Alfalaval JWSP-26-C100 User manual

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tr^vT^t
InstructionManual
forFreshwaterGenerator
TypeJWSP-26-C100
SerialNo.:
Shipname/
HullNo.:
Customer:
N-010770
JLZ020504
JinLingShipyard
Book Number O26WSE07.fm
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IMO9274654
JLZ-020504
InstructionManual
forFreshwaterGenerator
TypeJWSP-26-C100
SerialNo.:
Shipname/
HullNo.:
Customer:
N-010770
JLZ020504
JinLingShipyard
Book Number O26WSE07.fm
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AlfaLavalreservetherighttomakechangesatanytimewithoutpriornotice.
Anycommentsregardingpossibleerrorsandomissionsorsuggestionsforimprovement
ofthispublicationwouldbegratefullyappreciated.
CopiesofthispublicationcanbeorderedfromyourlocalAlfaLavalcompany.
Publishedby:AlfaLavalDesaltA/S
Maskinvej5
DK-2860Søborg
(Copenhagen)Denmark
©CopyrightAlfaLavalDesalt.
Thisdocumentanditscontentmustnotbecopied,reproduced,transmittedordis-
closedtoanythirdpartywithoutconsentofAlfaLavalDesalt.
O26WSE07.fm
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Table of Contents
SafetyInstructionsandWarnings
1.0.0SafetyInstructionsandWarningspage5
SystemDescription
1.0.0WorkingPrinciplepage7
1.1.0FreshwaterQualitypage7
1.2.0MainComponentspage7
1.3.0AlternativeSteampage8
OperatingInstructions
1.0.0StartingandStoppingProcedurepage9
1.1.0Starting-upthePlantwithJacketCoolingWaterHeatingpage9
1.1.1Evaporationpage9
1.1.2Condensationpage10
1.2.0AdjustmentofJacketWaterFlowpage10
1.3.0AdjustmentofSeaCoolingWaterpage11
1.4.0StoppingthePlantpage11
2.0.0BeforeStartingUpthePlantwithSteamInjectionEquipmentpage12
2.1.0StartingUpthePlantwithSteamInjectionEquipment(AS)page13
2.1.1Evaporationpage13
2.1.2Condensationpage14
2.2.0AdjustmentoftheFreshwaterProductionpage14
2.3.0StoppingthePlantWorkingwithSteamInjectionHeatingpage14
2.4.0ChangingfromSteamInjectionHeatingtoJacketCoolingWaterpage15
2.5.0LongTermStandstillpage16
Maintenance
1.0.0Whyyouneedtoperformregularmaintenanceduties.page17
1.1.0OverhaulIntervalspage17
1.2.0MaintenanceofSeparatorVesselpage18
1.3.0MaintenanceofEvaporatorSectionpage19
1.4.0MaintenanceofCondenserSectionpage20
1.5.0RenewalofPlateHeatExchangerGasketspage22
1.5.1RemovalofOldGasketspage22
1.5.2Cleaningpage22
1.5.3PreparationofNewGasketspage23
1.5.4FittingNewGasketspage23
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TableofContents
ChemicalDosingofScaleControlChemicals
1.0.0PreventionofScalingpage25
1.1.0FeedWaterRatiopage25
1.2.0ChemicalDosagepage25
1.2.1ScaleInhibitorDosageEquipmentforFeedWaterpage26
1.2.2SafetyPrecautionswiththeuseofChemicalspage27
Trouble-Shooting
1.0.0TestSheetpage29
1.1.0TroubleShootingTablepage29
MaintenanceofFreshwaterPump
1.0.0MaintenanceofFreshwaterPumpTypesPVVF1525-1532-2040page33
1.1.0OverhaulofthePumppage33
1.1.1Clearancepage34
1.1.2DismantlingPumpShaftpage34
MaintenanceofEjectorPump
1.0.0MaintenanceofEjectorPumppage37
1.1.0OverhaulofthePumppage37
1.1.1Clearancepage38
1.1.2DismantlingPumpShaftpage40
Salinometer
1.0.0SalinometerTypeDS-20page41
1.1.0TechnicalSpecificationpage41
1.2.0Installation(forDS-20)page41
1.3.0Instructionsforusepage42
1.3.1TestingtheInstrumentpage42
1.3.2AdjustmentofAlarmLevelpage42
1.3.3Maintenancepage43
SpareParts
1.0.0OrderingSparePartspage45
1.1.0AlfaLavalServicepage45
Index
O26WSE07TOC.fm
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Safety Instructions and Warnings
Shouldyouneedfurtherclarificationregardingthismanual,donothesitateto con-
tactyourlocalAlfaLavalrepresentative- orcallAlfaLavalDesaltdirectly;
Telephone+45(forDenmark)39536000
Telefax+45(forDenmark)39536566
1.0.0SafetyInstructionsandWarnings
Thefollowingsymbolsinthismanualpointoutsafetyprecautions.Itmeansyourat-
tentionisneededandyoursafetyisinvolved.
A WARNING
Thissymbolisusedtoindicatethepresenceofa hazardwhichcanorwill
causeseverepersonalinjury,ifthewarningisignored.
O CAUTION
Certainpassagesofthetext will bemarked with acautionmark.Thismark
indicatesthepresenceofhazardwhichwillor can causepropertydamage
iftheinstructionsarenotobserved.
NOTE
Thistypeofinstructionindicatesasituationwhich,ifnot avoided, couldre-
sultindamagetotheequipment.
Itistheowner'sandoperator'sresponsibilitytoseethatanypersoninvolved
withtheuseoroperationofthisequipmentfollowallsafetyinstructions.
ReadallsafetyInstructionscarefullyandinsistthattheywillbefollowedby
thoseworkingwithyou and for you. Not followingtheInstructionsmaycause
severepersonalInjuryordamagetheequipmentbeyondrepair.
Donotallowthisequipmenttobeusedifitisfaultyortheoperatordoesnot
understandtheproperuse.
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SafetyInstructionsandWarnings
A WARNING
Thefreshwatergeneratorisnottobeoperatedinpollutedwaterorwithin
20milesfromthecoast
Freshwatermustnotbeproducedfrompolluted water, astheproducedwatercan
beunsuitableforhumanconsumption.
Ifmanuals are translatedtolocallanguagetheunitcomply with theE€CMachinery
DirectiveandEN292-1/2standards.ForEEClandinstallationsmanualsMUSTbe
availableinlocallanguagebeforeinstallingandoperatingtheunit.
Theunitalsocomply withEN 50081-2and EN 50082-2"Industry" with regardstothe
EMCdirectivefromEEC.
A WARNING
Noisehazards
Useearprotectioninnoisyenvironments.
Crushhazards
Usecorrectliftingtools.
Donotworkunderhanging load.
Burnhazard
•Wearglovestoavoidburnsbyhotsurfaces.
Cuthazards
Wearglovestoavoidcutsbysharpedgeswhenhandliligmachined
parts. "''
Wearhelmet to avoidcutsbysharpedgesduringmaintenanceofthe
equipment.
NOTE
Max.ambienttemperaturefortheequipmentis50°C(122°F).
Min. ambienttemperaturefortheequipmentis0°C(32°F).
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System Description
1.0.0WorkingPrinciple
Thecombinedbrine/airejectordrivenbytheejectorpumpcreatesavacuuminthe
systeminordertolowertheevaporationtemperatureofthefeedwater.
Thefeedwater is introducedintotheevaporator section throughanorifice,andisdis-
tributedintoeverysecondplatechannel(evaporationchannels).
Thehotwaterisdistributedintotheremainingchannels,thustransferringitsheatto
thefeedwaterintheevaporationchannels.
Havingreachedboilingtemperature- whichislower than atatmosphericpressure-
the feed waterundergoes a partial evaporation, and themixtureofgeneratedvapour
andbrineenterstheseparator vessel, wherethebrineisseparatedfromthevapour
andextractedbythecombinedbrine/airejector.
Havingpassedademisterthevapourenterseverysecondplatechannelinthe con-
densersection.
Theseawater suppliedbythe combinedcooling/ejectorwaterpumpdistributesitself
intotheremaining channels, thusabsorbingtheheatbeingtransferred from the con-
densingvapour.
Theproducedfreshwaterisextractedbythefreshwaterpumpand led tothefresh-
watertank.
1.1.0FreshwaterQuality
Tocontinuouslycheckthequalityoftheproducedfreshwater,a salinometerispro-
videdtogetherwithanelectrodeunitfittedonthefreshwaterpumpdeliveryside.
Ifthesalinityoftheproducedfreshwaterexceedsthechosenmaximumvalue,the
dumpvalveandalarmareactivatedtoautomaticallydumptheproducedfreshwater
tothebilge.
Iftherearenospecialrequirementsfromtheauthorities,theproducedfreshwater
canbeuseddirectlyasdrinking water.
1.2.0IVIainComponents
Thefreshwatergeneratorconsistsofthefollowingcomponents:
1. Evaporatorsection
Theevaporatorsectionconsistsofa plateheatexchangerandisenclosedin
theseparatorvessel.
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SystemDescription
2. Separatorvessel
Theseparatorseparatesthebrinefromthevapour.
3. Condensersection
Justliketheevaporatorsectionthecondensersectionconsists of a plateheat
exchangerenclosedintheseparatorvessel.
4. Combinedbrine/airejector
Theejectorextractsbrineand in condensablegases fromthe separatorvessel.
5. Ejectorpump
Normally,theejectorpump is deliveredbyAlfaLaval, and the: ejectorpump is
asingle-stagecentrifugalpump.Thispumpsuppliesthecondenserwith sea
water and thebrine/airejector with jetwateraswellasfeedwater for evapora-
tion.
6.Freshwaterpump
Thefreshwaterpumpis a single-stagecentrifugal pump. Thefreshwaterpump
extracts the
producedfreshwater from thecondenser,andpumps the water to thefreshwa-
tertank.
7. Salinometer
Thesalinometercontinuouslychecksthesalinity of theproduced water. The
alarm set pointisadjustable.
8.Controlpanel
Normally, thecontrolpanelisdeliveredbyAlfa Laval. It containsmotorstarters,
runninglights,salinometer,contacts for remotealarm and isprepared for start/
stop.
1.3.0AlternativeSteam
1. steaminjector
Instead of jacketcoolingwater heating, saturatedlivesteamcanalternatively
beusedasheatingmediumfor the freshwatergenerator. In thesteaminjector
thesteamtransferspartlyheat,partlykineticenergytothecirculating water.
Thecondensateproducedinthiscircuit is transferredtothecondensatewell
through G3.
2. Safetyvalve
Ifthepressureafterthesteaminjectorexceeds 1 bar g thesafetyvalvewill
opentosecurethevessel.
3.Steamquality
Thesteamsuppliedtothesteaminjectormust be saturatedsteam.
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Operating Instructions
WARNING
A DONOToperatetheplantinpolluted
water.
Freshwatermustnot be producedfrompolluted water, as theproducedwater will be
unsuitableforhumanconsumption.
1.0.0StartingandStoppingProcedure
O CAUTION
Beforestarting up pleaseobserveinstructionsforfeedwatertreatment,see
"Chemicaldosingofscalecontrolchemicals".
PleaserefertoPl-diagram(see"FWGOrderSpecification").
1.1.0Starting-upthePlantwithJacketCoolingWaterHeating
1. Openvalves on thesuctionanddischargeside ofthe ejectorpump PU-SC-01.
2. Openoverboardvalveforcombinedbrine/airejector.
3.Closeairscrew VA-E1-01 ontheseparator.
4. StartejectorpumpPU-SC-01tocreateavacuumofmin.90%.
Pressureatcombinedbrine/airejectorinletminimum300kPa
(3.0kp/cm2).
Backpressureatcombinedbrine/airejectoroutletmaximum60kPa
(0.6kp/cm2).
1.1.1Evaporation
Whenthereisa minimumof 90% vacuum(aftermaximum10minutes),
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OperatingInstructions
O CAUTION
Tosecurethattheboilerwater and thejacketwaterdonotmixthetwobut-
terflyvalves inthe steaminjectorcircuitmustbeclosed.
5.Closethetwobutterflyvalvesinthesteaminjectorcircuit.
6.Openvalve for feedwatertreatment, if any.
7.Openhotwaterinletandoutletvalves.
8.Starthotwatersupplytodistiller by adjustingbypassvalvestep-wise 10°C,
untilthedesiredjacketwatertemperature is reached.
Theboilingtemperature now rises, while the obtainedvacuumdrops toapprox.
85%.
Thisindicatesthatevaporationhasstarted.
1.1.2Condensation
Afterapprox. 3 minutestheboilingtemperaturewilldropagain,andnormal
vacuum is reestablished.
9.Openvalve to freshwatertank.
10. Switchonsalinometer.
11. StartfreshwaterpumpPU-FR-01/PU-FR-02.
NOTE
Thefreshwaterpumppressuremust be between120and160 kPa(1.2
1.6 kp/cm2).
1.2.0Adjustment of JacketWaterFlow
Pleasereferto"FWGOrderSpecification" for specifiedhotwaterflow.
Inorder to obtainthespecifiedflow of hot water, it isnecessarytoadjustthebypass
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OperatingInstructions
.#
valveuntildesiredflowisachieved.
Theflowcanbecalculatedasfollows:
Mjw= Kjw X cap.m3/24h=m3/h
Atjw
Where:
MJW = Flowofhotwaterinonehour.
KJW = Constant=26.67for 1-stage freshwatergenerator
=Constant=15.52for2-stagefreshwatergenerator
At= Differenceintemperatureofhotwaterinandout.
Cap.m3/24h= Freshwaterproductionin24hours,i.e.productionin5
min.times288.
Example:cap. n\^/24h =20m3
Tsw=32°C
Atjw= 6°C
1 -stagefreshwatergenerator
MJW = 26.67 X 20= 89m^/h
6
1.3.0AdjustmentofSeaCoolingWater
Theseacoolingwaterflowiscorrect,whenthepressureattheinletof the combined
brine/airejectorisbetween300and400kPa(3.0- 4.0kp/cm^.).
1.4.0StoppingthePlant
1. Stophotwatersupplytodistiller.
2. Closevalveforfeedwatertreatment,ifany.
3.StopfreshwaterpumpPU-FR-01/PU-FR-02.
4. Switchoffsalinometer.
5.Stopejectorpump PU-SC-01.
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OperatingInstructions
6.Openairscrew VA-E1-01.
7.Closeinletandoutletvalvesforejectorpump.
8.Closeoverboardvalveforcombinedbrine/airejector.
9.Closethevalvetofreshwatertank.
O CAUTION
Allvalvesmustbeshut,whilethegeneratorisoutof operation. Exceptair
screw.
2.0.0BeforeStartingUpthePlantwithSteamInjectionEquipment
A WARNING
Thesteamarrangementmustbefilledwithfreshwaterfromhydrophone
system, beforesteamissuppliedtothesystem.
Whenchangingfromjacketwaterheatingtosteaminjectionheating
1. Closein-andoutletvalvesforjacketcoolingwatersystem(yardsupply)
2. EmptythejacketcoolingwaterbyG4tothebilge
3.OpentheplugatG2.
4. Whenempty:closetheoutletG4
Tofillupthesteaminjectionsystemwithcleanfreshwaterorsteamcondensate.
5.Openthetwobutterflyvalvesinthesteaminjectorcircuit
FitawaterhoseintoG2.
6.
7.
8.
9.
Fill upthe system, withboiler feed wateror cleanfresh water until waterescape
fromballvalveatthesteamcondensateoutletG3.
Thenclosethisvalve.
Dismantlethewaterhose.
12 OpaseOO.fm
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OperatingInstructions
10. ClosetheG2witha plug.
A WARNING
Novalveatallmustbefittedonthepipefromthesafetyvalve(G16)asthis
pipemustbeopentotheatmosphericpressure.
2.1.0StartingUpthePlantwithSteamInjectionEquipment(AS)
1. Openvalvesonthesuctionanddischargesideofthecombinedejector/cool-
ingwaterpump PU-SC-01.
2. Openoverboardvalveforcombinedbrine/airejector EW-ES-01.
3.CloseairscrewVA-E1-01ontheseparator.
4. Startcombinedejector/coolingwaterpumpPU-SC-01tocreateavacuumof
min. 90%.
Pressureatcombinedbrine/airejectorinletminimum300kPa(3.0kp/cm^).
Backpressureatcombinedbrine/airejectoroutletmaximum60kPa(0.6kp/
cm2).
2.1.1Evaporation
5.Openthetwobutterflyvalvesinthesteaminjectorcircuit.
Openvalveforfeedwatertreatment,ifany.
Openthesteaminletvalve(yardsupply)slowly.
Waita fewminutesuntiltheequipmentwillbenoiseless.
6.
7.
8.
9. Continuethesupplyofsteam untilthedesiredinletpressureisreached.Steam
pressuremustbeinaccordancewithpressurestatedin'Technicalspecifica-
tion".
A WARNING
Max.backpressureincondensatedischargelineis80kPa(0.8kp/cm^).
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OperatingInstructions
2.1.2Condensation
10. Openvalvetofreshwatertank.
11. Switchonsalinometer.
12. Startfreshwaterextraction/transferpumpPU-FR-01/PU-FR-02.
13. Readjustthesteamsupplytoreachthefreshwaterproduction.
NOTE
Thefreshwaterpumppressuremustbebetween120and160kPa(1.2
1.6kp/cm2).
2.2.0Adjustmentof the FreshwaterProduction
Thefreshwaterproductioncanberegulatedbyadjustmentofthequantityofsteam
suppliedtothesteaminjector.
Thesteaminletpressurecorrespondingtotheproductionoffreshwaterinquestion
canberegulatedeither by meansof a manuallyoperatedregulatingvalve(yardsup-
ply)orbyanautomaticreductionvalve(yardsupply).
Steampressuremustbeinaccordancewithpressurestatedin"FVVGOrderSpeci-
fication".
A WARNING
Donotopensteaminletvalveforthesteaminjectorbeforetheejector
pump PU-SC-01 has been started and serves feed watertotheevaporator.
2.3.0StoppingthePlantWorkingwithSteamInjectionHeating
1. Closesteaminletvalve(yardsupply).
2. Closevalveforfeedwatertreatment,ifany
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OperatingInstructions
3.stopfreshwaterpumpPU-FR-01/PU-FR-02.
4. Switchoffsalinometer.
5.Stopejectorpump PU-SC-01.
6.OpenairscrewVA-E1 -01.
7.Closeinletandoutletvalvesforejectorpump.
8.Closeoverboardvalveforcombinedbrine/airejector.
9.Closethevalvetofreshwatertank.
O CAUTION
Whenstoppingtheplantalwayscheckthatthesteaminletvalveiscom-
pletelyclosed.
Thistoavoidhightemperatureintheevaporator,asthismightcause:
Scaleformationontheinsideoftheheatexchangerplates.
Damagethegasketsintheheatexchanger.
2.4.0ChangingfromSteamInjectionHeatingtoJacketCoolingWater
1. Closethevalveforsteamsupply(yardsupply).
2. Closethetwobutterflyvalvesforsteaminjectionequipment.
3.OpentheballvalveatthesteamcondensateoutletG3.
4. EmptytheboilerwaterbyG4tothebilge.
5.Whenempty:ClosetheoutletG4.
6.Closetheballvalvementionedabove.
7.Openthevalvesforin-andoutletjacketcoolingwatertotheevaporator(yard
supply).
8.Starthotwatersupplytodistillerbyadjustingbypassvalvestep-wiseuntilthe
desiredjacketwatertemperatureisreached.
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OperatingInstructions
2.5.0LongTermStandstill
Ifthedistillerisoutofoperationforperiodslongerthan14days,pleaseobserve
"Maintenanceofseparatorvessel".
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Maintenance
1.0.0Whyyouneedtoperformregularmaintenanceduties
Regularmaintenanceoftheplantwillimproveperformanceandavailability.
Themaintenancescheduleonthefollowingpageswilltellyouhowoftenservice
shouldbeperformedonthemaincomponents.
As theactualoperatingconditionsof the plantareofmajorinfluence on thelifetime,
theoverhauldatesarenotobligatorybutonlyrecommendedintervals.
Whentheplanthasbeeninoperationfora longer period of time andexperiencehas
beenestablishedastotheactualperformance,it will bepossibletoadaptthemain-
tenanceschedule.
Forserviceonminorcomponentspleaserefertocomponentinstructions.
1.1.0Overhaulintervals
Component
Evaporatorsection
Condenseraction
Separatorvesselwithan-
odes
Combinedejector/cool-
ingwaterpumpwithmo-
tor
Freshwaterextraction
pumpwithmotor
Combinedair/brineejec-
tor
OperatingHours
Asrequired
Asrequired
2000h
8000h
8000h
8000h
Action
Cleanininhibitedacidbath
Cleanwithpurefreshwaterand
brush
Seeseparatorinstructions
Measuresealring and impeller.
Examinemechanicalshaft
seal, coolingwaterpipepas-
sage.
Megger-testelectric motor.
Cleanpumpthoroughlybefore
reassembly.
Seeabove
Measurenozzlesanddiffuser
andcompare to measurements
intechnicalspecification.
Max.wear20%ondiffusercy-
lindricalbore.
MajwpeOO.fm 17
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Maintenance
Component
MV-valves
Demister
iVIanometers
Salinometer
OperatingHours
4000 h
8000 h
8000 h
See"Maintenance
ofsalinometertype
DS-20"
Action
Disassembly and inspect for
damage
Clean in inhibitedacidbath
Adjustwithcontrolmanometer
See"Maintenance of salinome-
tertypeDS-20"
1.2,0Maintenance of SeparatorVessel
Thefrontcover and thepressureplatesfor the heatexchangersections(evaporator
andcondenser) are made of stainlesssteelwithaspecialchemicaltreatment.This
treatment will reestablishnormalsurfaceoxidationafterwork-up atthe factory.The
preparation isa naturalprotectionofthestainlesssteel.
O
CAUTION
TopreservethisnaturalprotectionDONOTscrape or scratchtheinside
surface of thefront cover.
Whenevertheseparatorvessel is opened,
checkthattheanodesarefunctioning.
Iftheanodesarenotfunctioningand/or scarified, replacethem.
NOTE
Iftheunit is stopped fora longerperiodthan14days.
Openfrontcoversandcleanunitinsidewithfreshwater.
Lettheunit dry outcompletely,beforeclosingcovers.
18 MajwpeOO.fm
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IVIaintenance
1.3.0IVIaintenanceofEvaporatorSection
Cleanevaporatorasfollows:^"!^
1. Removeboltsinfront cover, andopen.,,.,
2. Loosenthe
2nutsforP-16distiller
4nutsforP-26distiller
inplatestackgradually,sothatnonutiscarryingtheentireloadalone.
3.Removeplatestack.
NOTE
Ifsomeofthegasketscomelooseonremovingplatestack,pleasesee
section1.5.2^^f'
4. Submergeplatescompletelyina hot,inhibitedacidbathatmaximum 50-C. For
furtherinstructionssee"Chemicaldosingofscalecontrolchemicals".
A WARNING
Alwaysfollowcarefullythesuppliersinstructionswhenusinginhibitedac-
ids.
Remembertoneutralizeaccordingtosuppliersinstructions.
6.
Examineplates and gasketsforpossible damage, andremovedamagedplates
and/orreplacedamagedgaskets.
Ifa defectiveplateis found, removetheplatetogetherwithoneof the adjacent
plates.
MajwpeOO.fm 19
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