Overhaul of Purifier

Purifier General View

Purifier General View
Centrifugal Purifier Vertical Shaft Assembly
Centrifugal Purifier Horizontal Shaft Assembly
Centrifugal Purifier Main Bowl assembly
 Purifier Overhaul

On board ship Centrifugal purifiers are used for the purification of ME &
Auxiliary engine system lubricating oil, fuel oil & diesel oil etc. Generally, th
two lubricating oil, two fuel oil & one Diesel purifiers are there on board.
Proper maintenance of these machineries is very important for the efficient
operation of propulsion & power generation plant of the vessel.
 Purifier Overhaul
Planning for overhaul:

Purifier overhaul to be carried out in following situations:

 As per PMS (Plan Maintenance System) schedule which is based on the

total running hours of the purifier.

 Inspection by class surveyor during CSM (Every 5 Years)

 If purifier seals are breaking, abnormal noise or excessive vibration

observed.
 
 Purifier Overhaul
Planning for overhaul:
 If major break down has taken place due to components failure such as

ball bearings etc.

 Prior commencing overhaul on purifier, availability of required spare

parts must be ensured. It is prudent to order required spare parts

much in advance before overhaul activity falls due. For ordering spare
parts instruction manual guidelines must be followed.
  
 Purifier Overhaul
Standby Equipment:

From standby perspective following needs to be done before undertaking a

major overhaul on a purifier purifier:
 In case of HFO purifier, unless a break down has taken place, preferably

major overhaul on HFO purifiers to be undertaken in port or in

anchorage when the Main Engine is not in use or when vessel is
proceeding in long voyage.
 Purifier Overhaul
Standby Equipment:
 Prior dismantling HFO purifier proper operation of stand by purifier must

be confirmed.
 It is always prudent to top up all the service tanks before taking up

major overhaul of HFO purifier.

 Some times Vessel is provided with only one ME LO purifier , in this

case it is preferable to carry out major overhaul on this purifier while

the vessel is in port/anchorage. Purifier should be running sump to
sump while Main Engine in operation.
 Purifier Overhaul
Tools:

All special tools & spanners required for the overhaul should be
identified as per instruction manual & they should be kept ready for use
at the work site.

Spare Part:

Before commencing overhaul vessel should have all spare parts on

board as per the Instruction manual guidelines. It is very important that
after taking proper inventory, required spare parts for the overhaul to
be ordered much in advance.
Purifier Overhaul Special tool
 Purifier Overhaul
Manpower: Man power requirements for performing various Overhaul
on purifier is given below:

Main Bowl inspection & cleaning: Man Hour: 16 Man Hours (two person
working one full day)

Major Overhaul of Purifier:

Man Hours: 32Man Hours. (Two persons for two full days.)
 Purifier Overhaul
Safety Procedures: Prior commencing any overhaul on a purifier,
instruction manual to be referred to & all safety instructions therein need
to be strictly followed. Important safety precautions to be taken prior
undertaking any overhaul on a purifier are given in next slide:
 Purifier Overhaul
Safety Procedures:
 Work Permit: Prior commencing any overhaul on a purifier, various

hazards such as Personal injury, Slip, trip & fall, heavy load lifting &
Splash with hot oil should be considered. Robust Risk assessment with
senior engineers & other Engine room team members to be performed
& control measures to be placed for their mitigation. Work Permit as
per Company safety management system to be issued after tool box
talk to be carried out by senior Engineer. Permit to be signed by
Authorizing person & competent persons participating in the job. After
issuance of work permit, same to be posted at the Worksite by Work
team after ensuring proper isolation of the machinery.
 Purifier Overhaul
Safety Procedures:
 Isolation –Lock out/Tag Out: Purifier to be completely isolated & locked
out /tagged out by following procedures:
 Purifier Suction valve on Settling tank to be closed.
 Pneumatic & water supply to purifier control system to be
closed.
 Steam inlet & outlet valves to Fuel oil/LO heater to be closed.
 Electrical isolation by putting off the purifier breaker on Main
switch board.
 Above mentioned valves & Electrical breaker to be Locked out
& tagged out by responsible person. Notice “DO NOT START
MEN ARE AT WORK” to be posted.
 Lock out Tag Out File to be updated & signed by responsible
person.
 Purifier Overhaul
Overhaul:
For performing purifier overhaul, instruction manual guidelines to be
strictly adhered to. Generally following overhauls are carried out on a
purifier:

AA. Main Bowl Cleaning: Generally, this job is carried out when some
abnormalities such as excessive vibration, frequent seal breaking or
frequent activation of high water content alarm observed.

Procedures to be followed while inspecting & bowl cleaning of purifier (e.g.

Heavy oil purifier) are given on next slide:
Centrifugal Purifier Main Bowl assembly
Purifier Overhaul
Purifier Overhaul
Purifier Overhaul
 Purifier Overhaul
Overhaul:
 It is very important that purifier is stopped, isolated, risk assessment

performed, tool box talk given & work permit is issued before
commencing any overhaul job on the purifier system.
 Utmost cleanliness & hygiene to be maintained while the job is in

progress. Working area around the purifier to be covered with burlap or

paper roll, so that Oil & dirt will not spread around the work site & find
its way to other part of Engine room.
 Purifier Overhaul
Overhaul:
 All special tools & other spanners to be kept ready for use near the

purifier & preferably small buckets to be kept handy for keeping

removed parts securely while purifier is being dismantled.
 Oil inlet /outlet pipes to be removed after draining the system of any

remaining oil. Sealing water connection on top of the purifier to be

removed.
 Remove the sludge cover after removing circumferential securing bolts.

 Remove disc nut, heavy liquid chamber, impeller, packing & gravity disc.

For removing disc nut special tool to be used.

 Purifier Overhaul
Overhaul:
 Remove light liquid chamber, impeller & inlet pipe by a special tool.

 Now the bowl assembly can be pulled out by removing cap nut &

jacking it up by special tool.

 Mount Bowl assembly on dismantling stand, remove the Bowl nut by

special tool provided by the manufacturer. After dismantling of Bowl nut

remove bowl hood, disc stack & distributor of bowl assembly. Disc stack
to be kept in De- greaser solution for cleaning. Chemical handling PPE
must be used while handling de greaser solution.
 Purifier Overhaul
 Remove main cylinder (sliding bowl) from the bowl body using special
jacking tool.
 Remove pilot valve assemblies on Main bowl body for inspection &
cleaning by special jacking tool.
 All discs on disc stack to be removed cleaned & assembled back in same
sequence. Box back bowl assembly with cleaned components. Sealing
rings & pilot valve assembles to be inspected for any damage
/distortion, if any abnormality observed, they must be replaced. All
sealing rings & pilot valve assemblies are to be replaced after 4000
hours of running. & bowl nut to be tightened in such a way that marks
engraved on bowl nut & bowl body are matching. This ensures proper
tightening.
 Purifier Overhaul
 Inspect water supplying device assembly for proper functioning, replace

the sealing rings if found damaged. Generally, these rings are to be

replaced after 8000 hours of running.
 Install overhauled bowl assembly on the purifier & mount heavy/light

liquid chambers & their respective impellers & gravity disc & secure
them on bowl assembly with disc nut. For tightening disc nut special
tool to be used. While these components are being installed free
movement of horizontal & vertical shaft to be insured.
 All pipe connections to be fitted back in place, purifier to be turned by

hand from gear case for ensuring free rotation.

 Purifier Overhaul
 Open water, control air , suction valve on settling tank & open heating

steam for the heater(heat pack). Purifier system to be tried out for
proper operation after completing work permit, removing Lockout & tag
out and updating the concerning file.
 While checking the system special attention to be paid on any abnormal

noise, vibration, electric motor amperage & purifier seal. If any

abnormality observed purifier to be stopped immediately & fault to be
investigated.
 Purifier Overhaul
BB. Major over Overhaul of Purifier: Generally, this overhaul is carried
out after 16000 hours of running or in case of excessive vibration, or
abnormal noise observed or major break down has taken place.

This includes overhaul of main bowl assembly and Horizontal & vertical
shaft assemblies. Following need to be performed:
 Ensure purifier is isolated as discussed above, work permit is issued &

adequate manpower is allotted to the work team.

 Remove sludge cover & main bowl of purifier as discussed above (AA).

 Open the drain plug & drain gear oil from purifier gear case.
 Purifier Overhaul
BB. Major over Overhaul of Purifier:
 Disconnect Electrical motor & unscrew the securing bolts from the

purifier frame & withdraw the electric motor with the help of chain block
& wire sling.
 Remove friction clutches.

 Remove the Gear pump assembly & bearing housing cover after

unscrewing the cap screws (securing bolts).

 Pull out the friction clutch pulley after removing all securing bolts with

the help of puller.

 Purifier Overhaul
BB. Major over Overhaul of Purifier:
 Pull out the horizontal shaft from gear pump side.

 Remove water supplying device by removing securing screws &

operating water tube.

 Pull out Vertical shaft after removal of mist cover, bearing housing with

support springs.
 After thorough cleaning & inspection of horizontal shaft, reassemble it

with new bearings. If any abnormality observed shaft needs to be

replaced. Small scoring & scratch marks to be dressed by needle file or
fine emery paper.
 Purifier Overhaul
BB. Major over Overhaul of Purifier:
 After cleaning & inspection of vertical shaft, reassemble it with new

bearings. Before assembling shaft to be thoroughly inspected for any

abnormality, if needed to be replaced with new one. Small scoring/
scratch marks can be dressed up with needle file or fine emery paper.
 Clean water supply device & replace all sealing rings & joints.

 Now the reassembly process will begin. For reassembling opposite

sequence is followed.
 Purifier Overhaul
BB. Major over Overhaul of Purifier:
 Install vertical shaft assembly with new support springs. Measure the

vertical height of the shaft using special tool & compare the data with
that of Instruction manual. Water supply device to be reinstalled on the
vertical shaft. While vertical shaft is being reinstalled, its free/light
rotation must be ensured.
 After installation of Vertical shaft, install horizontal shaft assembly on

purifier, mount friction pulley on it. Replace Oil seals (lip seal) in both
friction pulley & gear pump side. After installation of Horizontal shaft
assembly, free rotation of purifier by hand must be ensured. Install gear
pump assembly after thorough inspection.
 Purifier Overhaul
BB. Major over Overhaul of Purifier:
 Install overhauled Bowl assembly on the vertical shaft. (For overhauling

Bowl assembly, please refer to procedure listed above).

 Install Sludge cover & fit back all pipe connections such as oil inlet

/outlet & sealing water connection.

 Install Electrical motor with new friction clutches.

 Turn the purifier assembly by hand from gear case, it should be rotating

freely by hand.
 Clean the Gear case & fill it up with appropriate gear oil. Box back the

gear case cover.

 Purifier Overhaul
BB. Major over Overhaul of Purifier:
 Open water, control air & suction valve on settling tank. Purifier line up

must be checked thoroughly. Purifier system to be tried out for proper

operation after completing work permit, removing Lockout & tag out &
updating relevant file.
 While checking the system special attention to be paid on any abnormal

noise, vibration, electric motor amperage & purifier seal. If any

abnormality observed purified to be stopped immediately & fault to be
investigated.
 Purifier Overhaul
BB. Major over Overhaul of Purifier:
 PMS to be updated with detailed work description & photographs.

Update spare parts consumed in vessel’s inventory system. Requisition

for used spare parts to be issued.
