INERTGAS GENERATOR
GENERAL INFORMATION
EXAMINED
This plan has been examined and given the status as shown in
the Design Appraisal Document (DAD) number below:
RTS/ETS/14.1294
Date: 18 Dec 2014 Initials: awv
LR001.4.2009
© 2012 Alfa Laval Aalborg Nijmegen B.V.
The information given in this document has been collected for the general convenience of our clients. It has
been based on general data pertaining to construction material properties and working methods known to us
at the time of issue of the document and is therefore subject at any time to change or amendment. The right
to change or amend is hereby expressly reserved. The instructions in this publication only serve as a guide-
line for installation, use and maintenance of the machine mentioned on the cover page of this document.
This publication is to be used for the standard model of the machine of the type given on the cover page.
Thus Alfa Laval Aalborg Nijmegen B.V. cannot be held responsible for any damage resulting from the appli-
cation of this publication to the version actually delivered to you.
This publication has been written with great care. However, Alfa Laval Aalborg Nijmegen B.V. cannot be held
responsible, either for any errors occurring in this publication or for their consequences.
INSTRUCTION MANUAL
7.6.5 Adjustments of the fuel-oil pump delivery 9.5 FREEZING PREVENTION ..... FOUT! BLADWIJZER
pressure .................. Fout! Bladwijzer niet NIET GEDEFINIEERD.
gedefinieerd. 9.6 COATING .................. FOUT! BLADWIJZER NIET
GEDEFINIEERD.
8 TROUBLE SHOOTING ..................... FOUT!
9.7 MAINTENANCE TABLES ..... FOUT! BLADWIJZER
BLADWIJZER NIET GEDEFINIEERD.
NIET GEDEFINIEERD.
8.1 FAILURES ................. FOUT! BLADWIJZER NIET 9.7.1 Before every start ... Fout! Bladwijzer niet
GEDEFINIEERD. gedefinieerd.
8.2 CONSEQUENCES OF FAILURES EXPLANATION 9.7.2 Every 250-hrs ......... Fout! Bladwijzer niet
....... FOUT! BLADWIJZER NIET GEDEFINIEERD. gedefinieerd.
8.3 TROUBLE SHOOTING CHARTS.................. FOUT! 9.7.3 Annually ................. Fout! Bladwijzer niet
BLADWIJZER NIET GEDEFINIEERD. gedefinieerd.
8.3.1 General trouble shooting chart ....... Fout! 9.7.4 After every stop ...... Fout! Bladwijzer niet
Bladwijzer niet gedefinieerd. gedefinieerd.
8.3.2 Consequences of failures trouble shooting 9.8 REPLACING THE PLC BATTERY ............... FOUT!
chart Fout! Bladwijzer niet gedefinieerd. BLADWIJZER NIET GEDEFINIEERD.
9.9 LUBRICATING SCHEDULE .. FOUT! BLADWIJZER
9 MAINTENANCE....... FOUT! BLADWIJZER
NIET GEDEFINIEERD.
NIET GEDEFINIEERD.
10 TEST PROTOCOL ....FOUT! BLADWIJZER
9.1 GENERAL MAINTENANCE INSTRUCTIONS . FOUT! NIET GEDEFINIEERD.
BLADWIJZER NIET GEDEFINIEERD.
9.2 COMBUSTION CHAMBER ... FOUT! BLADWIJZER 11 PROCESS DOCUMENTATION ....... FOUT!
NIET GEDEFINIEERD. BLADWIJZER NIET GEDEFINIEERD.
9.2.1 Draining combustion chamber ........ Fout!
12 DIMENSIONAL DRAWINGS........... FOUT!
Bladwijzer niet gedefinieerd.
BLADWIJZER NIET GEDEFINIEERD.
9.2.2 Rinsing the combustion chamber .... Fout!
Bladwijzer niet gedefinieerd. 13 ELECTRICAL DOCUMENTATION FOUT!
9.3 MAIN BURNER .......... FOUT! BLADWIJZER NIET BLADWIJZER NIET GEDEFINIEERD.
GEDEFINIEERD.
14 DOCUMENTATION .FOUT! BLADWIJZER
9.4 PILOT BURNER .......... FOUT! BLADWIJZER NIET
NIET GEDEFINIEERD.
GEDEFINIEERD.
3. When operating the equipment, do not If ventilation is insufficient this can cause
exceed the rated capacities, speeds, under-pressure (partial vacuum) in the
pressures or temperatures or act room. The result may be that doors cannot
otherwise than laid down in these be opened anymore.
instructions and the sub-contractors
manuals.
4. Do not remove any covers from rotating Do not enter any cargo space and/or
units, such as blowers, fuel pumps, tank before the oxygen content in
blowers etc. while the unit is in operation. these spaces is measured and found
sufficient to guarantee that these
5. At no time the unit should be energised places are not filled with inert gasses
and started in hazardous environments. or other gasses then air!
4. If more than one generator is placed on a 9. Inert gas generator must be installed
ship, each generator must be provided above highest waterline. For more details
with its own fittings, such as shut-off see the flow diagrams in the "Process
valves, filters, reducing valves etc in the documentation". If the generator is placed
various supply and discharge lines. This near or below water level, special ar-
in order to be able to guarantee an inde- rangements for the generator and the wa-
pendent operation of each generator. ter seal are required.
5. No rain or water from the outside may find 10. Seawater pipes must be protected against
its way into the venting and aerating corrosion;
pipes.
11. The temperature of the combustion air
6. The seawater supply pressure should may not be subjected to a sudden strong
remain as constant as possible (+/- 20%). variation. It is recommended to suck in
If big pressure fluctuations in the sea- the combustion air from "inside" the ship.
water are to be expected, it is recom-
mended to fit a dedicated seawater sup- 12. There should be a constant fuel quality
ply pump. and viscosity, this being important for the
fuel air ratio.
6B The sea water supply to the gas genera-
tor must be stopped when a failure in the 13. The compressed air supply may not con-
seawater discharge of the generator oc- tain rests of lubricating oil and must be
curs either by closing an automatic valve free of condense.
(to be fitted in the sea water supply line),
or by stopping the sea water supply 14. All blow-off piping indicated on the draw-
pump. For that purpose an electrical con- ings must be led to the "outside".
tact is made available.
3.2 Commissioning
The fuel oil is a hydrocarbon and the air a mix- The required final pressure of the generator is
ture of mainly 79% nitrogen and 21% oxygen. achieved by a blower installed in front of the
combustion chamber and a pressure control
valve in the inert gas line. This causes an
overpressure inside the combustion chamber
and the gas cooling section. A water seal un-
der the cooling section discharges the water, ratio can be changed by the pressure control
while at the same time maintaining the re- valve (2032).
quired pressure and avoiding the escape of Only the first time after installation the oil
inert gas. regulating valve (2032) has to be adjusted
stepwise. This fuel-regulating valve used has
an adjustable gradient. See the sub-suppliers
5.3 Detailed process description documentation of Maxon (the valve normally
is set by the commissioning engineer of Smit
5.3.1 General and this need be done only once and is com-
The process descriptions and tag numbers plicated; it is advice not to change if not need-
refer to the flow diagrams, which you will find ed)
in the chapter “Process documentation” This means that with the aid of several ad-
justment screws, the right quantity of fuel oil
5.3.2 Combustion air supply can be supplied to the main burner, to match
The combustion air is supplied to the main the combustion airflow at any position of the
burner (2001) by a centrifugal blower or blow- burner gun.
er (2202 or 2222).
The quantity of combustion air to the burner is By applying these kinds of valves a reliable
adjusted via the burner lance. and repeatable adjustment of the O2 content
can be obtained. The capacity will be auto-
The air pressure is monitored by a pressure matically adjusted via a hand wheel or cylin-
transmitter (2011) for ‘pressure too low’ (PIZA- der (option) at the main burner.
8011).
If the fuel-oil/air ratio is not correct over the
I.G. generator is equipped with two combustion whole of the capacity range, then the fuel-
air blowers according the classification re- oil/air ratio can be changed by the pressure
quirements. Both blowers have block valves regulating valve (1071).
(2205 and 2225) at the outlet This change is advised if the O2 content is too
The block valves are equipped with limit high/low over the whole range.
switches for safe operation and protection of If the fuel oil pressure is high, the O2 content
the blowers. The operator will not be able to will be low. If the pressure is low the O2 content
start the generator without having these valves will be high.
in the correct position.
To start the generator, the burner gun has to
5.3.3 Capacity control be in its start position, safeguarded by a limit
The capacity of the inert gas generator can be switch (2001a) and indicated on the mimic
adjusted by the hand wheel on the main burn- panel.
er. With this the burner gun (lance) can be
moved forward and backward in its casing. During inert gas or air production the capacity
The passages of the slots in the atomising must be adjusted in such a way that the deck
ring round the burner head will consequently main pressure can be maintained at the set
get smaller or bigger. value without blowing-off a too great quantity
of gas via the purge/excess gas valve (6021).
Because the supply pressure of the blower is
almost constant, less or more combustion air Note:
will flow through the slots. − After re-adjustment of the capacity during
inert gas production, especially with larger
By means of a linkage, the fuel-regulating changes, the system (pressure and
valve (2032) is coupled to the burner gun. temperatures) may require some time to
stabilise, before the oxygen content is
This results in a simultaneously controlled between the set limits again. Small steps
supply of fuel and of combustion air. are to be advised.
If the fuel-oil/air ratio is not correct over a part − The minimum and maximum capacity
of the capacity range, then the fuel-oil/air positions, the stroke of the burner gun, are
fixed by mechanical stops on the burner
mounting slides. These may never be The tangential impulse flow is created by sup-
changed. plying the air through slots in a ring fitted
around the spray nozzle.
5.3.4 Fuel oil supply
Fuel oil is sucked in and supplied at a con- The optimum gas quality is achieved by:
stant pressure by a fuel oil pump (1012). The - the correct atomization by combustion
fuel oil pump has a built in pressure safety air
relief valve. - The burner cone that concentrates the
heat, resulting in a complete chemical
Prior to starting the ignition, and while the reaction of fuel and air
pump is already running (pre-purge time); all
the fuel oil is pumped back via the overflow An optimal atomisation of the fuel is achieved if
valve (1071). By means of this valve, the oper- the differential pressure over the slots of the
ating pressure of the pump is adjusted as well. atomising ring is minimum 0.1 bar. This means
the difference between the combustion pres-
The fuel oil flows to the nozzle of the main sure (2012) and the pressure inside the com-
burner via two valves (1059, 2040) and a fuel- bustion chamber (= pressure indicator mounted
oil-regulating valve (2032). on controller 8005 in the control panel).
During ignition, a small quantity of fuel oil is At a lower atomising pressure, the quality of
supplied at the set pressure to the pilot burner combustion will grow worse and soot could be
(2101) via two solenoid valves (2103, 2105). formed.
A transmitter (1053) safeguards the fuel oil
pressure (8055). The burner cone is a part of wear and tear.
Therefore this cone must be checked periodi-
5.3.5 Pilot burner cally for damage, (see the chapter “Mainte-
During a certain interval of the ignition se- nance”), and replaced as soon as necessary
quence, the pilot burner is supplied with fuel (see drw P-X00047). The life of the burner
oil at the set pump pressure and instrument cone is strongly influenced by the quality of
air for atomisation and combustion. the fuel oil (DMA, DMB or DMC) and the cor-
rect adjustment of the system (setting of O2
The pilot burner is ignited with the aid of a spark content, above mentioned atomizing pressure,
generated by means of a spark plug. An ignition water pressure, etc). Alfa Laval Aalborg
transformer (2131) is supplying the high voltage Nijmegen B.V. experienced based on this, life
for the spark plug. times of less than 1000 hours and more than
3500 hours. So the correct operation is most
The burning of the flame is monitored by an UV- important.
flame detector (2121), in conjunction with the
flame safeguard relay in the electric system. 5.3.7 Combustion chamber and
scrubbing section
5.3.6 Main burner Main and pilot burners are mounted on the
The main burner (2001) is ignited by the pilot combustion chamber (2301). A cooling-water
burner. The burning of the flame is monitored jacket surrounds the combustion chamber to
by an U.V.-flame detector (2021), together discharge the generated heat as much as
with the flame safeguarding relay in the elec- possible. The cooling water jacket has a spi-
tric system. ral, so the cooling water flows round the com-
bustion chamber wall and an optimum cooling
The fuel oil is atomised in two steps. First a effect is achieved.
spray nozzle disperses the fuel oil. Then it is
subjected to the inside a tangential impulse The hot inert gas flows through the cool-
flow of combustion air, which added to the ing/washing tower, where it is directly cooled
mainly axially orientated impulse flow of the with seawater to a few degrees above sea-
liquid itself, results in an ultra-fine dispersion of water inlet temperature.
the liquid.
At the same time, the sulphur oxides are of the generator a constant and stable pres-
washed out of the inert gas. These sulphur sure can be maintained. The consequence is
oxides are formed during combustion of the a constant combustion air supply, thus a con-
fuel oil, as the fuel oil always contains sulphur. stant oxygen percentage.
The seawater is supplied to the sprayers and The height of the water seal smoothly follows
the combustion chamber jacket via orifices the pressure in the generator. In conjunction
(2314 and 2316), which distribute the cooling with the (optional) pressure control system of
water in the correct quantities. Orifice 2316 the generator a constant and stable pressure
has been adjusted during commissioning to can be maintained. Therefore a constant
meet a water inlet pressure of approx 1.8 combustion air supply and thus a constant
barg. oxygen percentage is obtained.
Note:
The purge valve only controls the deck main
line pressure if the inert gas generator is 4. Other protections which are not part of the
running and delivering inert gas to the tanks. Alfa Laval Aalborg Nijmegen B.V. scope
of supply are:
5.3.13 Deck main pressure control
The deck main pressure is controlled and pro- 7) PV-valves
tected by several protections. - Ship’s tank pressure monitoring system
1. The purge / excess gas vent valve pro- 5. Alfa Laval Aalborg Nijmegen B.V. delivers
tects the tanks against overpressure dur- standard a liquid filled P/V-breaker. In case
ing inerting of the tanks. If the capacity of of vacuum or too high pressure, the liquid
the generator is larger than the capacity in the P/V-valve will break through. This is
of the cargo pumps, a part of the inert gas an absolute emergency action which will
will be blown to the atmosphere. only happen if all other systems or actions
have failed. The liquid level of P/V-breaker
must be checked regularly and must be re-
2. Alfa Laval Aalborg Nijmegen B.V. delivers filled if necessary. Unlike the deck water
a deck main pressure monitoring set seal the P/V-breaker will not be filled
standard with the installation. This set automatically but has a permanent
comprises of two pressure transmitters glycol/water mixture as filling. One has to
(6306, 6304), and a pressure indicator fill up the liquid into the P/V-breaker up to
(6302). the height that the liquid flows out the filling
opening again.
The signal from pressure transmitter
(6306) is used by controller (8008) for the The standard sequence for the safety of the
control of the purge valve during inerting tanks is:
and indicating and recording the deck 1. Pre-alarm at CCRP or ship’s systems.
main pressure at the CCRP. Personnel will act to prevent the alarms
and or the shutdowns.
The signal from the pressure transmitter
also provides a signal for the deck main 2. The low-low alarm from the generator will
pressure alarms (high or low). shutdown the cargo-pumps.
tomatic control keep tension on the CCRP all (7001). This analyser gives a 4 – 20 mA
the time) signal, which corresponds linearly with the
analyser range.
Note:
The ship may have additional safety devices, The output (4 – 20 mA) is supplied to a
but this is outside the scope of supply and recorder (8009) in the cargo control room
responsibility of Alfa Laval Aalborg Nijmegen panel.
B.V..
5.3.15 Fuel to air ratio / oxygen con-
5.3.14 Measurement and safeguarding tent
of the oxygen content The fuel to air ratio, (and with this the oxygen
The oxygen analyser (7001) constantly content of the inert gas produced), has been
measures the oxygen content in the inert gas set over the whole capacity range by means
and will effect an alarm if a set maximum or of the adjustable screws in the fuel oil regulat-
minimum quantity of oxygen is exceeded. ing valve (2032).
The maximum value is fixed by the application This setting is permanent and should not be
of the inert gas (normally about. 4 vol. % O2). changed!
The minimum value protects against under-
stoichiometric combustion (a too high content In case of large changes in air temperature,
of combustibles CO + H2 with the risk of soot), air humidity or quality of the fuel oil, the O2-
normally set at 2 vol. % O2. content becomes too high or too low.
The generator will not stop at an O2 HIGH or In this event, the fuel-oil pressure before the
an O2 LOW alarm condition. A visible and fuel-oil regulating valve (2032) must be in-
audible alarm will occur. If such a failure creased or decreased by means of a pressure
remains for more than 60 seconds, purge control valve (1071) in the fuel-oil return line.
valve (6021) will open; delivery valve (6041)
will close. In case of a re-adjustment take care of the
following:
The inert gas produced will be blown off now
and not discharged to the cargo tanks. This • BE SURE, THAT THE FUEL OIL PUMP
enables the operator to change the adjustment DELIVERY PRESSURE, INDICATED ON
of the equipment and to see the result. THE MANOMETER (1003), DOES NOT
EXCEED A PRESSURE OF 20 bar (g)!
In case of an O2 alarm the O2 content can be This to prevent a back flow of oil in the
changed by supplying either more or less fuel pump via a built-in overflow valve.
oil to the main burner. This has to be controlled • Adjust with small steps, this due to the
manually by the pressure-regulating valve response time of the measuring system.
(1071) in the fuel oil supply line. This can be • In case an excess of fuel is supplied in
necessary e.g. at temperature variations of the proportion to the combustion air (O2-
combustion air. content measured below minimum setting)
or the atomising pressure is too low, the
When the oxygen content in the inert gas risk exists that soot is being formed. Soot
produced is in the correct range the product can foul and damage the equipment. An
can be led to the deck again. indication for this phenomenon is the
flame becoming yellow.
The analyser has to be calibrated regularly, • The fuel pressure on the main burner will
with the aid of a ‘span’ gas (instrument air) not always have the same value for certain
and with the aid of a calibration gas oxygen contents this depends on the fuel
(N2 + 1.5% O2). temperature, the viscosity and the quality
(see technical specifications).
Registration of the oxygen content • The blower takes in a constant volume of
The oxygen content of the inert gas is combustion air at a certain burner position.
constantly measured by an O2 –analyser
Noise level:
Noise produced
by blower*: max. abt 100 dB (A)
Measured at 1m distance (in free field)
4. Starting up the seawater supply: 13. The burner start up sequence is start-
- Open the valves in cooling water sup- ed now:
ply and the discharge lines of the com-
bustion chamber and the water seal. 0 sec. Blower starts running (pre-purge
- Open the valves in the water supply time of 60 seconds).
and the discharge lines of the deck wa- 0 sec. Fuel oil pump starts running.
ter seal (should always be stand-by).
- Start the cooling water supply pump. 60 sec Test UV detectors
- Check pressure: approx 1.8 barg 63 sec Ignition pilot burner.
- Start the deck water seal water supply Solenoid valves (2103, 2105,
pump. 2114) for fuel oil and instrument
air to the pilot burner open; The
5. Open the main fuel oil shut off valve ignition transformer (2131) and the
(1001). spark plug are energised.
70 sec. Ignition transformer de-energised.
6. Check that the fuel oil control valve UV-flame detector (2121) must
(1071), in the oil return line to the tank, is have detected the flame of the
opened. pilot burner, otherwise the genera-
tor shuts down and an alarm is
7. Open isolating valves (1015 and 1005) of given.
the fuel oil pump. Rotate the handle of the 74 sec. Ignition of the main burner.
fuel oil filter (1002) twice. The two valves for fuel to main
burner open (1059 and 2040). The
8. Open the fuel oil shut-off valve (1051) on pilot burner ignites the main burn-
the generator. er.
83 sec. The solenoid valves (2103, 2105,
9. Put the main burner in the starting posi- and 2114) for the fuel oil and the
tion (optional: automatic). If the burner is instrument air to the pilot burner
in the start position this is indicated on the are closed again. The Pilot burner
LCRP, the indicator light turns on. If the extinguishes.
light is blinking this indicates that it is not UV-flame detector (2021) must
in the starting position. have detected the flame of the
main burner, otherwise the gener-
10. Select the production mode ‘INERT GAS ator shuts down and an alarm is
PRODUCTION’. given.
The pressure control system is
11. Check that the deck seal and the P/V now being activated.
breaker are correctly filled. The air pressure inside the gener-
ator must be checked and if nec-
12. If the indication ‘SYSTEM READY TO essary adjusted to the set value of
START’ on the mimic panel lights up, start 0.15 bar (g).
the inert gas generator by pushing the 300 sec. From this moment on, inert gas
START button on the LCRP. If the indica- can be delivered to the tanks, pro-
tion light does not light up consult “Trou- vided that the O2-content is be-
ble shooting”. tween its limits.
14. Check:
- Pressures.
- Temperatures.
- Oxygen content of inert gas produced.
See the test protocol. Re-adjust, if neces-
sary.
15. Adjust the burner capacity with the hand 4. Put production mode selector, into posi-
wheel on the main burner if this is neces- tion ‘AIR PRODUCTION’.
sary (optional: automatic control by deck
pressure) 5. Adjust the main burner into its start ca-
pacity position (limit switch 2001) with its
16. Wait for at least 5 minutes. hand wheel.
17. If the generator operates normally and the 6. If the indication “SYSTEM READY TO
composition of the gas is correct (STAND- START” lights-up then start the generator
BY FOR DELIVERY blinking), then push with the START button. The blower starts
the ‘STAND BY FOR DELIVERY’ on the and the pressure control system is opera-
LCRP (the stand-by lamp starts steady). tive.
18. On the LCRP and the CCRP the indica- If the indication “SYSTEM READY TO
tion ‘STAND BY FOR DELIVERY’ will START” does not lights-up then consult
light up. This means the generator is the additional operation notes.
ready to deliver the inert gas to the tanks.
The necessary charging operations can 7. Check pressures and temperatures.
now be controlled from the Cargo Control
Room Panel. 8. If the generator operates normally then
turn the ‘STAND BY FOR DELIVERY’
19. Push the “START DELIVERY” button(on button on the LCRP
the CCRP)
10. On the LCRP and the CCRP the indica-
20. Provided the O2-content of the inert gas tion ‘STAND BY’ will light up. This means
produced is between the limits set on the the generator is ready to deliver the air to
alarm set points of the oxygen analyser the tanks.
the following will happen.
- The delivery valve (6041) of the gen- 11. Push “start delivery” button (on CCRP).
erator opens. This will have following effect:
- The purge/excess gas vent valve - The delivery valve (6041) of the gen-
(6021) is slowly controlled to the work- erator opens.
ing position. - The purge/excess valve (6021) is slow-
- Check if bleed valve 6051 is closed. ly controlled to its closed position or to
a controlled working position if the
If the required deck main pressure cannot deck main pressure increases.
be obtained then the capacity of the burn-
er has to be increased by the hand wheel
on the burner. 7.4 Switching off
Note:
The correct analyser range is essential for the
delivery valve (6041) to open.
Actions:
10 TEST PROTOCOL
List of documentation:
11 PROCESS DOCUMENTATION
List of documentation:
12 DIMENSIONAL DRAWINGS
List of documentation:
13 ELECTRICAL DOCUMENTATION
List of documentation:
14 DOCUMENTATION
List of documentation:
Supplier Description
01. Alfa Laval Aalborg Nijme- - Mounting instructions doc. Nr. 65010A051R04
gen B.V.
02. Alfa Laval Aalborg Nijme- - Operation Guidelines doc. Nr. 65010A054R02
gen B.V.
04. Besta - Besta level switches mounting and service instructions (APR 76)
06. Endress & Hauser - Operating Instructions FMD76 Differential pressure transmitter
(software version 02.11.zz)
14. Rotodyne - Operating instructions for fan centrifugal type (rev. 01)