IG Plant

INSTRUCTION MANUAL
INERTGAS GENERATOR
GENERAL INFORMATION
Series Gln
ORDER NR.: 072.14.1.9662
© 2008 Aalborg Industries Inert Gas Systems B.V.
All rights reserved.

No part of this publication may be copied or published by means of printing, photocopying, microfilm or oth-
erwise without prior written consent of Aalborg Industries Inert Gas Systems .This restriction also applies to
the corresponding drawings and diagrams.
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 Aalborg Industries Inert Gas Systems B.V. cannot be held responsible for any damage resulting from
the application of this publication to the version actually delivered to you.
This publication has been written with great care. However, Aalborg Industries Inert Gas Systems B.V. cannot
be held responsible, either for any errors occurring in this publication or for their consequences.
Aalborg Industries Inert Gas Systems BV Page 2 of 46

ORDER NR.: 072.14.1.9662
INSTRUCTION MANUAL
INERTGAS GENERATOR Series Gln
Type: Gln 2000 – 6 BUCD
Order number: 072.14.1.9662 .............................................................................
Manufacturing number: 07962 ..........................................................................................
Year of construction: 2009 ............................................................................................
Customer: LGE-Process / H.M.D. .................................................................
Ref. Customer: 06052-BB-QA-001 .......................................................................
Yard number: Hull 8010

ORDER NR.: 072.14.1.9662
TABLE OF CONTENTS 7.4.2 Inert gas production.............................. 23

7.5 SWITCHING OFF .............................................. 24
7.5.1 After wet inert gas or air production .... 24
1 GENERAL INFORMATION ....................... 5 7.6 ADDITIONAL OPERATION NOTES ..................... 25
1.1 SCOPE............................................................... 5 7.6.2 Check during operation ........................ 25
1.2 LIABILITY ......................................................... 5 7.6.3 Atomising pressure on main burner ...... 26
1.3 GUARANTEE ..................................................... 5 7.6.4 Fuel-air ratio/oxygen ............................ 26
7.6.5 Generator delivery pressure ................. 27
2 SAFETY ......................................................... 6 7.6.6 Pilot Burner .......................................... 27
2.1 GENERAL SAFETY INSTRUCTIONS ..................... 6 7.6.7 Fuel oil pump delivery pressure............ 27
2.2 SAFETY INSTRUCTIONS FOR OPERATING & 7.6.8 Compressor unit .................................... 27
MAINTENANCE .................................................. 7 8 TROUBLE SHOOTING ............................. 28
3 INSTALLATION ........................................... 8 8.1 FAILURES ....................................................... 28
3.1 INSTALLATION INSTRUCTIONS........................... 8 8.2 CONSEQUENCES OF FAILURES......................... 28
8.3 TROUBLE SHOOTING CHARTS......................... 29
4 STORAGE INSTRUCTIONS..................... 10 8.3.1 General trouble shooting chart ............. 29
4.1 GENERAL STORAGE INSTRUCTIONS ................. 10 8.3.2 Trouble shooting chart ig generator ..... 29
4.2 STORAGE INSTRUCTIONS FOR THE 8.3.3 Trouble shooting chart Compressor unit
CONSTRUCTION PERIOD .................................. 10 .............................................................. 34
5 TECHNICAL DESCRIPTION................... 11 9 MAINTENANCE ........................................ 35
5.1 PROCESS DESCRIPTION ................................... 11 9.1 GENERAL MAINTENANCE INSTRUCTIONS ........ 35

5.1.1 Combustion System ............................... 11 9.1.1 Rinsing the combustion chamber .......... 35
5.2 DETAILED PROCESS DESCRIPTION ................... 12 9.2 MAIN BURNER ................................................ 35
5.2.1 Introduction........................................... 12 9.3 PILOT BURNER ................................................ 35
5.2.2 Combustion air supply .......................... 12 9.4 DRYER ........................................................... 36
5.2.3 Fuel oil supply....................................... 12 9.4.1 Replacing the desiccant in dryer (5002/3)
5.2.4 Pilot burner ........................................... 12 or the carbon in filter 5700: ................. 36
5.2.5 Main burner .......................................... 12 9.5 FREEZING PREVENTION .................................. 36
5.2.6 Combustion chamber and scrubbing 9.5.1 Generator unit....................................... 36
Tower .................................................... 13 9.5.2 Screw compressor ................................. 36
5.2.7 Water seal ............................................. 13 9.5.3 Dryer unit.............................................. 36
5.2.8 Knock-Out drum .................................... 13 9.5.4 General ................................................. 36
5.2.9 Compressor unit .................................... 14 9.6 MAINTENANCE TABLES .................................. 37
5.2.10 Filtration (liquid) .................................. 15 9.6.1 Before every start .................................. 37
5.2.11 Dryer unit .............................................. 16 9.6.2 Every 250-hrs........................................ 37
5.2.12 Filtration (dust/ oil vapour) .................. 17 9.6.3 Annually or 500-1000 hrs ..................... 38
5.2.13 The oxygen content................................ 17 9.6.4 After every stop ..................................... 38
9.7 REPLACING THE PLC BATTERY ...................... 39
6 TECHNICAL SPECIFICATION ............... 19 9.8 LUBRICATING SCHEDULE ................................ 39
6.1 DESIGN BASIS ................................................. 19 9.8.1 Lubricating table................................... 40
6.2 INERT GAS SPECIFICATION .............................. 19 10 TEST PROTOCOL ..................................... 41
6.3 UTILITIES ........................................................ 19
6.4 MATERIALS .................................................... 20 11 PROCESS DOCUMENTATION ............... 42
6.5 COATING SYSTEM ........................................... 20
7 OPERATING INSTRUCTIONS ................ 21 12 DIMENSIONAL DRAWINGS ................... 43
7.1 GENERAL........................................................ 21 13 ELECTRICAL DOCUMENTATION ....... 44

7.2 OPERATION PANELS ........................................ 21
7.3 GENERAL SWITCHES ....................................... 22 14 SUB-SUPPLIERS DOCUMENTATION .. 45
7.3.1 Local control panel 2 ............................ 22
7.3.2 Compressor panels 13 ........................... 22
7.3.3 Other control panels ............................. 22
7.4 SWITCHING ON ................................................ 23
7.4.1 Production modes ................................. 23

ORDER NR.: 072.14.1.9662
1 GENERAL INFORMATION 1.3 Guarantee

The guarantee conditions that are stated in the
1.1 Scope 'General conditions of Sale and Delivery of Aal-
This manual contains information for the borg Industries Inert Gas Systems B.V. are ap-
proper functioning and maintenance of the plicable to this product. The guarantee will be-
inert gas generator. It also contains important come null and void if:
instructions to prevent accidents and serious - service and maintenance are not carried
damage prior to and during operation of the out strictly in accordance with the instruc-
inert gas generator. tions given,
- repair work is not carried out by author-
Read this manual carefully before using the ised personnel or has been performed
inert gas generator, familiarise yourself with without prior written consent;
the functioning and operation of the inert gas - the equipment has been modified without
generator and strictly observe the instructions prior written consent;
given. - non-original parts are used;
- the equipment is used incorrectly or not in
If you have any questions or need more de- accordance with its intended use.
tails on specific aspects relating to the inert
gas generator, please contact:
Aalborg Industries Inert Gas Sys-

tems B.V.
St. Hubertusstraat 10
6531 LB Nijmegen
The Netherlands
P.O. Box 6664

6503 GD Nijmegen
The Netherlands
Tel.: +31 24 35 23 200

Fax: +31 24 35 23 177
E-mail: inertgas.aftersales@aalborg-
industries.com
1.2 Liability
The data published in this manual are based
on the latest information available. They are
subject to future modification.
We reserve the right to change the construction

and/or design of the product, without being
obliged to adapt earlier supplies accordingly.

ORDER NR.: 072.14.1.9662
2 SAFETY - Before entering an enclosed or poorly venti-

lated area containing an inert gas generator
2.1 General Safety instructions or transmission equipment and piping, follow
This plant is designed to produce inert gas with all established local safety precautions and
low oxygen content. Inert gas is an asphyxiating procedures.
gas and contains nitrogen (N2), carbon dioxide
(CO2) and little or no oxygen (O2). Furthermore - Product gas should not be vented or other-
carbon monoxide (CO) and other toxic gasses wise discharged except through the normal
may be present. piping system. Appropriate signs should be
placed in the area of the nitrogen system
Exposure to or inhalation of the product gas warning of the hazard.
should be avoided; the more so as no oxygen is
present. Leakage or venting of product gas into - Piping of the inert gas flow to areas of high
closed or confined areas, or at places where air circulation is recommended. Consult your
personnel may be present, must be avoided. own safety personnel for local, state and
federal procedures or regulations.
Any violation of these warnings may result in
accidents causing personal injuries. A general - All electrical installation should be in accord-
indication about the effects and symptoms in ance with the recognised electrical codes.
case of low oxygen content is given below:
Oxygen content Effects and symptoms

15-19% Decreased ability to work strenuously. May impair the co-ordination.
12-14% Respiration increase with exertion, increase of pulse rate, impaired co-
ordination, reception and judgement affected.
10-12% Respiration further increases in rate and depth, poor judgement, blueness of lips.
8-10% Mental failure, fainting, unconsciousness, ashen face, blueness of lips,
nausea and vomit.
9- 8% 8 minutes exposure: fatal; 6 minutes exposure: 50% fatal; 4-5 minutes
exposure recovery with treatment.
4- 6% Coma in 40 seconds, convulsions, respiration ceased or death.
Note: oxygen contents are indicated by volume percentage at atmospheric pressure.

ORDER NR.: 072.14.1.9662
2.2 Safety instructions for Operat-

ing & maintenance
Operating the equipment in excess of the
conditions set forth in the Sales Contract and
the Technical Specification will subject it to
stresses and strains that it was not designed
to withstand.
Carefully read the cautions and instructions

before starting the equipment or doing any
maintenance.
1. Before doing any maintenance to the

electrical installation, be certain that the
electrical supply has been switched off by
the main switch.
2. Before doing any maintenance to the

equipment, be sure that all pressures of
the entire system have been vented.
3. When operating the equipment, do not

exceed the rated capacities, speeds,
pressures or temperatures or act
otherwise than laid down in these
instructions and the sub-contractors
manuals.
4. Do not remove any covers from rotating

units, such as blowers, fuel pumps,
compressors, fans etc. while the unit is in
operation.
5. At no time the unit should be energised

and started in hazardous environments.
6. Spilling oil (fuel or lubrication) may cause

slipperiness or fire damages.
Do not enter any cargo space and/or

tank before the oxygen content in
these spaces is measured and found
sufficient to guarantee that these
places are not filled with inert gasses
or other gasses then air!

ORDER NR.: 072.14.1.9662
3 INSTALLATION 7. For free discharge of the seawater (con-

sequently pressure less), the piping must
3.1 Installation instructions not have a great resistance (see dimen-
sions on the dimensional drawings). In
Carefully read the cautions and instructions order to be able to discharge the cooling
before installing the equipment: water pressure less during swinging (roll-
ing) of the ship, the water discharge lines
1. Remove all packing material carefully. must have a slope of at least 20°. This
applies to the connection line between the
2. The inert gas installations are delivered washing tower and the water seal and to
on foundation frames; on behalf of the discharge line of the water seal to
transport, the installation is divided or overboard.
parts are disassembled that are delivered
separately, depending on the dimensions. 8. When fitting the water seal and its supply
and discharge lines, attention should be
3. The diameters of the piping, to which the paid to the fact that during operation no
supply, vent, discharge and distribution air bubbles can arise in this line. Bubbles
lines on board must be connected, are can block the water passage; at possible
indicated on the diagrams and drawings air collecting places a venting pipe must
(Process documentation and dimensional be made, e.g. in bends, high fitted piping
drawings). In case a big pressure drop parts, under the lid of the water seal etc.
will occur in the pipe system, these lines
should be of an extra ample design. 9. Inert gas generator must be installed
When choosing the pipe diameters, the above highest waterline. For more details
capacities and pressures mentioned in see the flow diagrams in the "Process
the technical specification should be con- documentation". If the generator is placed
sidered. near or below water level, special ar-
rangements for the generator and the wa-
4. If more than one generator is placed on a ter seal are required.
ship, each generator must be provided
with its own fittings, such as cranes, fil- 10. Seawater pipes must be protected
ters, reducing valves etc in the various against corrosion;
supply and discharge lines. This is in or-
der to be able to guarantee an independ- 11. The temperature of the combustion air
ent operation of each generator. may not be subjected to a sudden strong
variation. It is recommended to suck in
5. No rain or water from the outside may the combustion air from "inside" the ship.
find its way into the venting and aerating
pipes. 12. There should be a constant fuel quality
and viscosity, this being important for the
6. The seawater supply pressure should fuel air ratio.
remain as constant as possible (+/- 20%);
if big pressure fluctuations in the sea- 13. The compressed air supply may not con-
water piping are to be expected, which is tain rests of lubricating oil and must be
the case at the deck wash piping. It is free of condense.
recommended to fit an own supply pump.
The water supply to the gas generator 14. All blow-off piping indicated on the draw-
must be stopped when a failure in the ings must be led to the "outside".
seawater discharge of the generator oc-
curs, either by closing a magnetic valve
(to be fitted in the supply line), or by stop-
ping the supply pump. For that purpose
an electrical contact is available.

ORDER NR.: 072.14.1.9662
15. When the generator is erected in a room

specially meant for it, there has to be a
forced purge of air to discharge the heat
developed; a fan must be fitted in the dis-
charge canal.
16. The I.G. generator is equipped with a

Zirconia type of O2-analyser. This item
contains no moving or rotating parts and
ship movements or vibrations will have no
effect. The O2 measurement and the O2-
sensor will last for many years. The only
attention this analyser requires is regular
calibration. Calibration requires a calibra-
tion nitrogen gas bottle including pressure
reducing set. A nitrogen cylinder must be
on board of the ship, close to the O2-
analyser.
17. The wiring of the auxiliary (control) cur-

rent part is performed according to the X-
wiring principle, which means that the
wires are running at the rear side of the
mounting plates. The internal wiring is of
the required flexible type for shipboard
use. All connections are made with wire
connectors.
18. The entrance of the main supply cables

can be made on a suitable place on the
starter panel. The electrical connections
(cables) between the terminal boxes, oth-
er electrical parts and the panels must be
laid alongside the ship's steel structure.
These cables should be laid during erec-
tion on board.
19. Compressors may not stand in warm air

flow of machines.
20. Always ensure adequate ventilation for all

systems. Ventilation of room housings
should be designed approx. 10-15% larg-
er than the sum of the cooling air quantity
required for all machines operating in the
room.
21. During stand-still and operation the ambi-

ent temperature should not be below +0
°C, to prevent damages caused by freez-
ing

ORDER NR.: 072.14.1.9662
4 STORAGE INSTRUCTIONS
4.1 General storage instructions

The equipment must be stored at a clean and
dry place, protected against weather and
moisture. Ambient temperature should not be
below 0 °C and above +50 °C.
During transportation, severe shocks or vibra-

tions should be prevented.
All equipment is packed by Aalborg Industries

Inert Gas Systems B.V. and suitable for stor-
age under above-mentioned conditions. If
equipment, such as blowers, is stored for a
period longer than
12 months, it may be required to check the
lubrication. If necessary, it must be replaced.
4.2 Storage instructions for the

construction period
With the construction period Aalborg Indus-
tries IGS Systems means:
”The period between removing the packaging
material, the installation of the equipment into
the ship (or into a segment of the ship) and
the commissioning of the complete ship”.
During this construction period of the ship the

equipment must be stored according to the
General storage instructions mentioned
above.
Great care must be taken to protect the

equipment against damages while working in
the surrounding area of the equipment.
Special care must be taken to protect the

equipment from sparks when welding near to
the equipment.

ORDER NR.: 072.14.1.9662
5 TECHNICAL DESCRIPTION To produce dry inert gas air the wet inert gas
is compressed by a screw compressor and
5.1 Process Description led to the dryer unit. After passing the dryer
The generator is capable of producing inert the inert gas is supplied via the delivery valve
gas air. to the deck main line.
Inert gas is produced by stoichiometric Drying inert gas:

combustion of fuel oil with air.
The fuel oil is a hydrocarbon and the air a In the final stage, the water is removed by
mixture of mainly 79% of nitrogen and 21% of adsorption in a desiccant dryer of the
oxygen. 2-chamber system, which is regenerated in a
heatless way. The required final pressure of
The combustion is a chemical reaction the plant is achieved by the compressor,
between the hydrocarbon and the oxygen, situated behind the combustion chamber.
mainly giving carbon-dioxide and water. Some The pressure inside the plant is maintained
little rest quantities of oxygen, constantly to ensure a stable flame during
carbon-monoxide and hydrogen also remain. operation, independently on pressure
The nitrogen leaves the generator unchanged. fluctuations in the piping system. This is done
The burner is not ignited at air production. via a pressure control valve at the end of the
installation.
The water is drained for the main part by
condensation, effected by cooling. So, the
inert gas produced mainly consists of nitrogen 5.1.1 Combustion System
and carbon-dioxide. A good combustion process is the first
The hot combustion gases are cooled, first requirement of a reliable inert gas generator.
indirectly in the combustion chamber by a The burner is of our special design, in
cooling-water jacket. accordance with the Smit Ultramizing
The main feature of its construction is the Combustion System.
absence of any internal brick lining. The
advantage is that inert gas of the correct By means of the combustion air which is
composition can be delivered within 5 minutes supplied under pressure to the burner, the fuel
(no lining need to be heated up). oil is atomised in such a way that a perfect
Main cooling occurs in the cooling/washing mixing of fuel and air is achieved, so that the
section of the combustion chamber, where the behaviour of the flame is identical to that of a
inert gas is directly cooled with seawater; at gas/air mixture.
the same time the sulphur oxides are washed
out. Sulphur is mostly present in the fuel and As a result, a bright blue flame is seen, which,
is oxidised during combustion. even at an oxygen content of nil, will not
The inert gas is cooled-down to a few degrees create any soot. This soot cannot be tolerated
over seawater inlet temperature and saturated in the plant, neither in the ship's cargo tanks
with water at that temperature. nor piping system. To prevent it, especially in
At the end of the cooling section, the water the long run, is only possible in an extremely
droplets are separated, as the gas passes stable and well-balanced combustion process.
through a demister.
Combustion air is supplied by a blower

installed in front of the combustion chamber.
This causes an overpressure inside the
combustion chamber and gas cooling section.
A water loop seal under the cooling section
discharges the water, at the same time
maintaining the required pressure and
avoiding the escape of inert gas.

ORDER NR.: 072.14.1.9662
5.2 Detailed process description Set-point of the overflow valve is also the fuel
oil deliver pressure.
5.2.1 Introduction The set point of the overflow valve is
The complete system consists of several sub- adjustable.
systems. In this chapter we take a closer look
at the sub-systems and the equipment. Fuel oil pressure on the main burner can be
adjusted by valve 2032. This valve is used to
The complete system contains the following reduce the pressure near to the required
sub-systems and main equipment: pressure.
Inert gas production: Fuel oil supply line to main burner is provided
- Combustion chamber, burner and with 2 block valves (1059, 2043) according
cooling/washing section the class requirements. Block valves will close
- Combustion air blower automatically during shut-down.
- Fuel oil pump
- Blow-off valve
- Oxygen analyser 5.2.4 Pilot burner
- Main electrical panel The combustion chamber is provided with a
pilot burner for ignition of the main burner.
Compressor units: The pilot burner is a reliable burner which
- Knock-out drum needs only fuel oil and compressed air
- Inert gas return line (instrument air from ship) for starting-up. Pilot
- Compressor units burner is ignited by a spark plug (2131).
During start-up of the generator the pilot
Dryer unit: burner will be started first. Ignition of the pilot
- Dryer unit burner is safeguarded by a UV-detector
(2121). When the pilot burner is in operation
and flame detection has been check by the
5.2.2 Combustion air supply UV-detector, the main burner will be started.
Combustion air is supplied to the main burner
by the blower unit (2202). Oil pressure of the fuel oil pump is the same
Via a regulating valve (2050) in a separate as the pressure on the pilot burner.
blow-off line, the quantity of combustion air
supplied to the main burner is adjusted:
5.2.5 Main burner
a) to adapt the combustion air delivery to the The main burner (2001) is ignited by the pilot
compressor capacity, burner. The burning of the flame is monitored
by an U.V.-flame detector (2021), in
b) to obtain the correct atomising pressure conjunction with the flame safeguarding relay
(delta p) over the main burner in the electric system.
The blower is protected against a too high The fuel oil is atomised in two steps. Firstly,
counter pressure by a high-alarm pressure the fuel oil is dispersed by a spray nozzle.
switch (2010). A too low combustion air Then it is subjected to a tangential impulse
pressure is monitored as well by a pressure flow of combustion air which, added to the
switch (2011). mainly axially orientated impulse flow of the
liquid itself, results in an ultrafine dispersion of
5.2.3 Fuel oil supply the liquid.
The fuel oil is supplied at a constant pressure
by the fuel oil pump (1012) with a built in The tangential impulse flow is created by
overflow valve. supplying the air through slots in a ring fitted
Before the ignition is started with the pump round the burner head.
switched on (pre-purge time), all the fuel oil is An optimal atomisation of the fuel oil is
pumped back via the built-in overflow valve. achieved if the differential pressure over the

ORDER NR.: 072.14.1.9662
slots of the atomising ring is approx. 0.2 bar, The mist is condensed and re-supplied as
i.e. the difference between the combustion water droplets, which are carried off via the
pressure (on gauge 2012) and the pressure water seal.
inside the combustion chamber (= approx. The seawater is supplied to the sprayers and
pressure on gauge 2332). the combustion chamber jacket via an orifice
(2314), which distributes the cooling water
The main burner is because of the robust into the correct quantities.
construction free of maintenance. The oil The seawater leaving sprayers and
nozzle at the end of the burner lance must be cooling-water jacket flows out via the water
replaced when dirty or blocked. seal. The seawater supply is safeguarded by
low- and high-alarm pressure switches (2320,
The burner cone is a part of wear and tear. 2321).
Therefore this cone must be checked periodi- Sufficient cooling of the combustion-chamber
cally on damage (see chapter 9) and replaced wall is safeguarded by high-alarm
as soon as it starts burning away (holes, de- temperature switch (2312).
crease of length, see drawing P-X00047). The Sufficient cooling of the inert gas is
life of the burner cone is strongly influenced safeguarded by high-alarm temperature
by the quality of the fuel oil and the correct switch (2335). During ignition blow-off valve
adjustment of the burner. It is STRONGLY 2360 will be open.
ADVISED to have a spare cone on board con-
tinuously. 5.2.7 Water seal
The required final pressure of the generator is
5.2.6 Combustion chamber and achieved by the 'roots'-type air blowers,
scrubbing Tower supplying the combustion air to the burner.
Main and pilot burners are mounted on the This causes an overpressure in the
combustion chamber (2301). The combustion combustion chamber and scrubber section. A
chamber is surrounded by a cooling-water water seal under the scrubber discharges the
jacket to discharge the generated heat as water, at the same time maintaining the
much as possible. The cooling water jacket required pressure and avoiding the escape of
has a spiral, so the cooling water flows round inert gas (or air).
the combustion chamber wall and an optimum
cooling effect is achieved. The water is flowing to overboard on atmos-
The hot inert gas flows through the pherically pressure. The water level in the
cooling/washing tower, where it is directly scrubber is monitored by a level switch
cooled with seawater to a few degrees (max (2322).
4) above seawater inlet temperature. At the
same time, the sulphur oxides are washed out
of the inert gas. These sulphur oxides are 5.2.8 Knock-Out drum
formed during combustion of the fuel oil, as In front of the screw compressors in the
the fuel oil always contains sulphur. suction line, a knock-out (K.O)-drum (2500) is
installed to be certain that no condensate
The scrubbing tower is filled with contact droplets can enter the compressor. The gas
material (2308), in order to ensure an intense speed in that vessel is so low that the droplets
contact between the seawater, which is have to fall out of the gas flow.
supplied via sprayers (2306/2304/2303) in The condensate formed is discharged to a
combustion room and on top of the scrubbing water seal (2503). The K.O. drum is provided
tower and the inert gas flowing in opposite with a level switch (2522) that switches the
direction. generator off in case the condensate level
The filling (2308) of the cooling/washing tower becomes too high.
consists of polypropylene material.
A demister (2307) on top of the scrubbing Valve (3500) is used for capacity control of
tower prevents a water mist from being the screw compressor.
carried away with the inert gas.

ORDER NR.: 072.14.1.9662
5.2.9 Compressor unit Gas circuit:

The compressor section consists of one single
stage oil-injected screw-type compressor with Inert gas is taken in by the air-end (3001).
an asymmetrical profile. The compressors The maximum inlet pressure is 1.030 bar(g)!
require no base; it rests internally on supports The inlet temperature should not exceed 40
that dampen the vibration. °C
The inert gas is compressed up to max. 8.5
The compressor is driven by a three-phase bar(g). To prevent under-pressure in the
squirrel-cage motor via a flexible coupling. knock-out drum the compressor is provided
The required compressor speed of rotation is with a low alarm pressure switch (3008). To
obtained by means of a transmission protect the air-end against overpressure a
integrated in the air-end. high alarm pressure switch (3111) is installed
downstream of the air-end.
Each compressor is provided with a local Compressor is also protected against low and
control panel, but units are operated from the high temperatures, see "Oil circuit".
main electrical panel.
The air-end is oil injected for cooling and
lubrication. Oil and compressed inert gas are
separated in the oil separator (3101). The air
is passing two stainless steel demisters
(3107, 3100) which will take out most of the
oil.
The oil losses are higher than in case of a
normal air compressor, so oil should be added
periodically. More over need the oil be
changed more often as the sulphur in the fuel
oil and the high (sea) water humidity are
responsible for a limited life time of the oil.
Always use the special oil supplied by Aalborg
Industries IGS as only this oil contains the
additives needed for inert gas.
The oil temperature at 3113 should never be
less than 85 °C. A lower temperature could
result in condensation of water in the oil,
which is very much undesirable as the oil us
used for lubrication of the bearings to.
The inert gas is then cooled in the after

cooler. A thermostat (3307) guards the
compressor outlet temperature of the inert
gas. Water separator (3401) collects and
drains all condensate which is formed during
the cooling down of the gas.
Oil circuit:
A good working of the oil circuit is essential

for the compressor:
- Cooling of inert gas and air end during
compression
- Lubrication of rotors
- Preventing backflow leakage between the
rotors during compression
- Lubrication of compressor bearings

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During operation of the compressor, a large it from being totally closed. Because of the
flow is re-circulating through the entire little gas flow, the compressor is almost
compressor system. Because of the running unload. The valves 3510/3513 are
overpressure in the oil separator vessel and closed. This allows a fast pressure build-up in
under pressure at the compressor inlet, oil the separator tank, need for the oil circulation.
floods into the air-end. Oil is then mixed with The minimum pressure valve (3029) will open
the compressed gas and led to the oil only at approx. 3 bar(g). The compressor will
separator. go on load if the pressure of 5,5 bar has
reached, pressure switch (5120) will release
The air-end outlet temperature is critical. If the the compressor. The valves 3510/3513 will
temperature is too low, condensate will occur open.
in the air-end during compression and can
damage rotors and bearings. A low During this unload running the compressor
temperature alarm thermostat (3109) is blows off a small amount of gas via no-load
installed. The oil temperature and air-end are valve (3411).
also restricted to a maximum temperature; The compressor keeps running unload till the
this is safeguarded by thermostat 3110. minimum temperature alarm is off (not
indicated on local control panel since this is
Oil separation is done in three stages. The not an alarm).
first stage the radial inlet in the oil separator,
oil will separate from the gas flow by means of Compressor is now ready to run unload,
centrifugal forces. In second stage the oil is however this happens after the rest of the
separated by demister (3107), the oil drips system is online (see start-up sequence of
down into the oil collecting tank. A smaller complete system).
amount of oil is of oil is separated by demister
(3100). Oil collected out of this third stage is Shut-down:
returned straight to the air-end via a non-
return valve (3116). Some oil will go with the When the compressor is shut-down, intake
gas to the after cooler (3301) and will be valve (3007) closes and E-motor (3002) stops
drained via 3403. running.
System depressurises via orifice (3420) and
The oil is pressed out of the separator tank no-load valve (3411).
again because of the overpressure and flow
through the oil filter (3120) to the oil cooler
(3201). The cooled oil is then sucked into the Instrumentation and controls:
air-end again.
The compressor is controlled from the main
Cooling water system: control panel. The compressor will start
automatically when the system is started on
The compressor is seawater cooled. Both the main panel.
after cooler and oil cooler are of shell-tube
type, with having the seawater flowing through The oil separator is provided with a level
the tubes. gauge and level switches. Compressor will
shut-down at high and low-low level alarm.
After cooler and oil cooler are placed in serie. Compressor will give pre-alarm at low level
The cooling water flow through the after alarm.
cooler is adjusted by hand valve (3205). Flow
through oil cooler is automatically adjusted by The pressure drop over demisters (3124,
control valve 3210. 3119) is monitored by pressure indicator /
switch (3117). In case of a too high pressure
Start-up: drop the unit will shut-down.
During the start-up of the compressor, intake 5.2.10 Filtration (liquid)

valve (3007) is closed. Valve (3007) is
provided with a small hole (12mm), preventing

ORDER NR.: 072.14.1.9662
The inert gas leaving the compressor will be will contain less H2O; the quantity of H2O per
filtered by two grades of filters, course (5101) volume unit will fall below the equilibrium
and fine (5111). The last one (5111) will have condition of the filling.
a constant high pressure drop. If the pressure If this dried and expanded inert gas or air is
drop is zero the filter should be checked purged through the vessel in opposite
(bursted or loose elements). direction, the filling will try to reach equilibrium
with this relatively dry inert gas and in this way
For gas entering the dryer is free of water and it will desorbs H2O.
oil mist now. The dryer is not sensitive to The process will take place all over the vessel.
minor oil contents. The H2O, which becomes desorbed in this
way, is expelled with the purged inert gas.
5.2.11 Dryer unit Adsorbing/regeneration cycle

In the dryer unit, the inert gas or air is dried to
the required dew point. While one vessel is on The total cycle time is abt. 10 minutes.
service, the other is being regenerated. The For 5 minutes, one vessel will adsorb and the
system for changing-over from adsorption to other vessel will be regenerated. Any 5
regeneration operates automatically. minutes the function of the vessels changes
over. For details see OEM documentation in
The adsorption dryer removes moisture from chapter 14
the air/inert gas. The operation is fully
automatic and based on the adsorption Oil vapour adsorption
principle. The adsorption material or desiccant
retains the moisture to be removed and when A carbon bed filter (5700) is installed to
its capacity limit is reached it may be remove oil vapour from the inert gas
"reactivated" i.e. restored to full adsorption
capacity.
The desiccant is selected according to the
required duty, but generally for these
applications (air/inert gas) 'Activated Alumina'
is used. Every gramme of desiccant is so
porous, that it can reach a surface area of
hundreds of square meters. This enables it to
adsorb water vapour. 'Activated Alumina' is
very resistant to break-down and is not
damaged by accidental overheating.
Construction
The dryer consists of two cylindrical mild

carbon steel vessels/ absorbers, each
containing a measured quantity of desiccant.
The vessels are suitable for the actual
working pressures and hydrostatically tested
according class-specifications.
The adsorbers are mounted on a foundation
frame and interconnected by a system of
pipes. Some indicating and monitoring
devices are mounted on these pipes.
Regeneration
If a part of the dried inert gas or air is

expanded, it will become relatively drier and

ORDER NR.: 072.14.1.9662
The cycles occur as follows: The inert gas leaving the dryer is filtrated by
an adsorber for oil vapour is used (5700) of a
Start: Compressor on load. carbon type that can adsorb oil vapour under
dry conditions. The carbon need be replaced
1 s: Solenoid 5013 is energised by periodically. After the carbon bed filter a dust
which pneumatic valve 5011 is filter is installed for the carbon dust of the car-
opened. Solenoid 5023 is de- bon bed filter.
energised by which pneumatic
valve 5021 is closed. Wet inert
gas or air flows through vessel 5.2.13 The oxygen content
1. The classification authorities require a
Solenoid 5053 is energised by continuous check (indication, registration &
which pneumatic valve 5051 is alarm) of the oxygen content.
opened. Vessel 2 is de- The analyser constantly indicates the oxygen
compressed and blows-off via content in the inert gas and will effect an
a silencer (5080). alarm if a set maximum or minimum quantity if
After that the vessel 2 is oxygen is exceeded.
purged with dry air/inert gas via The maximum value if fixed by the application
an orifice (5086). of the inert gas. The minimum value protects
against under-stochiometric combustion (too
210 s: Solenoid valve 5053 is high content of combustibles CO + H2).
de-energised, by which
pneumatically operated valve The generator will not stop at alarm condition.
5051 closes. End of purge This enables the operator to change the
period. adjustment of the equipment and to see the
result.
Via the orifice 5086, inert gas At alarm condition 'O2 HIGH' visible and
or air remains is flowing to audible alarm will occur and the inert gas
vessel 2 in order to pressurise produced will be blown off now and not
this vessel rapidly, thus discharged to the cargo tanks.
avoiding pressure dips during At alarm condition 'O2 LOW' the inert gas will
change-over of function of the be blown-off and audible and visible alarm will
vessels. occur too.
The vessel remains in this In case of an O2-alarm, the O2-content can be
mode until change over of changed by supplying more or less fuel oil to
functions occurs. the main burner to be controlled manually by
300 s: The vessels change of function the regulating valve (2032). This can be
now. The solenoid 5013 is de necessary e.g. at temperature variations of
-energised by which pneumatic the combustion air.
valve 5011 closes.
The solenoid valve 5023 is The alarm modules for a 'LOW' and a 'HIGH'
energised by which O2-content (HA, LA) will be activated if the O2-
pneumatically operated valve content exceeds one of the set limits.
5021 opens. In case of an 'O2 LOW' alarm, if the failure
remains for more than 60 seconds, purge
301 s: The regeneration of vessel 1 valve (6021) will open and delivery valve
starts. Vessel 2 is in the drying (6041) will close. In case of a 'HIGH' O2
mode. The regeneration cycle content alarm (HA) same will happen.
of vessel 1 is identical to that of
vessel 2. The full adjustment range of the alarm units
corresponds with the analyser range selected.
The high value is laid down by the application
5.2.12 Filtration (dust/ oil vapour) of the inert gas.

ORDER NR.: 072.14.1.9662
The low value protects against under- burner open; pilot burner ignites
stochiometric combustion (content of main burner.
combustibles CO + H2 too high, with risk of
soot). 30 sec.: Solenoid valves (2103, 2105 and
The analyser has to be calibrated regularly, 2114) for fuel oil and instrument
with the aid of a 'zero' gas (nitrogen) and a air to pilot burner are closed
'span' gas (instrument air). Calibration to be again. Pilot burner extinguishes.
done after abt. 10 hrs temperature
stabilisation (= power on). Automatic Main burner flame must have
ignition/start-up sequence been detected by UV-flame
After having carried out the preliminary detector (2021), otherwise
starting instructions, such as opening supply generator shuts down and alarm is
valves, starting up seawater supply, putting given.
mode selector switch into position 'INERT Dryer unit is started
GAS PRODUCTION' or 'AIR PRODUCTION', Compressor intake valve (3007) is
the generator can be started by operating the opened, compressor on load
generator start switch. Blow-off valve (2360) is closed.
The automatic program for inert-gas 235 sec.: Inert gas can be delivered to the
production then runs as follows: tanks, provided that:
a) the O2-content is between its
limits.
b) the dew point is below its
Start limits. If conditions are OK, the
• Blower starts. indication light "generator stand-
• F.O. pump starts. by" is ON. Gas to deck switch can
• Bypass valves 3510/3513 closed. now be operated.
• Compressor starts, intake valve 3007 is
closed.
• No load valve (3411) open when
compressor is warmed-up (thermostat
3213) or when 60 seconds of pre-purge
time have exceed, ignition sequence is
started.
Start time +
0 sec.: Ignition pilot burner
Solenoid valves (2103,2105,2114)
for fuel oil and instrument air to
pilot burner open; ignition
transformer(2131) and thus spark
plug energised.
10 sec.: Ignition transformer de energised.
Flame pilot burner must have
been detected by UV-flame
detector (2121), otherwise
generator shuts down and alarm is
given.
25 sec.: Ignition main burner. Solenoid

valves (1056, 2040 at wet inert
gas and 1058, 2043 at dry inert
gas production) for fuel oil to main

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6 TECHNICAL SPECIFICATION
6.1 Design basis Oxygen O2 : max. 0.1 vol%

- The design of the installation has been
based and calculated on the following Carbondioxide CO2 : abt. 14 vol%
principles:
- The unit is designed and will be built in Carbon-monoxide CO : 1000 ppm at 0.1%
accordance with the regulations of IMO O2
and the rules of the classification society.
- Shipboard use, indoor erection. Sulphur oxides Sox : max. 10 ppm
- Inert gas capacity and composition based
on an oxygen content of 1% in the IG and Nitrogen Nitrogen : N2 balance
calculated with combustion air of 25°C and
100% RH at atmospheric pressure. Soot (on Bacharach scale) :0 (= complete
- Quantities tolerances +/- 3%. absence)
- Temperatures tolerances +/- 1°C.
- Pressures tolerances (effective working Temperature : abt. 15oC above
pressures) +/- 5%. cooling water inlet temperature (inert gas)
- Voltage tolerances: - 15% / + 10%.
- Combustion-chamber cooling water jacket Dew point: Minus 40 °C after expansion to
is designed for 1 bar overpressure atmospheric pressure
maximum.
- Interface flanges according to DIN.
Effluent water loop seal mounted straight 6.3 Utilities
under generator. Fuel oil:
- Burner cone is subjected to normal wear
and tear and should be inspected Quality: Marine Diesel Oil acc ISO 8217
periodically (see maintenance manual). (1987) or BSMA 100 (1989),
- Electric motors switched directly on line. grade DMA.
- Process safeguarded by several Inlet pressure: atmospheric (max. 1 bar(g))
protecting devices. Fuel consump. approx. 225 kg/h at design
- Signalising 24 V - 60 Hz. capacity
- After use, the combustion chamber must
be rinsed by fresh water. Electricity:
Main system: 440V, 3 ph, 60 Hz

6.2 Inert gas specification Control system: 220V, 1 ph, 60 Hz
Capacity (fixed): Power failure supply: 24V, DC, 0.05 kW
Inert gas (dry) :

3
2000 Nm /h Rating Consumption
Capacity measured on dry basis at 15oC and Oil pump 0.65 kW 0.3 kW
at atmospheric pressure. Combustion air blower 35 kW 29 kW
Discharge pressure: 6 bar(g) Compressor: 330 kW 290 kW
Control system: 3.0 kW 3.0kW
Typical Gas composition: (on dry basis)
Ambient air:
Note: sufficient ventilation is obligatory.
- Temperature: between 0 and 45°C
- Pressure: atmospheric
-
- Consumption for combustion: abt.
2653 Nm3/h
-

ORDER NR.: 072.14.1.9662
Cooling water: - between generator and compressor:

stainless steel 316L
Quality: filtered seawater - between compressor and dryer:
(mesh-size 4 mm) mild steel
Supply pressure: constant value, - behind dryer:
between mild steel
2-4 Bar(g)
Outlet pressure: atmospheric
Inlet temperature: max. 32°C 6.5 Coating system
3
Consumption: 255 m /h - Stainless steel parts will be cleaned from
impurities.
Instrument air: - Control panels will have finish coat
according RAL 7032.
Quality: dry, clean and oil free - Main components from our sub-suppliers
Supply pressure: 6-9 bar(g) may have their own coating.
Rating: 20 Nm3/h - Steel parts will be shot blasted, cleaned
by hand and painted with one layer of
Consumption per start for pilot burner: primer and one layer of finishing coating.
0.17 Nm3
Consumption for pneumatic equipment: 2 Nm3
Fresh water for rinsing:
Pressure: See cooling water

Pressure
Consumption: abt. 15 m3/h
Temperature: max. 36 o C
Noise level: 96 dB(A) measured at

1 meter
6.4 Materials
Combustion air piping: mild steel

Fuel-oil piping: mild steel
Combustion chamber: stainless 316L
Cooling/scrubbing section: stainless steel
AISI316L
Cooling water piping: stainless steel
AISI316L
K.O. drum: stainless steel
AISI316L
After cooler: pipes: CuNi 90/10
Casing water side: Carbon steel,
coated
Condensate separator: mild steel
Dryer unit/vessels: mild steel
Inert gas piping (as far as delivered by

Aalborg Industries IGS):

ORDER NR.: 072.14.1.9662
7 OPERATING INSTRUCTIONS After opening the hand valves for all utilities,
doing the necessary checks, and starting-up
Before operating the unit, read the cooling-water supply, the generator can
the SAFETY INSTRUCTIONS. be started by one single switch. The starting
process is programmed by a contact drum
and is operating fully automatically. The
7.1 General process is safeguarded by safety devices.
This packaged equipment is a piece of
machinery that inherently has many possible 7.2 Operation panels
hazards. There are systems that operate
under pressure, at extreme temperatures, at Local control panel 2
high speeds and at high voltages. The local control panel 2 contains all
Therefore the equipment must be operated equipment for the start-up of the generator.
by qualified personnel who have been trained On the front door of this control panel all
to work on this type of machinery. status and failure lamps are inserted in a
coloured mimic diagram.
• Do not remove parts from pressure
containing systems without relieving Compressor panel 13
pressure first. Panel 7 contain motor starters, local
indicators and alarms for compressors.
• Do not operate this equipment without all
guards in place and properly adjusted. Starter panels 10 and 12
The starter panels contain the electrical
• Do not operate this unit in a manner for starting and safeguarding equipment for the
which it was not designed. E-motor (panel 10 for the combustion air
blowers, panel 12 for the fuel oil pump).
• There are parts of this equipment which
can cause electrical shock. Panel 20 for the oxygen analyser
This panel is mounted on the dryer unit.
• Do not remove any of the protective
devices or render them inactive.
• When doing any service work or
maintenance work on the compressor(s),
be absolutely sure the equipment is
locked out and all internal pressure is
relieved.
Failure to heed any of these warnings can

cause serious injury or death.
To prevent that soot is being formed, which

can foul and damage the system, always
make sure that:
a) the correct oil quality is used (acc. to ISO
8217, type DMA).
b) the atomising air pressure (delta p over
main burner) is correct, about 0.2 - 0.25
bar;
c) no excess of fuel oil is supplied, i.e.
oxygen content indicated on the
O2-analyzer must always be more than 0;
d) the oxygen analyser is regularly
calibrated.

ORDER NR.: 072.14.1.9662
7.3 General switches The start/stop switch gives the possibility to

The installation has the following safety purge the combustion chamber with air after
components to switch off in case of an stop.
emergency:
This switch has the following positions:
- EMERGENCY STOP pushbutton on local • Off
control panel 2, • Normal stop: Generator will be stopped
- EMERGENCY STOP pushbutton on screw including 3 minutes after-purge time.
compressor panel 13, • Normal operation: The switch must
remain in this position during operation.
For switching on the power supply to the • Start (pulse): The system can be started
units each panel has a Main power switch. via this position and returns automatically
to position 2).
7.3.1 Local control panel 2 Button: Reset all alarms

Switch : Power On/OFF
Button: Acknowledge button,
Button : Emergency stop button switches off the audible
alarm
Switch : Select production mode:
Button: Lamp test
1. Inert gas production
2. Air production Switch: Cancel bilge drain,
Switch is mounted inside
Switch : Start/stop switch: panel
Switch: Gas to deck local/remote:
Delivery valve can be opened Button: Reset all alarms
local or remote, depending on
the position of this switch. Button: Acknowledge, will stop
audible alarm
Switch: Gas to deck:
If switch S12 is in local Button: Lamp test
position, delivery valve can be
opened by this switch.
7.3.3 Other control panels
7.3.2 Compressor panels 13 On the starter panel 10 (blower) and starter
Switch: Power On/OFF panel 12 (fuel oil pump) a Main switch for
switching on/off is provided.
Button: Emergency stop
Switch: Automatic/manual
operation:
- When selected automatic, compressor is

started/stopped from local control
panel 2.
- When selected manual, compressor can
be started/stopped locally via switch.
Note: compressor can only run unload

when started locally!
Switch: Local start/stop of

Compressor

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7.4 Switching on 9. Put the selector switch on the screw

compressor panel 13 in the position
7.4.1 Production modes "AUTOMATIC".
BEFORE STARTING THIS INSTALLATION, 10. Check water seal under the k.o. drum
IT IS IMPORTANT TO KNOW, WHAT (2503) on following points:
PRODUCTION MODE MUST BE CHOSEN: - filled already with water?
- Inert Gas production - drain valve (if appl.) closed?
- Air (dry) production
11. Check if shut-off valves (3202, 3302) are
opened.
7.4.2 Inert gas production
12. Check if the screw compressors are filled
1. Put main supply switches 'ON' (keep 'ON'
with oil.
normally for analyser).
Switching on has to be done at least 5 -
13. Check if the drain valves are closed.
10 hours hour before the generator is
started, in connection with the
14. Open the instrumentation valves on the
warming-up time for the oxygen
compressor unit.
analyser.
15. Open the instrument air supply valve
2. After 10 hours:
(5301) on the dryer and stripper unit.
Open instrument air shut-off valve (1501)
and calibrate oxygen analyser according
16. Check if the sample point valves (5240)
to the instructions given in the Aalborg
on the delivery line of the dryer and
Industries IGS manual (see chapter 11).
(5243) on dryer inlet for the dew point
and oxygen analyser are opened.
3. Starting up seawater supply:
- Open valves in cooling-water supply and
17. Open the instrumentation valves for the
discharge lines of combustion chamber
pressure indicators on the dryer and
and water seal.
stripper unit.
- Open valves in water supply and
discharge lines of the deck seal.
18. If the indication "SYSTEM READY TO
- Start cooling water supply pump.
START" on the mimic panel lights-up (if
not, consult section ...), start the inert
4. Open the main fuel-oil shut-off valve
gas generator with the START/STOP
(1001) and check, if f.o. control valve in
switch and release the switch to position
oil return line to tank is opened.
"2" (NORMAL OPERATION).
Generator running indicator lights up.
5. Rotate the handle of the fuel oil filter
Compressors, fuel-oil pump and blower
(1002) twice.
start running.
6. Open the fuel oil shut-off valve (1051) on
19. The start-up sequence is started now,
the generator.
see chapter 3).
With the start of the generator, the
7. Put the mode selector switch in the
compressor and dryer are started as
position "INERT GAS PRODUCTION".
well. The compressor runs in the
"unload" mode.
8. Check if the instrumentation valves for
the pressure indicators and transmitters
20. When blow-off valve (2360) closes, inlet
are opened and if the drain valve (2351)
pressure of compressor should be
and rinsing valve (2340) on the generator
checked. If pressure is too high, adjust
are closed.
valve (3500).

ORDER NR.: 072.14.1.9662
26. If the generator operates normally and 7. Drain possible fuel oil out of the burner
the composition of the gas is correct: housing by opening the plug underneath
The indicator "Generator stand-by" lights the burner. Close this drain again!
up.
8. Note: Unit can also be stopped remote.
26. Now the gas delivery valve (6041) can be
opened, this can be done remote or local
depending on the position of switch S11 9. The jacket shall be rinsed before every
on the main panel. long stand-still period, open valve 2340
for rinsing.
27. Check:
- pressures 10. In case of long stand-still periods, drain
- temperatures oil and water from all systems and close
- oxygen content of inert gas valves.
See test protocol in chapter 10.

Re-adjust if necessary.
7.5 Switching off
7.5.1 After wet inert gas or air pro-

duction
1. Switch-off the "GAS TO DECK" switch
on the main panel, so the delivery of gas
to the tanks is stopped.
The purge valve (6021) opens and the
delivery valve (6041) closes.
2. Switch-off the "STAND-BY" switch on the

local panel.
3. Put the start/stop switch on the local

panel in position 1 (= NORMAL STOP) in
case of inert gas production and in
position "0" (=OFF) at air production.
In position 0 the installation stops
immediately. In stopping position 1 after
inert gas production, the main burner
extinguishes and the f.o. pump stops, but
the blower keeps running. The
combustion room is purged with air now
to remove the oil vapour and the gases
with sulphur. Compressors will stop
immediately.
4. The blower will be switched-off after abt.

3 minutes automatically.
5. Switch-off the cooling water pump.
6. Close the fuel oil shut-off valves

(1001, 1051).

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7.6 Additional operation notes
7.6.2 Check during operation
Period: Check:
Before every Check oil levels of: Blower

start: Screw compressor(s)
After every start - Check the O2-content (inert gas production).

and further every
4 hours' operating - Check pressures and temperatures (see test protocol).
time: Record these values to observe any irregularity as quickly as possible.
- Check oil levels of blower and screw compressors.
- Check whether an equal flow of inert gas is indicated on the flow

indicator. On the oxygen analyser panel (inert gas/nitrogen production).
- Check fuel oil pump discharge pressure after start; oil must return via
pressure control valve in f.o. return line;
IF NOT, STOP SYSTEM and RE-ADJUST valve (2032).
- Check filter (on oxygen analyser) in oxygen sample line (7022).
- Check purge gas capacity of the dryer and stripper unit.
- Check tension of V-belts of the blower.
- Check via sight glass (2502) the discharge of condensate from K.O.
drum to water seal (2503)
Every week: - Check calibration of O2-analyser.

An exactly calibrated O2-analyser is very important (correct gas quality,
prevention of soot formation)!
Lamp test.
Alarm test.

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7.6.3 Atomising pressure on main oxygen. Watch the combustion chamber

burner pressure which has to be abt. 300 mm WC.
The atomising pressure on the main burner is
the difference between the pressure at the - Be sure, that the fuel oil pump delivery
outlet of the scrubber, indicated on a pressure, indicated on the manometer
manometer (2332) on the demister holder (1003), does not exceed a pressure of 20
and the indication of the manometer (2012) bar(g)!!!
on the combustion air line to the burner. This - Adjust with small steps, because the
difference should always be abt. 0.2 - 0.25 measuring system has a certain response
bar(g). time.
- In case an excess of fuel oil is supplied in
The setting can be adjusted when the proportion to the combustion air
generator is starting up and when the (O2-content measured below zero) or the
compressor is running on load. atomising pressure is too low, the risk
The combustion chamber pressure can be exists that soot is being formed, which
set by adjusting manual operated valve can foul and damage the equipment. An
(2511) on the KO drum. When this valve is indication for this phenomenon is the
fully closed and the pressure in the flame becoming yellow.
combustion chamber is still too high, the
burner capacity must be reduced by valve - The fuel-oil pressure on the main burner
(2050) when this is done the fuel/air ratio will not always have the same value for
must be adjusted as well. certain oxygen content. This depends on
the fuel-oil temperature, the viscosity and
An indication for a proper atomisation of the the quality.
fuel oil is that an almost blue flame can be - The blower sucks in a constant volume of
observed through the sight glass of the combustion air. The quantity of kgs of
combustion chamber. oxygen in that air depends on the ambient
In case the atomising pressure is too low or if temperature and the humidity.
an excess of fuel oil is supplied (see also I.e. at different ambient conditions, it will
section 4.5.3), the risk exists that soot is be necessary to re-adjust.
being formed that can foul and damage the
whole equipment. In case all described adjustments do not
An indication for this phenomenon is that the meet the expected results, the regulating
flame becomes yellow. valve in the excess air line on the blower
discharge can be used for re-adjustment i.e.:
- opening a little at a too high oxygen
7.6.4 Fuel-air ratio/oxygen content,
The fuel-air ratio and thus the oxygen content - reverse at too low oxygen content.
of the inert gas produced, has been adjusted
by means of the fuel-oil regulating valve Prior to re-adjusting, first check the com-
(2032). bustion chamber pressure.
This adjustment should only be changed in
case of an O2-alarm or if another oxygen
content is required.
In case of large changes in air temperature,
air humidity or quality of the fuel oil, the
O2-content becomes too high or too low.
In that event, the fuel-oil pressure (PI 2034)
on the main burner can be increased or
decreased manually with the regulating valve
of the fuel-oil (2032) or the air blow-off valve
(2050) can be adjusted to open in case of too
high oxygen or to close in case of too low

ORDER NR.: 072.14.1.9662
7.6.5 Generator delivery pressure

The generator delivery pressure is set by the
pressure control valve (6001) on the dryer
unit. The setting is approx. 6 bar(g). The
setting can be monitored on pressure
indicator 5251.
7.6.6 Pilot Burner

The pilot burner is supplied with fuel oil at the
set pressure of the pump and instrument air.
The instrument air can be adjusted by
pressure regulator (2112) (approx. 0.8 bar).
Adjustment has to be carried out in such a
way that a stable non-flickering flame of
sufficient length is obtained.
7.6.7 Fuel oil pump delivery pressure

The fuel oil pump delivery pressure of 20
bar(g) is adjusted with the overflow valve built
on the f.o.-pump. This pressure may not be
raised. THIS PRESSURE MUST BE
CHECKED AT EVERY START-UP AND
FURTHER REGULARLY.
The f.o. pump (1012) discharge pressure is
monitored by a built-in overflow valve which is
adjusted on 25 bar(g).
Consult manufacturer's instructions
(Danfoss).
7.6.8 Compressor unit

The pressure control valve 3106 is set during
commissioning at approx. 3.5 bar(g). This is
necessary to ensure the oil circulation during
start up. The temperature of the oil is set via
controller 3214 such that the oil temperature
at indicator 3114 never will be lower than
85 ºC.

ORDER NR.: 072.14.1.9662
8 TROUBLE SHOOTING - The figures indicated are explained in

section 8.2.
8.1 Failures
- In case of a failure, an audible alarm - On the local control panel a general
is given and a failure indicating signal failure for the compressor is indicated. In
lamp lights up. this case look at the concerning panel of
the unit for more information about the
- After pushing the failure.
ACKNOWLEDGEMENT button on
the panels, the audible alarm is 8.2 Consequences of failures
switched off, but the signal lamp See column 'C.o.F.' in 'Consequences of fail-
remains lightened (steady). ures table'
- After eliminating the cause of the 1. a. Blower and cooling water pump are
failure, the installation has to be reset switched off after an after purge time
by pushing the RESET button on the of 30 seconds.
generator control panel. b. Fuel oil pump is switched off.
- Next, the generator can be restarted. c. Fuel oil valves close. Burner extin-
guishes.
- The setting of all safety devices is d. Purge valve opens.
given in the test-protocol. e. Delivery valve closes.
f. Visible and audible alarm.
- The alarm modules for 'O2-max.' and
'O2-min.' are mounted in the local 2. a. Blower switched off immediately.
panel. Their inputs (4-20mA) are b. Same as 1b up to 1f incl.
connected with the output of the
oxygen analyser. The alarm values 3. a. Blower switched off immediately.
depend on the chosen analyser b. Cooling water supply pump switched
range. off.
- The full range of the set point c. Same as 1b up to 1f incl.
potentiometer of the alarm modules
corresponds with the selected
4. a. Purge valve open.
analyser range; i.e. selecting another
b. Delivery valve closes.
analyser range will automatically alter
c. Audible and visible alarm.
the alarm values for 'O2-LOW' and
'O2-HIGH', thus it might be necessary
to re-adjust. 5. a. Cargo pumps stop.
b. Audible and visible alarm.
- In section 5.2 a trouble chart is given
in which all failures that are indicated 6. a. Audible and visible alarm.
on the control panels, plus some
general generator failures, are
mentioned.
- For specific failures in operation of the

various accessories belonging to the
installation, the manufacturers'
instructions in chapter 9 have to be
consulted.
- In the trouble chart, one column is

named 'C.o.F.', which means
'Consequences of Failures'.

ORDER NR.: 072.14.1.9662
8.3 Trouble Shooting Charts
8.3.1 General trouble shooting chart
Failure Possible causes Remedies

Generator doesn't start, while Blow off valve (2360) not com- If one of these valves is not in
no failure is indicated and indi- pletely open. its correct position, the valve
cating light 'SYSTEM READY may be jammed, or its actuator
TO START' doesn't light up on Drain bilge valve (2410) not or solenoid valve may be defec-
control panel: closed. tive. Un-jam, clean, replace.
Emergency stop button Release the emergency stop
pressed. button.
Start position of burner relay Reposition the main burner.
program relay not (yet)
reached.
Remote stop switch (if applica- Correct position
ble) in wrong position
Compressor switched to manu- Switch to automatic.
al control.
Seawater pump not started yet Start the seawater pump.
Inert gas delivery pressure high Relief pressure
Failure cooling water lev- check
el/pressure (high)
Circuit breakers not switched Switch on
on
First failure circuit generator Push 'RESET' button.
energised.
Loose electrical connection. Reconnect.
System does not change over Delivery is interlocked. Wait for 5 minutes after starting
to 'charging' (inert gas/air to the generator.
deck): The O2-content of the produced Change the O2-content or the
inert gas is not between the alarm settings.
limits set on the high and low
alarm units of the oxygen ana-
lyser
Switch not operated correctly. Turn the switch to its 'START'
position and then release to
position '1' (INERT GAS OR
AIR TO DECK)?
8.3.2 Trouble shooting chart ig generator
Failure CoF Safety Possible causes Remedies

Fuel oil pump motor 1 1013 Motor overloaded. Check and repair.
failure: Heavy run of the fuel
oil pump.
Adjustment of the Re-adjust (see specifica-
overload relay is incor- tion plate on the motor).
rect.
Fuel oil pressure 1 PZA-L 1053 Pump isolating valves Open it.
low: closed.
Pump not running. Check fuses, isolating
switch, etc.

ORDER NR.: 072.14.1.9662

Air in fuel oil lines. Vent.
Filters (1002, 1052) Clean them.

clogged.
Instrument air pres- 1 PZA-L 1505 Shut off valve (1501) Open it
sure low: closed.
Filter (1502) clogged. Clean them.
Leaks in system. Check for leaks and re-
pair.
Supply system defect. Repair.
Blower motor failure 2 2203 Motor overloaded In case of heavy run or
failure: consult the RO-
BUSCHI manual in chap-
ter 14
Combustion air 1 PZA-L2011 Fan not running. -Check fuses, isolating
pressure low: switch, etc
Flexible joint in blower Repair/replace
outlet defective
Combustion air 2 PZA-H 2010 Combustion air blow- Readjust
pressure high: off valve (2050) not
adjusted correct
Pollution of main burn- Clean it
er
Demister (2307) in Clean it.
scrubber clogged.
No flame: The main 1 XZA 2021 Main burner flame de- Check main burner flame
burner does not ig- tector (2021). Window detector. Clean of replace.
nite or extinguishes may be dirty or the
during operation detector may be defec-
tive.
Flame safeguard relay Repair/replace.
in generator control
panel defective.
Oil pressure low. Check fuel oil pressure
before regulating valves.
Oil nozzle main burner Clean or replace it.
dirty.
Solenoid valves (1056 Check functioning
and 2040) in fuel line
to main burner not
functioning correctly.
No flame The pilot 1 XZA 2121 Check instrument air Adjust with pressure regu-
burner does not ig- pressure to pilot burn- lator PIC 2112 (see Pilot
nite: er. burner).
Oil and/or air atomiser Clean them.
of pilot burner dirty.

ORDER NR.: 072.14.1.9662

No flame The pilot 1 XZA 2121 Delivery pressure of Check pressure.
burner does not ig- the fuel oil pump incor-
nite (continued): rect.
Pilot burner flame de- Clean or replace it.
tector (2121) not func-
tioning correctly. The
window may be dirty or
the detector may be
defective.
The flush airline of Un-block it.
detector (2121) is
blocked
Flame safeguard relay Replace
in generator control
panel defective
Solenoid valves for Check and or replace.
instrument air and fuel
oil to pilot burner not
functioning correctly
Spark plug not func- Check, replace or adjust.
tioning correctly. Distance between elec-
Insufficient contact of trodes should be approx. 2
sparkplugs cap. Elec- mm.
trodes worn out or
wet?
Cooling water outlet 1 TZA-H 2312 No free discharge of Check free discharge of
temperature high: cooling water from cooling water.
combustion chamber. Check that the discharge
valves are open.
Orifice 2314 in cooling Clean it.
water line to combus-
tion chamber may be
clogged.
Cooling water inlet 1 PZA-L 2320 Cooling water supply Check fuses, duty switch-
pressure low: pump not running. es etc.
Pump isolation valve Open it.
closed
Filter clogged... Clean it

ORDER NR.: 072.14.1.9662

Cooling water supply 3 PZA-H 2321 Stoppage in combus- Clean it
pressure combustion tion chamber cooling
chamber high: water discharge line.
Excessive supply of Reduce.
cooling water.
Cooling water level 3 LZA-H 2322 Check free discharges Clean it.
high: of cooling water from Open the discharge valve.
water seal.
Air vent clogged. Open it (them).
Inert gas tempera- 1 TZA-H 2335 Supply cooling water Check pressure.
ture behind the low.
scrubber high: Sprayer pipes in Clean them.
scrubber clogged.
Orifice 2314 clogged. Clean them.
Valve 2313 not correct Adjust it.
adjusted.
Water level knock- 2 LZA-H 2522 Condensate discharge Clean it.
out drum high: line clogged
Compressor capacity Readjust (see adjustment
too high against the of atomizing pressure)
blower capacity
Common alarm 3000 See next chapter about
compressor unit trouble shouting of com-
pressor unit and sub sup-
plier manual of Airconet
Condensate level 1 LZA-H5104 Valve 5108 clogged or Clean and/or open more
high closed to much
Condensate level 1 LZA-H5114 Valve 5118 clogged or Clean and/or open more
high closed to much
Dryer 5000 Consult the Sub-suppliers
documentation manual in
Sub-suppliers documenta-
tion
Inert gas delivery 4 PZA-H6053 Tank full or valve
pressure high closed
Inert gas delivery 1 PZA-H6053 Valves downstream Check valves
pressure high closed/blocked
Dew point analyser 1 7100 Consult the Sub-suppliers
defect: documentation manual in
tion
Dew point high 1 QIAH7101 - dryer malfunction- -Check sample line on
ing leaks and flow.
- sample flow low -dry desiccant vessel 7109
(7105) at 150 °C
- Desiccant vessel -Consult the Sub-suppliers
7109 saturated. documentation manual in
- PIC 5241 leaking Sub-suppliers documenta-
- Block valves tion
7104/7103 leaking
- By-pass line 7110

ORDER NR.: 072.14.1.9662

open to much
-
O2 analyser defect: 1 7001 Consult the Sub-suppliers
documentation manual in
tion
O2 content low: 4 QIA-L 7001 Change in oxygen con- Re-adjust pressure by
tent may be the result means of pressure control
of changes in condi- valve (2032) in fuel oil line.
tions of ambient air
(temperature, humidi-
ty) or a result of a
change in fuel quality.
If generator delivery Re-adjust the generator
pressure is too high, delivery pressure
the air capacity supply
by the fan will be too
low to match the fuel
supply at the given
capacity position; as a
result the oxygen con-
tent will be too low.
Oil nozzle dirty. Clean it.
O2 content high: 4 QIA-H 7001 Change in oxygen con- Re-adjust pressure by
tent may be the result means of pressure control
of changes in condi- valve (2032) in fuel oil line.
tions of ambient air
(temperature, humidi-
ty) or a result of a
change in fuel quality.
If generator delivery Re-adjust the generator
pressure is too low, the delivery pressure
air capacity supply by
the blower will be too
high to match the fuel
supply at the given
capacity position; as a
result the oxygen con-
tent will be too high.
Oil nozzle damaged. Check it.

ORDER NR.: 072.14.1.9662
8.3.3 Trouble shooting chart Compressor unit
Failure C.o.F Safety Possible causes and remedies

device
Compressor 5 3002 - Adjust operating pressure.
motor Check pressure drop filters
overload:
Low inlet 4 PZAL3008 - Filters 3006, 2506 clogged
pressure: - Valve 3500 closed to much, leak, check
3006/3007
Compressor 5 TZAL3109 -control valve 3210 not correct
discharge
temperature
low:
Compressor 5 TZAH3110 - Valve 3210 not working properly
discharge - Cooler 3201 fouled, clean with steam
temperature - Set point 3214 not correct
high:
Discharge 5 PZAH3111 - Check pressure switch 3111
pressure - Check pressure drop filters 5101, 5111, 5201
compressor - Check set point control valve 6001
high: - Check pressure drop downstream cooler 3301
Low lub-oil 5 LZALL3103 - Check oil return 3116, clean filter 3114
level - Check demisters incl. seals 3124, 3119 if
compressor reached within 150 hours operation (some oil
low: losses is normal)
- Oil cooler 3201 leaking?
Lub-oil level 5 LZAH3102 - Oil temperature to low (min. 85ºC at 3113).
compressor Check 3113 and 3109.
high: - Risk of condensed water in oil.
Check drain 3104 (water?)
Low 4 TZAL3109 - Valve 3210 not working correct
temperature
alarm:
Differential 1 DPZAH3117 - Correct Lubricate-oil used?
pressure - Check oil separator vessel 3101 and drain quality
lub-oil filter 3104
high:
- Demister 3107 fouled.
Clean with solvent, change oil, change oil filter
(3120)
Outlet 4 TZAH 3307 - After cooler fouled
temperature - Demister 3119 fouled (carry-over of oil)
high: - Oil cooler (3201) clogged by water (possible if
TI 3113 lower than 85 ºC)

ORDER NR.: 072.14.1.9662
9 MAINTENANCE The combustion chamber of the generator

must be rinsed with fresh water after each
Before operating the unit, read the stop (only if the installation is stopped for a
SAFETY INSTRUCTIONS. period of 1 day or longer).
The fresh water is entered into the combus-

9.1 General maintenance tion chamber through valve 2313. Rinse the
instructions chamber with fresh water for about 20
Next pages include the maintenance sched- minutes.
ule for the installation. The detailed instruc-
tions for maintenance and repair of equip-
ment can be found in the instruction manuals 9.2 Main burner
of the sub-suppliers. Consult the Sub- The burner cone is a wear and tear part.
suppliers documentation. Therefore this cone must be checked period-
ically on damage and replaced as soon as it
Because maintenance greatly depends on starts to burn away (holes, decrease of
the operating conditions, the maintenance length).
intervals might have to be shortened or ex-
tended due to these conditions. The life of the burner cone is strongly influ-
This is to the operator's experience. enced by:
- The quality of the fuel that is used
- The correct adjustment of the burner (no
In case of a longer stand still the instal- soot production).
lation must be switched on each month
for approximately half an hour. To avoid If both conditions above are correct, the life-
corrosion, valves being jammed, etc. time of the burner cone can be several years.
IMPORTANT: To replace the cone the upper cover of the

- In the lower side of the internal wall of combustion chamber must be removed:
the jacket of the combustion chamber - Depressurise the combustion chamber
there is a hole (inside combustion and all supplies.
chamber). Through the filter, the jacket - Disconnect all pipes to the main burner.
of the combustion chamber is drained - Remove the cover by loosening the bolts.
during standstill. Also see “Rinsing the - Take out the cone.
combustion chamber” below. - Place the new cone.
- Reassemble in reverse order.
KEEP THE HOLE CLEAN AT ALL Note:
TIMES Mind the correct position for the hole for the
pilot burner.
- Even stainless steel (especially welds) can
corrode if it is exposed to non-flowing
seawater for longer periods. 9.3 Pilot burner
- Keep the electric power to the local control

panel turned on to prolong the lifetime of
the O2-sensor.
9.1.1 Rinsing the combustion cham-

ber
NEVER USE SALT WATER.

1

ORDER NR.: 072.14.1.9662
Fig. 9.2 Purge nozzle instrument air. 9.5 Freezing prevention

In case the ambient temperature for the Inert
Always keep the 1.5-mm hole in the purge gas installation becomes below 0 °C and the
nozzle (fig. 9.2-1) clean and open. This hole installation is out of service, attention must be
is used for purging the UV detector (2121) paid to the draining of the below mentioned
and the ignition transformer (2131). items.
Use a needle to un-block the hole.
From all these items the water (condense,
9.4 Dryer fresh water from rinsing) must be removed
The dryer and stripper unit needs a general and or drained.
overhaul regularly.
9.5.1 Generator unit
Especially when the drying or stripping - The combustion chamber and the scrub-
process is worsening the following items ber jacket. Normally these jackets will
must be checked: drain automatically and if the maintenance
is carried out as indicated in the Mainte-
- Clogging of silencer (5080): nance tables below, the jackets will be
Check and renew if necessary. empty.
- Proper functioning of all valves: - Cooling water supply and discharge pipes,
Check, clean, replace. - Water seal (2401): drain via valve (2410).
- High pressure drop over vessels: - Water seal (2503) of the k.o. drum: drain
Desiccant overage; replace. via valve
- Pre-filters (5101, 5111) clogged:
Clean or replace. 9.5.2 Screw compressor
- Compressed air capacity too high: - Oil separator (3101): drain via valve
Re-adjust. (3104).
- Lubrication oil cooler (3201) and after
9.4.1 Replacing the desiccant in dry- cooler (3301) with cooling water circuit for
er (5002/3) or the carbon in fil- both: drain via valves (3202/3302).
ter 5700: - Water separator (3401) and condensate
Close all inlet and outlet valves. Depressurise discharge: drain via valve (3408).
the vessel(s). Remove the upper and lower
side piping and remove the sieve tubes. The 9.5.3 Dryer unit
desiccant/carbon will flow out of the vessels. - Condensate separators (5103, 5113).
Fit the lower sieve and piping and fill the
vessel. Fit the upper sieve and piping. 9.5.4 General
- Drain the cooling water supply and
RUN THE INSTALLATION FOR MIN. 12 discharge pipes.
HOURS IN THE AIR PURGE MODE TO - Drain the storage tanks.
REMOVE THE DUST THAT IS CAUSED.
Remark:
CLOSE ALL DRAIN VALVES AGAIN!

ORDER NR.: 072.14.1.9662
9.6 Maintenance tables 9.6.2 Every 250-hrs
9.6.1 Before every start Component: Maintenance Remarks:

description
Component: Maintenance Remarks: Pilot burner Dismount and
description 2101 clean oil and
O2-analyser Check calibra- See sub- air atomiser.
QIA-7001 tion supplier man- Check and Distance be-
ual clean spark tween elec-
Fuel oil filter Rotate handle plug. trodes approx.
1002 twice 2 mm.
Filter in O2 Clean Main burner Dismount and
measuring 2001 clean oil noz-
line (7022) zle.
Filters in in- Clean Check cone Replace if
strument air on damage. necessary
line (5302) Fuel oil filter Drain sump
Filter in in- Clean 1002, 1052
strument air Instrument air Disassemble
lines (1502) filter 1502 and clean
Blower (2203) Check oil level See sub- Filters of Clean filter
supplier man- pressure element
ual regulators
Screw com- Check oil level 6004,6024,
pressor 7050
(3001) Filters 7022 Clean filter
Dryer General See sub- element
supplier man- Compressor Analyse oil Pending on
ual 3001 sample (only the analyses
after first 250 result: replace
hours) oil (Smit oil
stock no
380958)

ORDER NR.: 072.14.1.9662
9.6.3 Annually or 500-1000 hrs 9.6.4 After every stop
Component: Maintenance Remarks: Component: Maintenance Remarks:

description description
Combustion Remove the Combustion Rinse with DO NOT USE
chamber 2301 inspection lid chamber 2301 fresh water. SALT WA-
on the cooling TER!
tower and Filter 2350 Clean.
clean with
solvent
Demister Clean it
2307
Water spray- Inspect and
ers, pipes clean if nec-
2303/4 – 2306 essary.
Temperature Check the
& pressure calibration
gauges
Compressor Replace oil Smit oil stock
3001 no 380958
Inert gas fil- Replace
ters
(5101,5111
and 5201)
Carbon filter Replace
(5705)
PLC battery Replace bat- See Replac-
tery ing the PLC
battery
Safety devic- Check correct See the set-
es adjustment tings in the
and functional test protocol.
operation

ORDER NR.: 072.14.1.9662
9.7 Replacing the PLC battery 9.8 Lubricating schedule

The PLC is almost maintenance free. There For lubricating instructions of the E-motors,
are only a few points for maintenance. consult the instructions in the Sub-suppliers
documentation.
Replacement battery of Mitsubishi PLC.
There are two plc types used with different
backup systems.
FX1N for cargo control room: no battery, only

EEPROM memory backup.
FX2N for local panel: battery and EEPROM

memory backup.
The battery is maintenance free. It must be

replaced every 3 years. So make sure there
is a spare battery on board of the ship for
each CPU FX2N unit.
Actions:
- Replacement battery of FX1N
Nothing to do, because there is no battery to

replace.
- Replacement battery of FX2N PLC.
Replacement to be done in 20 seconds, to

keep the ram memory intact. Some status
values can be lost, but will not effect the
normal working of the PLC. The ram memory
will be reloaded from EEPROM, when the
power is back on.
The PLC starts then from the beginning with
a cold start and starts at the correct point in
the program.
1. Turn off the power supply to the PLC.

2. Remove left top cover of the PLC.
3. Remove battery form holder.
4. Disconnect the connector of battery.
5. Replace the new battery.
6. Connect the connector of battery.
7. Refit the cover.
8. Turn on the power supply to the PLC.
9. Power and Run led should light up.
10. Check? Try lamp test. If all led light’s
up, then the program runs and the
unit can be started.
Batt.V led should be off. CPU led
should be off.

ORDER NR.: 072.14.1.9662
9.8.1 Lubricating table
Lubricant: Shell ALVANIA or equal lithium based grease
See sub-supplier documentation.

ORDER NR.: 072.14.1.9662
10 TEST PROTOCOL
List of documentation:
No. Document no. Title
1. BGS19662-1E Test protocol

ORDER NR.: 072.14.1.9662
11 PROCESS DOCUMENTATION
No. Drawing no. Title
1) 19662PL Parts list PID

2) 19662001. Flow diagram generator
3) 19662002 Flow diagram compressor
4) 19662003 Flow diagram dryer
5) SSYMx005 Symbols/ codes

ORDER NR.: 072.14.1.9662
12 DIMENSIONAL DRAWINGS
1) 19657299 Generator
2) 19657309 FOP
3) 19657319 Blower
4) 19657549 Compressor
5) 19657374 Dryer
6) P-000590 Maintenance Main Burner
7) P-000588 Maintenance Pilot Burner
8) P-X00047 Status burner cone

ORDER NR.: 072.14.1.9662
13 ELECTRICAL DOCUMENTATION
1) 19662802 Main control panel generator

2) 19662810 Blower panel 10
3) 19662812 FOP panel
4) 19662816 Compressor Panel

ORDER NR.: 072.14.1.9662
14 SUB-SUPPLIERS DOCUMENTATION
Supplier Description
01 AIRTORQUE - Airtorque manual 4 generation actuators
02 SONDEX - Manual Plate Cooler
03 ECO-AIR - Operating Instructions compressor model IG 180/285
04 SERVOMEX - Xendos 1800-1900
05 EL-O MATIC - Engineering manual pneumatic actuators "P" and "E" series
06 FESTO - Instruction manual actuators
07 FUELMASTER - Nozzle art. 144
08 GHH - Air ends: for information only, dismantling not allowed
09 DONALDSON Dryer manual
10 HONEYWELL - Minipeeper Ultraviolet flame detectors C7027A, C7035A, C7044A

- Flame detector relay R 4343 D,E.
11 PANAMETRICS - Panadry type MTS5
12 GIULIANIANELLO - Strainers, turners
13 PHILIPS - Industrial controller KS50
14 ROTOR - Maintenance and installation procedures and re-greasing periods
15 ROBUSHI - Operating & maintenance instructions for RB-LP and RB blowers
16 DANFOSS - KSN Oil Pump

16A HP Technik - Series B-VB-VBR-NV
17 SAMSON - Pressure control valve type 41-73
18 SAUNDERS - Saunders_IDV_GB_2009
- Saunders_ES_Modular_Actuato_336129_6-04[1]
- 171
19 SIEMENS - Sipart PS 6DRxxx1-1N/E, -2N/E. Operating instructions
20 HANKINSON - HF-brochure
21 HOERBIGER - Minimum pressure valve
22 BESTA - Level switch high
23 ECONOSTO - Safety relief valve

ORDER NR.: 072.14.1.9662
Aalborg Industries Inert Gas Systems B.V.

St. Hubertusstraat 10
6531 LB Nijmegen
P.O. Box 6664
6503 GD Nijmegen
The Netherlands
tel.: +31 (0)24 35 23 200
fax: +31 (0)24 35 23 177
E-mail: inert.aftersales@aalborg-
industries.com
www.aalborg-industries.com

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INSTRUCTION MANUAL

© 2008 Aalborg Industries Inert Gas Systems B.V.

All rights reserved.

Aalborg Industries Inert Gas Systems BV Page 2 of 46

INERTGAS GENERATOR Series Gln

Type: Gln 2000 – 6 BUCD

Order number: 072.14.1.9662 .............................................................................

Manufacturing number: 07962 ..........................................................................................

Year of construction: 2009 ............................................................................................

Customer: LGE-Process / H.M.D. .................................................................

Ref. Customer: 06052-BB-QA-001 .......................................................................

Yard number: Hull 8010

Aalborg Industries Inert Gas Systems BV Page 3 of 46

TABLE OF CONTENTS 7.4.2 Inert gas production.............................. 23

5 TECHNICAL DESCRIPTION................... 11 9 MAINTENANCE ........................................ 35

5.1 PROCESS DESCRIPTION ................................... 11 9.1 GENERAL MAINTENANCE INSTRUCTIONS ........ 35

7.1 GENERAL........................................................ 21 13 ELECTRICAL DOCUMENTATION ....... 44

Aalborg Industries Inert Gas Systems BV Page 4 of 46

1 GENERAL INFORMATION 1.3 Guarantee

Aalborg Industries Inert Gas Sys-

P.O. Box 6664

Tel.: +31 24 35 23 200

We reserve the right to change the construction

Aalborg Industries Inert Gas Systems BV Page 5 of 46

2 SAFETY - Before entering an enclosed or poorly venti-

Oxygen content Effects and symptoms

Aalborg Industries Inert Gas Systems BV Page 6 of 46

2.2 Safety instructions for Operat-

Carefully read the cautions and instructions

1. Before doing any maintenance to the

2. Before doing any maintenance to the

3. When operating the equipment, do not

4. Do not remove any covers from rotating

5. At no time the unit should be energised

6. Spilling oil (fuel or lubrication) may cause

Do not enter any cargo space and/or

Aalborg Industries Inert Gas Systems BV Page 7 of 46

3 INSTALLATION 7. For free discharge of the seawater (con-

Aalborg Industries Inert Gas Systems BV Page 8 of 46

15. When the generator is erected in a room

16. The I.G. generator is equipped with a

17. The wiring of the auxiliary (control) cur-

18. The entrance of the main supply cables

19. Compressors may not stand in warm air

20. Always ensure adequate ventilation for all

21. During stand-still and operation the ambi-

Aalborg Industries Inert Gas Systems BV Page 9 of 46

4.1 General storage instructions

During transportation, severe shocks or vibra-

All equipment is packed by Aalborg Industries

4.2 Storage instructions for the

During this construction period of the ship the

Great care must be taken to protect the

Special care must be taken to protect the

Aalborg Industries Inert Gas Systems BV Page 10 of 46

Inert gas is produced by stoichiometric Drying inert gas:

Combustion air is supplied by a blower