centring has
to be adjusted.
The Shaft has been deformed and needs to be replaced.

Disclaimer: The authors’ views expressed in this article do not

necessarily reflect the views of Marine Insight. Data and charts, if
used, in the article have been sourced from available information
and have not been authenticated by any statutory authority. The
author and Marine Insight do not claim it to be accurate nor
accept any responsibility for the same. The views constitute only
the opinions and do not constitute any guidelines or
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 recommendation on any course of action to be followed by the
reader.

The article or images cannot be reproduced, copied, shared

or used in any form without the permission of the author and
Marine Insight.

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