DNVGL-CP-0210 Edition March 2016

Transcription

1 CLASS PROGRAMME Type approval DNVGL-CP-0210 Edition March 2016 The electronic pdf version of this document, available free of charge from is the officially binding version.

2 FOREWORD DNV GL class programmes contain procedural and technical requirements including acceptance criteria for obtaining and retaining certificates for objects and organisations related to classification. March 2016 Any comments may be sent by to This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibility for loss or damages resulting from any use of this document.

3 CHANGES CURRENT This is a new document. Changes - current Class programme DNVGL-CP Edition March 2016 Page 3

4 CONTENTS Changes current... 3 Contents Section 1 General Introduction Documentation...5 Section 2 Technical requirements Design requirements Test requirements Performance test Mechanical and functional tests...11 Changes historic...12 Class programme DNVGL-CP Edition March 2016 Page 4

5 SECTION 1 GENERAL 1 Introduction 1.1 Objective The objective of this class programme (CP) is to give a description for the type approval (TA) of Fuel oil separators. For a description of the DNV GL type approval scheme in general and further information on general conditions and procedures for obtaining DNV GL TA certificate, see class programme CP 0338, DNV GL type approval scheme. The procedures and requirements described in this CP are applicable for obtaining DNV GL TA certificate based on requirements in: DNV GL rules for classification of ships RU SHIP Pt.4 Ch.6, DNV GL rules for classification of High speed and light craft RU HSLC Pt.4 Ch.6 DNVGL OS D101 Other standards may be accepted within the framework of these rules. The certified flow rate (CFR) performance testing specified in Sec.2 [3] shall be in compliance with ISO standard CWA15375: Separators for marine residual fuel. Performance testing using specific test oil. Section Scope This CP gives a description of the procedures and requirements related to documentation, design and type testing applicable for TA of. This CP does not set the design requirements to the. TA is based on compliance with design requirements given in the DNV GL rules and/or other regulations and standards. The CP describes the applicable design requirements and how to document compliance with the requirements in order to obtain a TA certificate for the equipment. This includes, where relevant, technical requirements for how the type tests shall be performed. 1.3 Application TA of equipment in accordance with this CP is not mandatory, but may be used as an alternative to case by case design approvals for equipment to be installed on DNV GL classed vessels. A TA certificate in accordance with this CP will confirm compliance with the requirements as specified in [1.1]. The TA certificate will not confirm compliance with requirements in other parts of the DNV GL rules. In case additional requirements in other parts of the DNV GL rules shall be covered by the TA certificate, this shall be specified in the application for TA and will be stated in the TA certificate. 2 Documentation For TA of, the following documentation shall be submitted by the manufacturer before type testing: DNV GL application form for TA and asbestos free declaration assembly drawings of separator including parts list, specification of materials and connected accessories operation and technical manual for each separator type overview of recommended and CFR separation capacities for the individual fuel oil qualities specification of distance between discs, number of discs and disc angle Class programme DNVGL-CP Edition March 2016 Page 5

6 piping and instruments drawing (P&ID) for each separator system configuration, i.e. operation modes (purification, clarification), self-cleaning, manual cleaning, monitoring of clean oil etc. logic diagrams for the control system, wiring diagrams with parts list and specifications of electrical equipment including control and monitoring equipment hazardous area (EX) certification documentation as applicable, if the equipment shall be certified for hazardous area type testing programme, including method of analysing oil samples drawing of permanent plates giving any operational or installation limits, if any test plan for CFR performance testing and description of analysis method and equipment test report with result from type testing and data as specified in ISO standard CWA15375:2005, paragraph 7 report from initial assessment. Section 1 Class programme DNVGL-CP Edition March 2016 Page 6

7 SECTION 2 TECHNICAL REQUIREMENTS 1 Design requirements shall comply with the relevant requirements as listed in Sec.1 [1.1]. The shall be so designed that they will remove an acceptable percentage of the particles (cat fines) in the fuel oil at the certified flow rate. To estimate the ability to remove particles, the separator shall be tested by using a standardised test rig and test medium composed of an unambiguous mixture of synthetic oil and spherical particles. The separator shall be fitted with necessary monitoring, shut-down and safety functions to prevent critical operational conditions. The material used shall be resistant to all applicable fuel oil characteristics. Metallic materials shall be used in parts containing oil. Section 2 2 Test requirements Each type and size of fuel oil separators shall be subject to following prototype tests witnessed by a surveyor: performance test as described in [3] visual inspection verifying compliance with drawings automation safety functions alarms. 3 Performance test Performance testing shall establish a certified flow rate. This is the flow rate at which 85% separation efficiency on the spherical particles described in [3.2.2], is achieved 30 minutes after the previous sludge discharge The performance test shall be carried out to establish a curve (graph) showing percentage of separated particles versus flow rate. This curve will be used to determine the certified flow rate (CFR). Class programme DNVGL-CP Edition March 2016 Page 7

8 3.1 Description of test stand Section 2 S01: separator T01: system tank or mixing tank (minimum 5 m 3 ) T02: waste tank (minimum 5 m 3 ) T03: hot water tank E01: heat exchanger (used for heating) E02: heat exchanger (used for cooling) P2: hot water pump (centrifugal type) P3: regeneration pump P4: system pump or circulation pump (adjustable screw pump) SV: CV1: TC1: TT1: TTin: TTout: safety relief valve control valve temperature controller (PID type) temperature transmitter (accuracy ± 0.1 C) temperature transmitter (accuracy ± 0.1 C) (calibrated) temperature transmitter (accuracy ± 0.1 C) Class programme DNVGL-CP Edition March 2016 Page 8

9 PI: pressure indicator (accuracy ± 0.1 bar) PI1: pressure indicator (accuracy ± 0.1 bar) F: flow meter (screw type) (accuracy ± 0.1%) (calibrated) H: heating coil CW: cold water (from tap) Section 2 HV1: HV4: HV6: HV11: HV12: HV13: HV21: HV22: stop valve stop valve stop valve stop valve 3-way valve stop valve sample valve sample valve (always open during test) N: revolution measuring (calibrated) 3.2 Test medium Test oil specification The test medium shall be an automotive lube oil of type PAO 6 or equivalent. This is a polyalphaoleophine used by several automotive lubrication oil producers as a base for synthetic lubrication oils. The oil density can be approximated with: T C = temperature in Celsius and the kinematic viscosity with: T K = temperature in Kelvin. A and B are constants applicable for the actual test oil. For PAO 6 oil, constants are: A = and B = This formula shall be used with two accurately measured values of temperature and corresponding viscosity for finding A and B. The chosen temperatures should be one at each end of the actual measuring range. Then the formula shall be used for determining the correct temperature for the desired viscosity for the tests. To improve the dispersing properties of the test medium an appropriate dispersing additive of borated bissuccinimide type shall be added to the PAO 6 oil base. The dosage needed to prevent agglomeration in the temperature interval of interest is 0.1% weight/weight. Class programme DNVGL-CP Edition March 2016 Page 9

10 3.2.2 Particle specification To simulate catalytic fines and other contamination of fuel oil, monodispersed plastic 5 µm particles shall be used. These particles shall have a composition of 45% polystyren and 55% divenylbenzene. The density shall be 1.05 g/cm 3. The size variation shall not be more than 2.5%. Section Testing procedures Oil viscosity To simulate a typical heavy fuel oil of 380 cst (50 C), the test oil shall be heated to the temperature, which corresponds to a viscosity of 35 cst according to the interpolation described in [3.2.1]. To simulate a typical heavy fuel of 700 cst (50 C) the test oil shall be heated to the temperature which corresponds to a viscosity of 55 cst Particle concentration Particle concentration in oil feed to the separator should be 30 g of test particles per 1000 kg of oil. Dispersing of particles into test medium. The particles shall be dispersed into a small volume of oil by using a high power ultrasound. Then this mixture shall be blended into the oil in test rig Test sequence The objective of the testing is to find the certified flow rate for the viscosity in question. This necessitates testing at two or more flow rates in order to determine the efficiency graph in way of the 85% point. One or more points shall be positioned in the efficiency range from 95% to 85% and the other point between 85% and 75%. The sought position of 85% efficiency is found by linear interpolation between these two points Procedure Set the temperature controller to the correct value for the desired viscosity (see [3.2.1]). Set valve HV12 to bypass. Set the flow rate to the desired value by adjusting the valves HV11 and HV1. Alternatively pump with frequency control may be used. Discharge the separator S01. Set the valve HV12 to production. Start the timer when the bowl has been filled. (Indicated by pressure on PI1 and bleed flow through the sampling valve HV22.) Sample oil effluent at 28, 30 and 32 minutes. Repeat for the next flow rate. In order to ensure that the feed concentration is constant, feed samples are to be taken at least two times per test run. After the tests, the oil is pumped back from the effluent tank (TO2) and a sample of the mixed remaining oil feed and re-pumped effluent is taken as a preparation for the next test Sampling Samples shall be taken before the separator (by opening valve HV21) and after the separator (through valve HV22, which may be in open position during testing). To verify the results, samples shall be taken 28, 30, and 32 minutes after test start, and the average value of the three samples will be used in further calculations. Class programme DNVGL-CP Edition March 2016 Page 10

11 3.3.6 Analysis Analysis and calculation of CFR is to be carried out according to ISO standard CWA15375:2005, paragraph Test report After finalising of the type test sequences a test report according to ISO standard CWA15375:2005, paragraph 7 shall be issued. 3.4 Certified flow rate Certified flow rate determined for a viscosity of the test oil of 35 cst is considered applicable for a residual fuel of 380 cst (50 C) and a maximum density of 991 kg/m 3. Certified flow rate determined for a viscosity of the test oil is of 55 cst is considered applicable for a residual fuel of 700 cst (50 C) and a maximum density of kg/m 3. It is assumed that the fuel has contaminants not exceeding levels in ISO 8217/1996 (E) and relevant fuel grades. Section 2 4 Mechanical and functional tests test of automation test of alarm and automatic shut-down. Class programme DNVGL-CP Edition March 2016 Page 11

12 CHANGES HISTORIC There are currently no historical changes for this document. Changes historic Class programme DNVGL-CP Edition March 2016 Page 12

13 DNV GL Driven by our purpose of safeguarding life, property and the environment, DNV GL enables organizations to advance the safety and sustainability of their business. We provide classification and technical assurance along with software and independent expert advisory services to the maritime, oil and gas, and energy industries. We also provide certification services to customers across a wide range of industries. Operating in more than 100 countries, our professionals are dedicated to helping our customers make the world safer, smarter and greener. SAFER, SMARTER, GREENER