INSTRUCTION MANUAL FOR SASAKURA FRESH WATER GENERATOR K SERIES SASAKURA ENGINEERING CO., LTD.CAUTION 1. Welding and other working with fire are prohibited due to the prevention of coating inside of plant. Observe the following items strictly for keeping tube plates and cooling tubes of condenser from corrosion and erosion. A) While operating the plant, open Cooling Water Inlet-Valve of Condenser fully and regulate Cooling Water Quantity by Outlet Valve only and keep the back pressure of minimum about 0.2 kg/cm2G.(0,019MP2) B) And Also regulate Cooling Water Outlet Valve so as to keep the prescribed temperature difference between inlet and outlet of condenser. (Please refer to the heat balance as to temperature difference.) C) Watch over Anode Protectors in Condenser Cover about every six months. 3. Carry out following items in order to prevent scale formations in heating tubes. A) Keep the feed water pressure within green belt of pressure gauge. B) Output shall be kept at or less than normal capacity specified. ~ 4. Centering of the shaft is important for Rigid coupling type pump. Identification mark shall be made when the shaft end is removed. Keep centering at the shaft end within 5/100 when the pump is assembled. (Do not remove the shaft during normal maintenance.) 5. Alignment of ejector pump and motor shall be re-adjusted by the shipyard/shipcrew whenever they are newly installed, replaced or maintenance work is done. 6. If gauge (vacuum, pressure, compound) shows wrong indication,pull yellow plug on the top of the gauge to release air inside.INDEX Page 1. DESCRIPTION OF THE PLANT... 1 2. FEATURES OF THE PLANT AND ITS SYSTEM eee . 2 3. OPERATION. +s seseeeeeeeeeee 3 Sele STARTING UP ects. 5 3-2, REGULATING. THE CAPACITY « s 3-3, STOPPING... sss. sees 5 3-4, ATTENTION DURING OPERATION «++ eeseeeeeeeeereeeees 7 G5 (iti ef! ocoococuoruooesuodeounosoouossedadebouncsod 4) 4ol. TESTING THE PLANT FOR LEAKS. ...+.sse0eeeeeeeeeeees 10 4-2. PRESSURE TEST OF HEAT EXCHANGER AND CONDENSER .... 10 5. CLEANING THE TUBES (DESCALING METHOD)........+ ll 5-1. CLEANING INTERVAL FOR DESCALING....--++-+ iL CLEANING METHOD... Sennen etree eee nee eee + ln WAY TO PROLONG THE INTERVAL OF DESCALING . - 1s ‘CONTINUOUS INJECTION OF FEED TREATMENT.... 1s 6. REPAIR OF INSIDE COATING... es sees cece cece cece eeeeees wz 7. TROUBLE SHOOTING .. +. 4-45 . Gonba0 20 8. MAINTENANCE LIST... eee ” 9. OPERATION BY STEAM (In case that steam injector is installed)... . 31 10. HANDLING OF MECHANICAL SEAL FOR DISTILLATE PUMP....-.++++ 55 11. SCALE INHIBITOR "SASABIT" + 36 ILLUSTRATIONS Skeleton of Internal Arrangement for Fresh Water Generator Data Sheet for Fresh Water Generatorov DESCRIPTION OF THE PLANT ‘The Fresh Water Generator consists of heat exchanger, separator shell and condenser. And the water ejector, the ejector pump, the distillate pump, the salinity alarm, the deflector, the mesh separator, the solenoid valve, and the water meter are supplied as the attachments. K series F.W.Generators consist of K, KM, KE types. Followings are main features of each type. Ejector pump is installed under the waterline as the former type. 1, Energy saving type Driving water of the ejector pump is taken from the outlet of condenser jacket cooling water. 2. Easy operation Ejector pump is assembled with the main body, and a complete set of compornents of F.W.Generator is installed on the same floor. Unnecessary to supply sea water from the general service pump because driving water of the ejector pump is used for condenser jacket cooling sea water.2. FEATURES OF THE PLANT AND ITS SYSTEM Since the Fresh Water Generator utilizes the waste heat in the circulating cooling water from the diesel engine. In case of damage to the fresh water cooler, it may be possible to use the fresh water generator only as cooler during the repair of the fresh water cooler. Part of the engine cooling water is led to the heat exchanger in the fresh water generator where it circulates on the outside of the heating tubes, giving off heat to the feed water (sea water) passing through the inside of tubes. The feed water then evaporates at a comparatively low temperature because the inside of the generator is formed vacuum by the water ejector. The generated vapor in the heat exchanger passes through the deflector and mesh separator to the condenser where it is condensed by the cooling sea water. ‘The brine, concentrated sea water, is constantly taken out from the evaporator shell and discharged to over board. ‘The ejector pump supplies sea water to water ejector. The distillate pump extracts the fresh water produced from the condenser of the Fresh Water Generator and transfer it to the fresh water tank, Part of cooling sea water heated by condenser is used as feed water and flow into the bottom cover of the heat exchanger after heated by the preheater and passing through the feed water orifice. Produced fresh water is always registered by the salinity alarm (salinity indicator). When the salinity is up to the prescribed value (normally 10 ppm, adjustable to the other value), the solenoid valve on the improper fresh water line opens which leads improper fresh water into the evaporator automatically. Fresh water with high purity flows into the fresh water tank. ~OPERATION 3-1A. STARTING UP (K, KM type) Before starting, the following valves are to be closed. Inlet and outlet valves for jacket cooling water of heat exchanger Vacuum breaker valve Outlet valve for distillate pump Feed water inlet valve for heat exchanger Bottom blow valve 1) Open the outlet and inlet valves of condenser cooling water and lead cooling - water into the condenser. 2) Start the ejector pump and then open the pump outlet valve and the overboard discharge valve. 3) Open the feed water valve and lead sea water into the heat exchanger. Feed water quantity can be seen by the readings of the compound gauge in front of the feed watr orifice. Control feed water quantity within range of green belt shown in the compound gauge. 4) When the vacuum in the generator become about J 79 SsmHe, ‘open the inlet and outlet valves for jacket cooling water of the feet Oe. The outlet valve for jacket cooling water is to be opened slowly lest the heat exchanger should be overheated suddenly. 5) The air vent cock at the upper part of the heat exchanger shell should be opened whenever jacket cooling water passes through the heat exchanger and should be closed after confirming that the air in the shell is completely discharged. 6) Work the salinity alarm in order to check purity of the fresh water. 7) When the distillated fresh water comes up to the sight glass of the suction pipe of distillate pump, start the distillate pump and regulate the water quantity by the outlet valve of the pump. If there is not abnormality on the discharge Pressure of distillate pump, the level need not always be fixed. (normal discharge pressure is 1.4 - 2.2 kg/em2) (0,137 — 0.216 MPa ) Fresh water quantity is increased as the sea water temperature falls after adjusting to the fixed fresh water quantity. Naturally water level at the distillate pump suction side increases, produced water stays inside of the condenser, the effective heating area of the condenser decreases, evaporation quantity decreases, accordingly, the operating condition will be naturally balanced.3. OPERATION 3-1B, STARTING UP (KE type) Before starting, the following valves are to be closed. Inlet and outlet valves for jacket cooling water of heat exchanger Vacuum breaker valve Outlet valve for distillate pump Feed water inlet valve for heat exchanger Bottom blow valve » 2 3 4) 3) 6 ”n Start the ejector pump and then open the pump outlet valve and the overboard discharge valve. Open the outlet and inlet valves of condenser cooling water. Open the feed water valve and lead sea water into the heat exchanger. Feed water quantity can be seen by the readings of the compound gauge in front of the feed watr orifice. Control feed water quantity within range of green belt shown in the compound gauge. When the vacuum in the generator become about 70 cms, open the inlet and outlet valves for jacket cooling water of the heat Se The outlet valve for jacket cooling water is to be opened slowly lest the heat exchanger should be overheated suddenly. The air vent cock at the upper part of the heat exchanger shell should be opened whenever jacket cooling water passes through the heat exchanger and should be closed after confirming that the air in the shell is completely discharged. Work the salinity alarm in order to check purity of the fresh water. When the distillated fresh water comes up to the sight glass of the suction pipe of distillate pump, start the distillate pump and regulate the water quantity by the outlet valve of the pump. If there is not abnormality on the discharge Pressure of distillate pump, the level need not always be fixed. (normal discharge pressure is 1.4 - 2.2 kg/cm2)( 0.137 ~ 0.216MPa) Fresh water quantity is increased as the sea water temperature falls after adjusting to the fixed fresh water quantity. Naturally water level at the distillate pump suction side increases, produced water stays inside of the condenser, the effective heating area of the condenser decreases, evaporation quantity decreases, accordingly, the operating condition will be naturally balanced.3-2. 3.3. REGULATING THE CAPACITY ‘The capacity (quantity of produced water) of the Fresh Water Generator is regulated by increasing or decreasing the quantities of jacket cooling water to the heat exchanger. ‘The capacity of the plant is now measured by means of the water meter, the quantity of the jacket cooling water shall be regulated by the by-pass valve to the fresh water cooler until the plant produces its normal capacity. In case that the temperature of the jacket cooling water is lower than the prescribed one, the flow quantity passing through the heat-exchanger shall be increased more. The supply of cooling sea water to the condenser is regulated so that the cooling sea water temperature rises about prescribed value when passing through the cooling tubes of the condenser. ‘The evaporation temperature should be about 45°C to 60 OC, If the evaporation temperature is too iow which may occur at low sea water temperature area, the vacuum breaker valve is opened little or the quantity of the cooling sea water for the condenser is decreased which will make the evaporation temperature rise. If the evaporation temperature is too high which may occur at high cooling sea water temperature, the quantity of cooling sea water to the condenser is increased which will make the evaporation temperature drop. Too high evaporation temperatures increase the risk of scale formation in the tubes of the heat exchanger, and too low evaporation temperature will owing to the resulting great vapour volumes mean a risk that sea water drops are brought with to the condenser resulting in fresh water with a too high salt content. STOPPING When the vessel approaches a port, land or estuary the Fresh Water Generator is desirable to be stopped because at such places the sea water may be heavily infected with bacteria, and there is a risk that bacteria can be transferred to the fresh water produced. Before the Fresh Water Generator is stopped the by-pass valve for the jacket cooling water should first be opened.) 2) 3) 4) 3) 6) K, KM type Close the inlet and outlet valves of the heat exchanger. Stop the distillate pump. Turn off the salinity alarm. Close the feed water valve. Stop the ejector pump. Close the outlet and inlet valves of the condenser. a) 8) Open the vacuum breaker valve. Close the overboard discharge valve and inlet valve of the ejector pump. Note: a) b) ¢) ) 2 3) % ) 68) KE type Close the inlet and outlet ~. valves of the heat exchanger. Stop the distillate pump. Turn off the salinity alarm. Close the feed water valve. ‘Stop the ejector pump. Close the outlet valve of the condenser. (overboard discharge valve) Supply the feed water for few minutes in order to cool the heat exchanger. Don't open the bottom blow off valve in order to make atmospheric pressure because sea water in the heat exchanger spout and strike the deflector. In case that the plant is stopped for a long time, the heat exchanger is emptied of sea water by opening the bottom blow off valve at the bottom of the heat exchanger.3-4. ATTENTION DURING OPERATION 1) 2) Regulating the Capacity Any regulation of the capacity of the Fresh Water Generator should be effected by regulating the amount of jacket cooling water to the heat exchanger. Although when the tubes are clean, the Fresh Water Generator will be able to produce fresh water in excess of its rated capacity, we recommend that you will operate the plant at the prescribed quantity of fresh water or less as production in excess hereof can involve the risk of scale formations. ‘The Condenser In order to condense all generated vapor in the heat exchanger, cooling sea water, as cold as possible should be flowed to the condenser and also should be checked temperature difference of cooling sea water between inlet and outlet of condenser for regulating the amount of cooling sea water. In case excess cooling sea water should be supplied, turbulent corrosion may possibly caused due to too high velocities in the cooling tubes of condenser. (On the contrary, when cooling sea water is short, the capacity of produced fresh water should decreased because of short cooling performance.Calculation for quantity of cooling sea water of condenser : - dD tL 2 : Outlet temperature of condenser Q + Capacity of cooling sea water Capacity of produced fresh water (T/day) Inlet temperature of condenser Dx 22.4 (tm (ty - Q It is requested to adjust outlet valve of condenser in case that capacity of cooling sea water is exceeded more than the value specified in heat balance. Maximum quantity of cooling water of each type (t/n) K. KM type 10 1s | 20 25) |) 20) 35 40 50 | 60 Max. Flow Q'ty | 24 T/h | 37 T/H] 52 T/h| 67 T/h] 79 Tin) 90 T/n] 95 Th | 133 Th | 1427/1) 3) Automatic Control of the salinity in the Fresh Water ‘The Fresh Water Generator is furnished a salinity alarm which automatically registers the selinity in the fresh water produced. This salinity alarm gives an alarm if the salt content exceeds prescribed value. In addition to the alarm lamp, a solenoid valve is operated which automatically return improper fresh water produced to the vapore shall. When the value of the sea-salt content returns to the normal readings, this alarm circuit is automatically restored from the alarming state and consequently alarm lamp is turned off, the alarm and the solenoid valve are stopped and the fresh water with high purity begins to flow into the fresh water tank of the ship again. As for the detailed explanation of the salinity indicator, please refer to the annexed "Instruction manuals for a Salinity Alarm".° 4) dD Checking the Evaporation Temperature It is very important, in order to avoid the risk of scale formation, to maintain as low an evaporation temperatue as possible, without the salinity in the fresh water produced being too high. Therefore, we recommend that the evaporation temperature should be checked regularly on the thermometer, fitted on the separator shell. ‘The thermometer on the separator shell states the exact evaporation ‘temperature when the Fresh Water Generator is working steadily after having run for 15 ~ 30 mins-- ---- ~ Keeping of Journal We recommend that the water production, the various temperature and so on are regularly recorded in the operation journal inserted at the end of this instruction manual. When the various data are recorded regularly standard of comparison will be available if irregularities or troubles should arise in connection with the operation of the Fresh Water Generator, and which may be of great significance in establishing the reason for these irregularities or troubles.4, INSPECTION At suitable intervals, for instance twice a year, the top cover of the separator shell and the bottom cover of the heat exchanger should be removed in order to inspect whether scale has formed in the tubes and the state of exfoliation of inside coating. At the same time, the condenser covers are removed in order'to check that the condenser cooling tubes are not fouled with sludge or the like. ‘The pumps shoulld be inspected and cleaned regularly, and the corroded parts, if any, shouyld be replaced to the spare ones. 4-1. TESTING THE PLANT FOR LEAKS. After an inspection or if there is any difficulty in maintaining the vacuum - a leak test should be carried out, as in course of time leaks may occur due to deterioration of packings and joints. ~ This test procedure is as follows. 1) Close the outlet valve of the distillate pump, vacuum breaker valve, bottom blow off vaive and feed water valve. 2) Inject air to evaporator shell. 3) Keep the shell pressure of about 0.5 kg/cm2G. (0.049MPa ) 4) Spray soap solution to packings and joints. 4-2. PRESSURE TEST OF THE CONDENSER AND THE HEAT EXCHANGER ~ Condenser Remove the water chamber of the condenser, keep the inside pressure of the shell 0.5 kgf/cm? by injecting air to the inside of the evaporator, find out leakage by C4 PE) , ‘Spraying soap solution. Heater Remove the bottom cover of the heater. Leakage can be found aut by giving 4 - 5 kgf/cm2 water pressure on the shell side. (0.392 -049MPa ) For tube crack and pin hole, spread soap solution on the surface of tube plate and give the atmospheric pressure of 1.0 kgf/cm? on the shell side. (0-098MPa ) -10-10 5. CLEANING THE TUBES (DESCALING METHOD) Sel. CLEANING INTERVAL FOR DESCALING ‘The fresh water generator is equipped with a heater, a conderiser and a preheater. Scale forms mainly in the heating tubes of the heater and it is hardly found in the cooling tubes of the condenser under normal operation. Chemical cleaning of the whole system can be made by fitting adapter (option) to the corrosion plate connection of the condenser water chamber. Sea water boils and evaporates in the heating tubes, and consequently sea water touching the heating tubes is considerably concentrated and supersaturated. This is why scale is deposited in the heating tubes. Cleaning (descaling) of the inside of the heating tubes should be made twice or three times a year in general. However, the interval depends upon the operating conditions and the properties of sea water. Therefore, note the following phenomena as the standards for judging the time for cleaning. a) Quantity of jacket cooling water can be estimated by temperature difference at the outlet and inlet of the heater when the temperature in the shell is kept at or below evaporation temperature of the heat balance, and jacket cooling water quantity requires much more than that of the heat balance in order to produce the fixed capacity on condition that jacket cooling water temperature is same as that of the heat balance. Calculation : D_: Capacity of produced fresh water (T/day) QJ +: Jacket cooling water quantity (T/h) T + Temperature difference at the outlet and inlet of the heater 9 = 245 XD (Tm) T 1») When the vessel if fitted with a steam injector, condition of scale formation can be easily found out. While the temperature in the shell is kept same as that of the heat balance as well as item a), inlet temperature of jacket cooing water is balanced at higher temperature than before. When a steam injector is used, quantity of produced fresh water has almost no change. It is necessary to keep operation journal for check of scale formation. eleIf. any of the above mentioned phenomena is observed, remove the sight glass in front of the separator shell and insert the test rod which is supplied with the Fresh Water Generator, if the test rod is not inserted into the heating tubes, scale formation occurs more than | mm thickness in the heating tubes therefore clean it soon. 5-2. CLEANING METHOD ‘Scale may be either peeled off by physical methods of dissolved by chemical methods. The former includes the use of brush and-drifiy-the-rapid coeling-method, injection of pressurized water, etc., but it is rather difficult to completely remove ~ scale by these methods. We will explain a method to use chemicals which prevails recently because it requires shorter cleaning time, hardly damages the tubes and is economical and effective. 5-2-1. Preparations for Cleaning a) Draw sea water in the shell from the Bottom Blow Off Valve b) Close the Bottom Blow Off Valves completely and remove the sight glass. 5-2-2. Making Soultion Make up solution in the drum. (in this case, be sure to pour water into the drum first and then chemicals.) 5-2-3. Recommended Types of Clemicals and the Names of the Manufacturers Brand Distributor SAF - ACID Drew Chemical Corporation U.S.A. D.S.C. Yokosuka Kasei Co. Ltd. Japan Chiyoda Kignas Oil Co., Ltd. Japan Mitsukane Japan GAMLEN XD Gamlen Chemical Company U.S.A. ATLAS H-400 ATLAS Preservative Company U.K. ** Please refer to the catalogs of each manufacturer for detailed. -12-1L 5-2-4. a) Submerged Cleaning Pour solution into the heater through the sight hole until the upper tube plate is soaked and leave it as it is. The time required for cleaning vaties in the thickness of scale. When the solution becomes saturation, it has no capacity for cleaning. In this case, interchange with new solution a few times. ADAPTER (K 15 ~SOTYPE) Mt That w= [por ped (K 3~10 TYPE) CHEMICAL, TANK b) Circulated Cleaning As the above drawing shows, by fitting the adapter for the inlet of solution to the connection of corrosion plate at cooling water inlet nozzle of condenser water chamberr, and using the socket of bottom cover for outlet of solution, clean the whole system of heat exchangers. Quantity of solutin required for each type is shown as follows. Density of solution shall be a little bit higher than recommendable density by each maker. -13-KKM, KE 3 | 5 | 10|-15] 20] 25} 30]. 35] 40] -50] 60 Condenser ai] 12). 27] 43] 52] 64] 77])-93/100/150/160 Submerged Cleaning Heater |e] 22] 25} 44] 62} 85/105}145}146/1701 206/230 Circulated Cleaning 33] 37| 71|105}137]169]192]239| 270/356] 390 5-2-5, 5-2-6 5-2-7. During circulated cleaning, add the capacity of the cleaning tank to the total quantity. Discharging Solution after Cleaning After cleaning, solution should be discharged through the bottom blow-off valve fitted to the bottom cover of the heater. Since the above mentioned chemicals are for dissolving but not for peeling off, there is nothing to worry about damage to the impellers of the pump of clogging of the pipes. Finishing Cleaning by Running Sea Water After discharging solution, let sea water run through the heater for the cleaning of the inside in the following way: Flow sea water into the heater through the feed water line. Then discharge it overboard through the ejector by operating the ejector pump. Repeat the pumping and discharge alternately until the inside of the heater becomes clean. In this case, take care not to let sea water in the condenser. Inspection after cleaning Cleaning is usually finished if no scale is found at the upper part of the inside of the heating tube by putting the light from a flashlight on that part from the sight glass. However, scale forms most around at the part of 1/5 - 1/4 of the distance between the tube plate from the lower tube plate, or at the lower part of the vertical heating tube. -1b-12 5-3. 5-4 Shel. Therefore, be sure to confirm that the whole inside of the tube has become clean by thoroughly checking the lower part of the inside of the heating tube with-such an electric light that can light that part or by inserting a test rod, and continue cleaning until no scale is found throughout the tube. Never feed steam during the cleaning work as it will damage the inside coating of the Fresh Water Generator. WAY TO PROLONG THE INTERVAL OF DESCALING In order to prolong the interval of descaling as long aé possible, please keep the following items: a) To operate the plant with the capacity under the prescribed one. b) To feed the sea water as much as possible the ejector can discharge. ¢) If possible, not to operate the plant at the contaminated water area such as harbors and ports. d) In stopping the plant, continue to feed water until the heat exchanger shell grow enough cold for you to be able to touch by hands and fill the new sea water, which is not concentrated, to the upper tube plate of the heat exchanger. CONTINUOUS INJECTION OF FEED TREATMENT The above mentioned cleaning method is that applied periodically while the fresh water generator stops running. ‘On the other hand, the method mentioned here is that positively prevents scale from forming by continuously injection the prescribed amount of feed treatment into the feed water line during the operation of the Fresh Water Generator, thus lengthening the life-span of the plant without lowering its performance. Recently many vessels have adopted this method dur to ecomonical merit. Kinds of Feed Treatments (Scale Inhibitor) Although there are various chemicals, we recommend "SASABIT" which was specially developed for F.W. Generators. -15-5-4-2. 5-4-3. Saba. Injection Method ‘Chemical tank piping is to be connected with the screw connection for scalé inhibitor which is located behind feed water orifice, and chemical must be supplied continuously during operation. (injection pump is not required because feed water line after orifice is vaccum.) Feed Treatment Injection System The standard type of feed treatment injection system(capacity : 25 liters) including an electromagnetic pump) specially arranged for this fresh water generator is suppliable on request. Care to be Taken When Pouring Feed Treatment Continuously Keep watch on the remaining quantity of solution in the tank and supply solution in good time lest air is put in the fresh water generator from the empty tank. -16-13 6. REPAIR OF INSIDE COATING If during an inspection of the Fresh Water Generator it is ascertained that th side coating is damaged. a) Repair can be effected in the following way; Damaged covering is scraped off and the surface is thoroughly dried. By means of sandpaper coating and the steel surface with the width of 20 mm from the damaged part is ground and cleaned. Therefore under coating is put on the steel surface and ‘then Epoxyresin is applied, but now also-on the previously ground part of coating. The way of coating is as follows : - Material for repair and its package Material 1. Epoxyresin 2145 (grey) net — 300gr. d ii) 2. Harder 2145 (grey) net 90 gr. Method of repair ii-1. Kind of damaged part damaged —_—2—— coat ing rubber iron Rooting rubber atteMethod of repair (1) Grinding the rubber of iron and rubber by grinder. Remove the damaged coating rubber, If coating rubber become off from the iron part, the damagee rubber shall be cut off by knife or grinder and repaired. (2) Cleaning and drying ——a Cleaning with gasoline Dry with infrared ray Surfaces to be primed should be cleaned and dried. In order to clean and degrease to be primed, wipe with a gasoline soaked cloth. Other solvent of commercial paint may be used instead of gasoline. ~18-+14 Q) w ii-3. Application of Epoxyresin 2145 Hardener (90 gr.) "—————Epoxyresin (300 gr.) After drying, Epoxyresin shall be applied. Epoxyresin 2145 and curing agent 2145 should be mixed throughly. Epoxyresin 2145 300 gr. Hardener 2145 90 gr. ‘The pot life of Epoxyresin 2145 is decided on volume of the batch and the temperature. At room temperature, the pot life of the mixture of Epoxyresin is about 40 minutes. Curing of Epoxyresin 2145 Epoxyresin 2145 cures at room temperature by mixing of harder 2145. Curing generally completed for one or two days. Notice ‘These materials should be handled carefully. If the material touch skin, immediately wash the skin with water thoroughly. -19-7. Trouble Shooting YES Leaks in Repair the leak's part. Is ejector pe Normal? Scale formation in the cooling tube: Too low capacity v ‘Seale formation of YES. heating tubes (In & Out side)? I the plant? NO YES s? [ne Normal evaporation temperature? YES formance ) 0 No Fresh water stay in condenser shell? E No Clean the cooling tubes. 1 Clean the heating tubes. Nozzle clogged? YES Clean the nozzle. -20- Erosion of diffuser? Renew the diffuser. NO Back pressure of ejector more than 10 M? ‘Check the pipe line NO | of ejector outlet. B<Trouble of ejector pum Jakcet cooling water temperature is lower than prescribed one? Check the air line of ejector. See "Trouble Shooting” of "Trouble of Pumps". Raise the jacket cooling water temperature. eed Short of jacket cooling water quantit Non-return valve of ejector stick Increase the jacket cooling water quantity. No Air stay in| shell? heater Discharge air. Trouble of solenoid Repair the solenoid 0 valve. ‘of water YES Troub! mete ¥ High salinity of produced fresh water ‘See "Trouble Shooting" of ‘igh Salinity of Produced Fresh Water" Renew the water meter. No —21-Watermeter of Produced Fresh Water ‘This watermeter is liquid crystal digital watermeter which contains a lithium battery. ‘The watermeter is one of extremely important accessories to check the condition of the F.W. Generator. ‘Watermeter's life depends on frequency of use, during four to six years operation, the number of revolution will be about several billions. It will be the time for which watermeter shall be replaced completely when liquid crystal display disappears. ‘According to the Measuring Law, one of the Japanese domestic law, all sorts of watermeters for home use shall also be replaced with calibrated one once for six years. c D { | (i late a Air stay in cooling out of order tudes, See "Trouble Shooting” of “Trouble of Pumps". No Repair the air vent valve at the Suction and discharge pipes condenser cover. of distillate pump clogged. —22-i6 alacm? Too low ev: YES. (Open the vacuum breaker valve a little. Disorder of salinity temperature less than 35 °C 7 High salinity of produced 3 g 5 Operate under normal capacity. No Stain of cell? No Clean the cell. ‘aporation| Repair the salinity alarm. NO (Damage YES, Plug the damaged tubes. No Too high brine level \_yeS _ /Trouble of xo in evaporator shell? ejector? Trouble of YES ejector pump NO Nozzle YES [As operated in port or at ( clogged? > Clean the mouth of river, feed water NO ; nozzle. is excessively contaminated. Erosion of \__YES dittuser? Renew the 7 = diffuser. a ‘Stop the plant. Back pressure of ejector outlet more than 10 M -23-: Repair the NO leak's part [Feoubie of poms | Trouble of electric motor. YES No a Repair the 7 electric Pump seizes. motor. Suction pipe or \¥ES strainer clogged cleaning Repair the pump NO YES Cimpelter clogged? )-9f cleaning NO Motor rotating direction is wrong. : ‘ 3 zie Sucking air.) No 0 Repair the a The first, discharge leak's part. water but soon ceases to discharge [oo low water? rotating speed? ‘Check the electric source NO —24- discharge pressure YES Correct pi piping Sucking aie? p—"=2>—y Repair the No leak’s part. B | |Casing ring is worn? Renew the b casing ring.| [ Erosion of impeller? | t i Renew the i impeller. 17 ‘Sucking air ‘through stuffing box.. ad ‘Check sealing pipe. Adjust gland packing or mechanical seal. —25-YES Motor overloaded? Abnormal metal NO contact exisits Bearings YES in the rotating overheated? ‘Connection is\_yEs parts? wrong. l i) Correct YES vo 4 xo the Remove Vibration takes center. contact. [| place. Bearingsare\ yes ves _/ Connection is weong? 1 wrong. Renew the }— Impeller balance NO bearings. Correct No is wrong. Shait is YES the center. Ge v [~ Bearing assembly xo Renew the yes _/Packing is too is wrong. shaft. }— Connecting is increased. Loosen gland or o wrong. otherwise renew packing. }— Shaft is beat. Bearings are wrong. Renew the bearings. |~ installation is wrong. acings are worn. |— Foundation is weak. L_ Other vibration is transmitted. —26- Check up whether excessive wear exists or impeller balance holes are clogged, and reassemble if necessary. i18 Maintenance list Part To be checked Work Interval £./2./2 s| Eflzs|ée €| $3/8812$ 5] e2|e2/E3 & aeivs|te B| B8l2s/es 2 | oclgsles &| aslaslas Heat Seale Check the scale formations exchanger | formations inside the tubes. inside the If scale is formed, ° tubes clean (descale) according l to the instruction manual. Leakages Pressure test outside the tubes as stated in ° the instruction manual. Evaporator | Defects on Check for damage to shell the coating surface and take ° coating @ proper step according to the instruction manual. Defects of ‘Check the damage and ° deflector repair if necessary. Condenser Scale The condenser covers: formations are removed and the inside the tubes are inspected ° tubes for scale formations possibly the tubes are cleaned. -27-Part To be checked Work Interval 2,/2./2 2 | ssegies 5 | e2/esles E | mslweslSs =| 28lesles & | dslasjas Condenser Corrosion of Check for corrosion the tube ends | and repair if necessary. Corrosion of | Check for damage and the tube corrosion, and repair plates if necessary. Conditions of Check for fitting corrosion conditions and degree plate of wear and replace if necessary. Defects on the | Check for damage to coating inside | coating surface and take of cover a proper step according to the instruction manual. Water Wear scale Nozzle and diffuser are ejector formations checked and cleaned. Worn out nozzle and diffuser is replaced. Strainer Impurities Cleaning tor water meter -28-19 Pact To be checked Work Interval a| 58/83/88 5 | €2/23)&2 E | msleslSs 2 | 28l2sles a) aslaslas Non-return Scale Cover is removed, valves formations housing and.non-return ° mobility of valve are controlled and flap cleaned. Strainers Impurities Filter screen are taken in front of out and cleaned. ° feed water orifice Feed water | Impurities Cleaning ° orifice Air vent Obstruction Cleaning valve for . condenser cover Gland Wear Check condition of packing, packing and leakage and S cepair if necessary. Impeller | Wear Check the condition of casing | corrosion wear down and corrosion. 2 ir ° § | cine a © | shate 3 £ | steeve Bearing | Insufficiency Infuse the grease ° case . -29-Part To be checked Work Interval | 2 lz |é 2| s§sejes = 3 s | €2)es\c2 € | asles|is 2] 2slesies a | dsldslais Gland Wear ‘Check condition of pack- packing ing and leakage and repair ° if necessary. 5 & | Impeller | Wear ‘Check the condition of = | casing | Corrosion wear down and corrosion. = | cing ° & |. sMechani- cal Seal Salinity Impurities Clean with care not to ° | cell injure the element. eI Contra! {| Adjust Adjust the indication and 3 | panel alarm according to the ° instruction manual. Note: * ies wd: o3e For cleaning interval for descaling, refer to the instruction manual. The degree of wear of the corrosion-proof plate varies with the properties of sea water and other conditions. Therefore, change inspecting intervals properly, making good use of experience gained in the ship. When the material of the ejector pump impeller is PBC/ALBC, the impeller will wear out as time goes by and its surface will be damaged. Please note that this is enevitable due to high speed revolution. (SUS impeller will also wear out, but its speed is lower than that of the above impeller.) -30-9. OPERATION BY STEAM (IN CASE THAT STEAM INJECTOR INSTALLED) Distillation can be achieved also by steam instead of jacket cooling water. For operation with steam, a built-in steam injector is to be used. 9-1. OPERATION SEQUENCE ‘The vacuum in the shell should be more than 70 cmHg-V. Feed water should be supplied in normal condition and always at a pressure within the range of green mark on the feed water pressure gauge. “Before starting operation as mentioned below, see if sufficient cooling sea water is being supplied to the condenser. (1) Close the inlet and outlet valves of jacket cooling water completely, and open the valves in the jacket water outlet line (for drainging jacket cooling water). As it is not contain various kinds of unticorrosive chemicals, drainage of such cooling water should be accelerated by opening the air vent cock. (2) After blowing jacket cooling water, shut the jacket water outlet and then supply fresh water usable for boiler to the heater (shell side), pipings and the steam injector. When they are competely filled with water, which can be ascertained by opening the air vent cock, close the fresh water inlet valve (for filling fresh water). (3) The cock at the top of the drain pipe shall be always opened because it serves as a syphone breaker. (A syphone breaker is unnecessary when a drain tank is installed on the higher location than F.W.Generator or on the same floor.) (4) After the above mentioned preparation, open the steam valve before the steam i jector gradually in order to let steam in. Fresh water in the piping is circulated as well as heated by steam. As heating fresh water is cooled in the heater, steam drain goes up through the drain pipe and then it is exhaused into ‘the drain tank. 9-2. CAUTION (1) Fill the heater (shell side) and the pipes with fresh water. If there is air inside the shell, the packing for the heater may be damaged by abnormal rise in temperature. Such air will also cause abnormal noise or vibration due the cabitation or pulsating movement of inside water. =31-(2) Do not open the steam valve rapidly. If so, water in the shell will pour into the drain tank and cause vibration. (3) If steam pressure is lower than the designed value, inside water will pulsate and cause abnormal noise and vibration. REMARKS ON THE INSTALLATION OF THE STAM INJECTOR (1) If the back pressure is exerted to the discharge line of the steam drain of the steam injector, extraordinary vibration’ may occur in the-injector and there is a possiblity that the operation of the system may become impossible. As the limit of this back pressure varies in accordance with the supplied steam pressure, piping must be carried out referring to the following criteria. Supplied steam pressure Back pressure 3.0 kg/em2G ( 0.294MPa ) Max. 3 mAq 4.0 (.0.392MPa} 4 5.0 (0,49 Mpa) 5 | 6.0 (0.588 Mpa) 6 { 7.0 (O.686MP ) 7 i 8.0 (0.784MPa) 8 i 9.0 ( 0,862MPa) 9 | 10.0 (0,96 mPa) 10 (2) If the supplied steam pressure is lower than the designed pressure, the same vibration may be caused to the system. The flucturation from the designed value must be within about + 5%. (3) The heating drain outlet pipe of the steam drain discharge is necessary only when the drain tank is located lower than the installation position of the distilling plant. The height of this heating drain outlet pipe is min. 1800 mm from the base surface of the plant. (4) Valves must not be contained in the discharge line of the steam drain. This is because the fact that the valves are located in the drain line and the operation is carried out with the valves closed, the steam pressure is exerted to the shell side of the heater of the Fresh Water Generator.21 20. HANDILING OF MECHANICAL SEAL FOR DISTILLATE PUMP Since a mechanical seal is a precision component of rotating - ‘equignents, ik should be handled with utmost care. Also an “ equiment to which the seal is installed shall be carefully prepared so that the seal efficiently performs. Followings are part names‘ of ‘the seal, its handling procedure and notices on maintenance of equipments. You are requested to read them carefully for proper handling. . 4 1. :Part Name of Mechanical seal No. Name 2 S 1 Cup Gasket 2 Mating Ring 3 Seal Ring 4 Case 5 Packing 6 Drive Ring a Coil spring 8 ‘Spring Holder BeBe —33-i ——— ___ aun vas wagany aovains 4yrwas aovs w%s . “yW YATA.peaaam sy;OTS azA:e9ez OY] UReTO ‘aDey Twas B43 UO PEyoeggE By x999Uu UBFoxos x0 A3z7p S} BOUZ Tees 943 Fx (S) “uoFIUTTeI SUT aya z09ze SUTy SuyzeK O43 FO USWUB;TeSTU ou aq PINoYs exOUL (¥) suoPaeTTeasUy 9y3 709Fe Buysnoy 943 09 ATIYSTI peaatz ang payooTzop oq JOU pTnoys yaxskH dno aus (c) : suoFaeTTeIaSUT BAz309T59 pue sea xoz popuaumiosex st Too] uOTIeTTeISUT UW (Z) suotguTTegeut Asva x03 vaxe oTaeT -Te3sUy Vy} JO VoUZANS ay; UO ZeqNM Gand epTACrd (T) Buysnon oF ( = FUTY SuTIeH puy qexseg dno) Buyy AxeuoyzwaSs JO UOTFIVTTRISUT Cf ‘ON touo mou e Yat Buyxedq 943 voetder ‘os Fr "3324s yy UO ¥No sunz yenay3 x0 TwTpex sexe Buyzeeq 94yq FF XO94D (C) sBuyxoed 943 pue 3aX8v6 dno 94; Jo vorzans By} Uo Bq PTNoYs sxa;;eW UBpexosy x0 sxeDS ON (Z)° : systuyg pue adeys ‘azts pazynbax uy Atq0exe sy : PETTURSUT By Tes Jy BAdYM woe sy) 3eyI WITZUOD (T} quaudtnba 30 uoyzoadsur © z ‘ON *yaoTs uveTo @ YaTA WeYa sAoUDT ‘ue 31 ‘Buyyoed oy3 x0 Jaxseb dno ayy JO aovzans BuyTeas ay; uo astxa sa9qqeu uByeI0y AUD zy 994d (Fr) *2u0 MOU B Y3TH 37 vovtder ‘eouewxoyxed sz] obewep ptnom yoTYR Buyddyyo 20 Your Bey sous Teas ayy JUBAe yz UT (C) ToyooTe 20 (NH) VOIeX TAWA ‘TFUIAN YAaTA peqaeM “UROTD 9JOS YaTA 9ovF OY UvaTS "Aue Zr‘ 9dRz | [89s yz UO ABTxXO Braz;eU UGFex0y Aue JT X99UD (z) “TFRE ANOUITA S{UauOdUOD T{e ervdazd 03 vINs BxVH (T) [was TeoTUVYDIN Fo UOTZ0edsUT T ‘ON [was TwoTueyoaN Jo BInpsooIg UOTITTVISUT z —34—SHEET _ ‘PewxyzUOD sf uoTaTPUCD TeuIOU ay T8ATT uoyzvrado 34x 42033 “:uoT]TPUCD TeuroUGe zo abexe9T Aue ef 233y3 FT yoayo 07 spuey Aq azeys ayy 2avz0u (S *pearaqzuord ATIOFIIS |q plMoys buyuuns Arq (¥) seBexeay Ou suy Teas TeoTURYOSW oy; avWG WxTFUCO 03 xoq BuyyINgs B43 03 sanssezd prnbyT apyaoza (C spabuezae Atxadozd by PTNbyT vopaetnoryo roy Buydyd ayy aeuy wxysuod (z, ” + Ayaoar709 POTTERSUT SF Teas TeoTUBYSAW BI F¥ya WTZUOD (T voraezedo 9 ‘ON *patteasuy Atzedozd aze xeptoy Buyzds ayy pue Buyxde TFOo 84a avy WxFFUCD (1) -35— xeT{aduz pur xaptoy Buyzds *Buyzds Tyoo zo voyIeTTeISUL ¢ ‘ON +Suyy Suyaey ayy 03 s3o"qQUCD Buy [wes ayy Tyaun azeYs O49 TVA HUTA ‘buyaezor ayy BPTTS (S razeys 9u9 qsuyebe Buydumq fq 99vz Twas 84a sBeuep oF Qou paTTejeuy ATINyoxeo vq prnoys Buys Buyayegor aus (br) suoTa eT Tea SUT 8U3 799z¥ p29z036T7p aq JOU PTNoYs ‘Buyxoed VuL (C) SuOTaeTTEIBUT’ BAFRO3TZe PUT Aewa 303 papuammosat sy TOO] UOFIVITeISUT SUL (Zz) suopaeT Tea oUy Asve TOF vere vOTIeT -Teasuy 9A JO eoRFING yz Uo 39zeM vInd ePTAoId (T . ageys 243 Teno (BuTU aatza ‘a5ed ‘Buyyows “Buy Twas) Buyy Buyaegou zo woTAeTTeISUT ‘ON a a onicinat”SCALE INHIBITOR FOR FRESH WATER GENERATOR SASABIT SASABIT is developed as a scale inhibitor of poly carboxylic acid for the use of fresh water generators. Mechanism of scale inhibitor is to ‘prevent scale deposits by dispersing scale formation as well as delaying reaction and to prevent this scale from adhering to the heat transfer surfaces, in general this is called "Threshold Effect". SASABIT increases threshold effect more than usual scale inhibitor, so as that its performance of preventing scale formation is much improved. SASABIT prevents scale formation of calcium carbonate and magnesium hydroxide which is produced by heating and enriching sea water by pouring into feed water. SASABIT ensures stable fresh water production without long~ time cleaning. Typical Physical Properties Main components : Poly carboxylic acid aqueous | macromolecule Appearance Red brown liquid Specific gravity: 1.25 ( at 25°C ) 70 cps { at 25°C ) 2.1 ( 1% solution ) Viscosity PH Dosage Dosage is based on the standard of 10 cc per produced water 1 ton in case of submerged tube type distilling plant whose brine densities lower than 1.5 . SASABIT is fed continuously to the evaporator inlet line by means of electromagnetic pump or vacuum injection system. Please refer to the attached "SASABIT injection manual" for detailed injection method.Nvave _ vavsO 2 Nave vaso LevZ-SLb(90)XV43IAL pSSt-12(90) TAL BBlE-EzS XT vElz-ELy (90) TaL ~—QUTOD URLN39 J1NN3S VUNHVSYS “QIT"09 SNINSINISNA VUNHYSYS wee BREE ep engin Le Rith UXA NCH LOL HRM LS “ : “esate YY SG ‘ uvamonasiovavo — MQLAQIGE “AVE EBOISzaEENY (4751073 AKG TONS 07 SAE GA GUE SY “LUM OBB %'ION C'B +1 eee cee ce cena UY GAMES 4 UU 1 ENG SUMOACALMUT CLS “% OS sy oy SE OF sz’ oz si Gt Hien SIY _ (agind/99)@/0118/99pR0'O “WRC RM *t 001 06 OB OL 09 OS OF Oe OZ % ION EB EY ECA. EEA ce yas pue ydes6 ay} 0} Gulpiooce sayoujs yo Jaquinu ayy XIy | oF ‘dn yt ANS PUB JBJEM YSaly YIM YEW 3 GZ 0} dn jy pue UR} O} LIGYSVS 40 @ SZO'2 snod S40°% = €80'0X SZ “9.SZ S| ue) yeoIWaYo Jo Ayoedeo uaYyM UOINIOS %']OA E'g BYEW 0} : BIdWEXd UB} J2OIWAYO 0} UOI|N|OS ayy Try aa} pue yde6 0} Guipioo0e Ajisuap uoNNjOs Bly asoOYD Z oor “a0N1S/99 pBO'O SI dwnd jo Ajoedeg 4 poyjaw uoysalul dwnd ajaubewos9a/y SFY EID! HR UOL | BHR HY CALA, TIIMOOUd UILVM 40 NOL 1 Hdd O38 SI LIVSYS 40 990) Hees YENCAAA QOHLIIN NOLLOIPNI TWOHNSHD LIGVSYS os 09 on (unmexons) Be-oie sayous jo JequNN \—| og -37- 23Precautions on handling Stock should not be, exposed to thé direct rays of sun and kept in the place where the temperature is under 50 °c. Do not worry if SASABIT spills on the skin, please wash in water. If SASABIT comes into the eyes, Please rinse out and see a doctor. When SASABIT spills on the floor or the equipment, wash.or wipe up by cloths. Packaging 20 kg polyethylene tank 60 kg polyethylene tank 220 kg iron drum inside polyethylene coating or polyethylene tankWONG 401271 SS FRESH WATER GENERATOR SECTIONAL ARRANGEMENT TO WATER EJECTOR + = Feeb WAIgR bRE—HEATER) ‘CONDENSER’ JACKET COOLING / ‘WATER OUTLET. JACKET COOLING. ‘WATER INLET Part WATERIAL no. | NAME OF PART Focanarion Barba, COmnC 1 | Tor cover STEEL _|$5400 PORE EPO 2_ | EvaPORATOR SwELL | STEEL | S8400] NEOPRENE 3] verector FREESE | ra a 4 | CONDENSER SHELL |STAINLESS STEEL BUS30- S| COND, TUBE SHEET | NAVAL BRASS @ | COoUNG TUBE _[ALUWINUW BRASS| ~ 7_|COND, WATER CHAMBER] CAST IRON URE EPOXY| @_|_AEATER SHELL STEEL [3 | HEATING TUBE [ALUMINUM BRass| +s 10_| HEATER TUBE SHEET | NAVAL BRASS 11 | BOFTOm COVER STEEL [58400 | NEOPRENE 12 | _ BAFFLE PLATE STEEL [38400 13 FORROSION PLATE/BAR| ZINC OR IRON [20/Fe L MESH SEPARATOR _| STAINLESS STEEL SUS304 ieee le SASAKURA ENGINEERING CO.,LTD. el —39-Ria C2 2 110) (520)(305) (301 158) PHENO 10078 BRON FRESH WATER GENERATOR : [DISTILLATE PUMP] 124 | IMPELLER WASHER [STAINLESS STEEL BUS3O: 158 COUPLING SET SCREW Cr=Mo STEEL_BOMA3: 301 COUPLING cASTIRON _|FC200 (03) (001 raat WATERAL Jovan] PART] WATERTAL Journ] No. | NAME OF PART NOMINATION Byveoy-TITY} NG. eacuae NOMINATION _Bymsou-TITY| Dor) CASS CASTIRON [F200] 1_|[ 305] CUPREREETROT[-eowceo Steet |55400|3 SET] 003] _MPELLER | PHOS. BRONZE | PEC2| 1 [404] PUMPFRAE | _CASTIRON [FC200| 1 20-1 CASING RING eronze | acs | 1 20-4 CASING RING BRONZE Bc3 | 1 |[520] MECHANICAL SEAL | EAS60-25(SP)| -_ [1 SET Ti] sharT____[Stanuess sree fusca) 1 TOS] wPELLER KEY [STAINLESS STEEL Puseaod 1 10] RING museer | ne | 1 120 | _wPELLER nT [STAINLESS STEEL BuSSod 1 1 1 1 SASAKURA ENGINEERING CO.,LTD. —4D-337 8% ware | .wa78x | Konus waa] weeveor | set 2 3 m Es > aatino | aarm fastino | sai omgvau aunssaug| ustan 3univuaawai|aunivusanal walva aunssaua “a1Ni| “ssaug auras | astovavo | UaivM uaive ¥3S Ons 1003, ON 11009" 43x3vr| Ausariza | woidara| waivm | wanovA saway awag "1810 waive) “osss | “Sans FFSRRIETES! waswaonos warvan | tans fawiuprval: ‘ON TH "ON GaN w BdAL GuvAd INS SAVN JIMS, i3aHs vivo HOLVUSN3O WSLVM HS3HS VENNVSVS 41 26SASAKURA ENGINEERING CO.,LTD. 6-45 Takeshima 4-Chome, Nishiyodogawa-ku, OSAKA JAPAN MAKER’ S CERTIFICATE No, C-95027 Date. February 23rd 1995 Sasakura Engineering Co., Ltd. Onoda Works. Ohama Onoda City Yamaguchi Pref. Japan Customer : Daewoo Shipbuilding & Heavy Machinery Ltd. Intended : Ship No. 1094 Job No. : 014-7455 This is to certify that the SASAKURA FRESH WATER GENERATOR (MODEL :KE25) have been inspected, tested in accordance with specification and the maker's standard. INSPECTION & TEST RESULTS 1st Hydrostatic test Evaporator shell. Cover of Condenser... 2nd Hydrostatic test Condenser Shell .. soorereseee 1.5) Heat Exchanger She] 1... Final inspection Dimension and Appearance inspection — Air Leak test after assembly... 0.6 Conditions of Fittings & Accessories——— Conditions of Spares & Tools. Z- c Qo. [Fact Manager of Inspection & Testing Section. Inspéctor of SASAKURA ENG.CO..LTD- Pa— TEST RECORD OF puscror pump FoR: DAEWOO S.1094 SASAKURA ENGINEERING lospacted by co., LTD. nw te | [O0HC-B.M 15 kW |Freaveney | 60) Ha Sevoets | G0 Th 440 V c. [Total heod | m A TALYO esis 3500 rom 3460 roa" | GT109a es ( Taran ad 7 aa a : ‘eon eight ttciner +l tne pa bate | Secon rod al cone SL meando | gy [eT ato ly | n w [x T_T O01 8.0 1 ee 6.731 0 z To] 4A 67.0 bed 5.48 * 180 11:02/49.5) ae Se aaa toe x : ates : 1471619 | =] P1194 T8480 [35.07 30 8 28°5 4.291604 o i | [ey T o i tame Tom [veneer 1. Consimous runing test wos corred out Sire [ Gad 15 | Seif goviy 10. [eeceama aa Worst PPD 2 pny mea expe sie BVA) 90°Triangular Weir Tank 2 RPM Capacity (mr) Q D} tewoww wachwert wows, ur