Instruction Manual

for Freshwater Generator

Type DPU-2-36-C125

Serial No.: N-016443

Shipname Mega Express

Hull No.:

Customer: Corsica Ferries

Book Number ON-016443.fm

Alfa Laval reserve the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvement of this publication
would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval company.

Published by: Alfa Laval Copenhagen A/S

Maskinvej 5
DK-2860 Søborg
(Copenhagen) Denmark

© Copyright Alfa Laval Copenhagen.

This document and its content must not be copied, reproduced, transmitted or disclosed to any third party
without consent of Alfa Laval Copenhagen.

2 ON-016442.fm
 Table of Contents

Technical Specifications
1.0.0 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
2.0.0 Hot water: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
3.0.0 Sea water:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
4.0.0 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
5.0.0 Parts included in delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

Safety Instructions and Warnings

1.0.0 Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8

System Description
1.0.0 Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
1.1.0 Freshwater Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
1.2.0 Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12

Operating Instructions
2.0.0 Starting and Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
2.1.0 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
2.1.1 Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
2.1.2 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16
2.2.0 Adjustment of Hot Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16
2.3.0 Adjustment of Sea Cooling Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
2.4.0 Stopping the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
2.5.0 Long Term Standstill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18

Maintenance
3.0.0 Why you need to perform regular maintenance duties . . . . . . . . . . . . . . . . . page 19
3.1.0 Overhaul Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
3.2.0 Maintenance of Separator Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
3.3.0 Maintenance of Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
3.4.0 Maintenance of Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
3.5.0 Renewal of Plate Heat Exchanger Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . page 23
3.5.1 Removal of Old Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23
3.5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
3.5.3 Preparation of new Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
3.5.4 Fitting new Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24

Pressure Test
4.0.0 Pressure Testing Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26

ON-016442TOC.fm 3
Table of Contents

Chemical Dosing of Scale Control Chemicals

5.0.0 Prevention of Scaling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
5.1.0 Feed Water Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
5.2.0 Chemical Dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
5.2.1 Scale Inhibitor Dosage Equipment for Feed Water . . . . . . . . . . . . . . . . . . page 28
5.2.2 Safety Precautions with the use of Chemicals . . . . . . . . . . . . . . . . . . . . . . page 29

Trouble-Shooting
6.0.0 Test Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30
6.1.0 Trouble Shooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31

Maintenance of Freshwater Pump

7.0.0 Maintenance of Freshwater Pump Types PVVF 1525-1532-2040 . . . . . . . page 34
7.1.0 Overhaul of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34
7.1.1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 35
7.1.2 Dismantling Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 35

Maintenance of Ejector Pump

8.0.0 Maintenance of Ejector Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
8.1.0 Overhaul of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
8.1.1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39
8.1.2 Dismantling Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41

Salinometer
9.0.0 Salinometer Type DS-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42
9.1.0 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42
9.2.0 Installation (for DS-20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42
9.3.0 Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
9.3.1 Testing the Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
9.3.2 Adjustment of Alarm Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
9.3.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44

Spare Parts
10.0.0 Ordering Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45
10.1.0 Alfa Laval Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45

Index
General description, DPU-2-36-C(AS)100/125 (MDPC No.: 9.2.4.1) . . . . . . . . . page 49
Technical data, DPU-2-36-C(AS)125 (MDPC No.: 9.2.4.2-3) . . . . . . . . . . . . . . . page 51
Technical data, Pump and Motor for DPU-2-36-C(AS)125 (MDPC No.: 9.2.4.2-4) page 53
Flow Chart (incl. options), DPU-36-C125 (MDPC No.: 9.2.4.3-5) . . . . . . . . . . . . page 55
Equipment specification, DPU-2-36-C(AS)125 (MDPC No.: 9.2.4.4-2) . . . . . . . . page 57
Dimensional drawing - DPU-2-36-C125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 59

4 ON-016442TOC.fm
 Table of Contents
Vertical Plant Positioning, JWP-16/26 and D-PU-(2)-36 (MDPC No.: 9.2.8.1) . . page 61
985 15915 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 63
984 70207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 65
985 20129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 66
Lifting brackets for DPU-2-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 67
Ejector assembly drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 69
Ejector DN100 2 AIR, DIN, Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 71
Solenoid valve - NO/230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 73
Fresh water pump type PVVF-2040 Assembly drawing . . . . . . . . . . . . . . . . . . . . page 77
984 10253-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 79
Outline drawing for motor 71B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81
Feedwater treatment 130 L build-on DPU-36-C(AS)100/125 (left side) 
(MDPC No.: 9.2.9.1-13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 83
Technical data, Control panel for Freshwater Generator (MDPC No.: 9.2.6.1-4) page 85
Dimensional drawing, Control panel for Two-stage FWG (MDPC No.: 9.2.6.2-5) page 87
Electrical diagram, Control panel for Two-stage Freshwater Generator 
(MDPC No.: 9.2.6.3-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 89
985 20578-R00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 97
Thermometer straight w.pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 99

Instructions manual for CNL pumps size 160 and 200 

Alfa Laval Freshwater Generators
Ejector pump assembly and spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . page 127
Ejector pump, Pump curve CNL 80-80/200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 129
Dimensional drawing, CNL 80-80/200 (MDPC No.: 9.2.5.2-3) . . . . . . . . . . . . . . . page 131
Test sheet for Single-stage Freshwater Generator . . . . . . . . . . . . . . . . . . . . . . . page 133

ON-016442TOC.fm 5
 Technical Specifications

1.0.0 Technical data

Freshwater Generator Type: DPU-2-36-C125
Number of Plates: 54/54/54
Capacity: 60.0 m³/24h
Connection standard: DIN

2.0.0 Hot water:

Flow: 99.8 m³/h
Inlet temperature: 85.0 °C
Outlet temperature: 76.3 °C
Heat consumption : 867.6 Mcal/h
Pressure drop: 0.29 bar

3.0.0 Sea water:

Flow: 88.0 m³/h
Inlet temperature: 32.0 °C
Outlet temperature: 40.5 °C
Pressure drop: 0.23 bar

4.0.0 Electrical data

Power supply: 3x440V/
Frequency: 60Hz
Control voltage: 230 Volt

N-016442 -Technical-Specifications.fm 6
 Technical Specifications

5.0.0 Parts included in delivery

MM-111-01 1 FWG, basic equipment, DPU-2-36-C125
39503723-83 1 P-36 ES Plate
39503648-03 26 P-36 EV Plate
39503723-03 26 P-36 ED Plate
39503722-76 1 P-36 EE Plate
39503724-86 1 P-36 KS Plate
39503724-03 26 P-36 KV Plate
39503725-03 26 P-36 KD Plate
39503722-76 1 P-36 KE Plate
39503723-83 1 P-36 ES2 Plate
39503722-03 26 P-36 EV2 Plate
39503723-03 26 P-36 ED2 Plate
39503722-76 1 P-36 EE2 Plate
985 18923-80 1 Basic equipment DPU-2-36-C125
985 13949-82 18 Clamping Bolt L=450
985 23202-19 1 Ejector
984 57864-10 1 Feed water orifice DPU-2-36
985 15120-80 1 Freshwater outlet system
984 23490-00 1 Solenoid valve - NO/230V
984 10253-00 2 Fresh water pump type PVVF-2040
985 63002-04 2 Motor size 71 B, 0.75 kW
985 13505-01 1 Name plate
included 1 Packing for DPU-2-36-C125
MM-111-19 1 Transport: FCA/FOB cost
984 10346-00 1 Ejector pump type CNL 80-80/200
985 63012-04 1 Motor 160L, 21.5 kW
985 64026-00 1 Standard control panel
985 19815-80 1 Feed water treatment build on left
985 21193-80 1 Parts enlosed with delivery - standard
MM-XX-62S 1 Standard certificate
AB-INSTA-CD-GB 1 Electronic Installation manual in 
English on CD-ROM
AB-INSTR-CD-GB 1 Electronic Instruction manual in 
English on CD-ROM
AB-INSTA-EM-GB 1 Electronic Installation manual in 
English by E-mail
AB-INSTR-EM-GB 1 Electronic Instruction manual in 
English by E-mail

N-016442 -Technical-Specifications.fm 7
 Safety Instructions and Warnings

Should you need further clarification regarding this manual, do not hesitate to con-
tact your local Alfa Laval representative - or call Alfa Laval Desalt directly.

Telephone +45 (for Denmark) 39 53 60 00

Telefax +45 (for Denmark) 39 53 65 66

1.0.0 Safety Instructions and Warnings

The following symbols in this manual point out safety precautions. It means your at-
tention is needed and your safety is involved.

WARNING

This symbol is used to indicate the presence of a hazard which can or will
cause severe personal injury, if the warning is ignored.

CAUTION

Certain passages of the text will be marked with a caution mark. This mark
indicates the presence of hazard which will or can cause property damage
if the instructions are not observed.

NOTE

This type of instruction indicates a situation which, if not avoided, could re-
sult in damage to the equipment.

It is the owner’s and operator’s responsibility to see that any person involved
with the use or operation of this equipment follow all safety instructions.

Read all safety instructions carefully and insist that they will be followed by
those working with you and for you. Not following the instructions may cause
severe personal injury or damage the equipment beyond repair.

Do not allow this equipment to be used if it is faulty or the operator does not
understand the proper use.

Samare04.fm 8
 Safety Instructions and Warnings

WARNING

The freshwater generator is not to be operated in polluted water or within

20 miles from the coast

Freshwater must not be produced from polluted water, as the produced water can be
unsuitable for human consumption.

If manuals are translated to local language the unit comply with the EEC Machinery
Directive and EN 292-1/2 standards. For EEC land installations manuals MUST be
available in local language before installing and operating the unit.

The unit also comply with EN 50081-2 and EN 50082-2 “Industry” with regards to the
EMC directive from EEC.

WARNING

Noise hazards
• Use ear protection in noisy environments.

Crush hazards
• Use correct lifting tools.
• Do not work under hanging load.

Burn hazard
• Wear gloves to avoid burns by hot surfaces.

Cut hazards
• Wear gloves to avoid cuts by sharp edges when handling machined
parts.
• Wear helmet to avoid cuts by sharp edges during maintenance of the
equipment.

NOTE

• Max. ambient temperature for the equipment is 50°C (122°F).

• Min. ambient temperature for the equipment is 0°C (32°F).

Samare04.fm 9
Safety Instructions and Warnings

10 Samare04.fm
 System Description

o21t
Jacket water in Jacket water out

age
m st
Feed water stage 1 in

m fro
Stea
Sea cooling water in

Feed water stage 2 in

Fresh water out

Sea cooling water out

1.0.0 Working Principle

The combined brine/air ejector driven by the ejector pump creates a vacuum in the
system in order to lower the evaporation temperature of the feedwater.

The feedwater is introduced into the evaporator section stage 1 through an orifice,
and is distributed into every second plate channel (evaporation channels).

The hot water is distributed into the remaining channels, thus transferring its heat to
the feedwater in the evaporation channels.

Having reached boiling temperature - which is lower than at atmospheric pressure 

- the feed water undergoes a partial evaporation, and the mixture of generated va-
pour and brine enters the separator vessel, where the brine is separated from the
vapour and is introduced into every second channels of the evaporator stage 2 as
feed water.

The vacuum steam generated in the first stage passes via a demister into the re-
maining channels in stage 2 of the evaporator section.

Sy2dpe00.fm 11
System Description

Transferring its heat contents to the feedwater of the second stage, the vacuum
steam condenses and is extracted by one of the freshwater extraction- and transfer
pumps.

The brine from the second stage is extracted by the combined brine/air ejector.

The vacuum steam generated in the second stage passes via a demister into every
second plate channel of the condenser section of the second stage.
The seawater supplied by the ejector pump is distributed into the remaining chan-
nels, thus absorbing the heat being transferred from the condensing vapour.

The produced freshwater is extracted by the freshwater pump and led to the fresh-
water tank.

1.1.0 Freshwater Quality

To continuously check the quality of the produced freshwater, a salinometer is pro-
vided together 
with an electrode unit fitted on the freshwater pump delivery side.

If the salinity of the produced freshwater exceeds the chosen maximum value, the
dump valve and alarm are activated to automatically dump the produced freshwater
to the bilge.

If there are no special requirements from the authorities, the produced freshwater
can be used directly as drinking water.

1.2.0 Main Components

The freshwater generator consists of the following components:

1. Evaporator section
The evaporator section consists of a plate heat exchanger and is enclosed in
the separator vessel.

2. Separator vessel
The separator separates the brine from the vapour.

3. Condenser section
Just like the evaporator section the condenser section consists of a plate heat
exchanger enclosed in the separator vessel.

4. Combined brine/air ejector

The ejector extracts brine and incondensable gases from the separator vessel.

12 Sy2dpe00.fm
 System Description

5. Ejector pump
The ejector pump is a single-stage centrifugal pump. This pump supplies the
condenser with sea water and the brine/air ejector with jet water as well as feed
water for evaporation.

6. Freshwater pump
The freshwater pump is a single-stage centrifugal pump. The freshwater pump
extracts the produced freshwater from the condenser, and pumps the water to
the freshwater tank.

7. Salinometer
The salinometer continuously checks the salinity of the produced water. The
alarm set point is adjustable.

8. Control panel
Normally, the control panel is delivered by Alfa Laval Desalt. It contains motor
starters, running lights, salinometer, contacts for remote alarm and is prepared
for start/stop.

Sy2dpe00.fm 13
System Description

14 Sy2dpe00.fm
 Operating Instructions

WARNING

DO NOT operate the plant in polluted water.

Freshwater must not be produced from polluted water, as the produced water will be
unsuitable for human consumption.

2.0.0 Starting and Stopping Procedure

CAUTION

Before starting up please observe instructions for feedwater treatment, see

“Chemical dosing of scale control chemicals”.

Please refer to PI-diagram (see “FWG Order Specification”).

2.1.0 Starting
1. Open valves on the suction and discharge side of the ejector pump
PU-SC-01.

2. Open overboard valve for combined brine/air ejector.

3. Close air screw VA-E1-01 on the separator.

4. Start ejector pump PU-SC-01 to create a vacuum of min. 90%.


Pressure at combined brine/air ejector inlet minimum 300 kPa (3.0 kp/cm²).
Back pressure at combined brine/air ejector outlet maximum 60 kPa (0.6 kp/
cm²).

2.1.1 Evaporation
When there is a minimum of 90% vacuum (after maximum 10 minutes).

5. Open valve for feedwater treatment, if any.

Opjwe00.fm 15
Operating Instructions

6. Open hot water inlet and outlet valves.

7. Start hot water supply to distiller by adjusting bypass valve or hot water pump
if any, step-wise 10°C, until the desired jacket water temperature is reached.

The boiling temperature now rises, while the obtained vacuum drops to approx.
85%.

This indicates that evaporation has started.

2.1.2 Condensation
After approx. 3 minutes the boiling temperature will drop again, and normal vacuum 
is reestablished.

8. Open valve to freshwater tank.

9. Switch on salinometer.

10. Start freshwater pump PU-FR-01/PU-FR-02.

NOTE

The freshwater pump discharge pressure will be between 120 and 160 kPa
(1.2 - 1.6 kp/cm²).

After starting the freshwater pump the flow sight glass in the air suction pipe must
be empty.

CAUTION

If water remains in the flow sight glass in the air suction pipe, please refer
to “Trouble shooting”.

2.2.0 Adjustment of Hot Water Flow

Please refer to “FWG Order Specification” for specified hot water flow.

In order to obtain the specified flow of hot water, it is necessary to adjust the bypass
valve until desired flow is achieved.

16 Opjwe00.fm
 Operating Instructions

The flow can be calculated as follows:

MJW = KJW  cap.m³/24h =m³/h

tJW

Where:

MJW = Flow of hot water in one hour.

KJW = Constant =25.6 for 1-stage freshwater generator.

KJW = Constant =15.52 for 2-stage freshwater generator.

tJW = Difference in temperature of hot water in and out.

Cap.m³/24h = Freshwater production in 24 hours, i.e. production in 5

min. times 288.

Example: cap. m³/24h = 15 m³

TSW = 32°C
tJW =18.4°C

MJW = 25.6  15 ................= 20.9 m³/h

18.4

2.3.0 Adjustment of Sea Cooling Water

The sea cooling water flow is correct, when the pressure at the inlet side of the com-
bined air/brine ejector is between 300 and 400 kPa (3.0 - 4.0 kp/cm²).

2.4.0 Stopping the Plant

1. Stop hot water supply to distiller.

2. Close valve for feedwater treatment, if any.

3. Stop freshwater pump PU-FR-01/PU-FR-02.

4. Switch off salinometer.

5. Stop ejector pump PU-SC-01.

6. Open air screw VA-E1-01.

Opjwe00.fm 17
Operating Instructions

7. Close valves on the suction and discharge side of the ejector pump.

8. Close overboard valve for combined brine/air ejector.

9. Close the valve to freshwater tank.



CAUTION

All valves must be shut, while the distiller is out of operation. Except air
screw.

2.5.0 Long Term Standstill

If the distiller is out of operation for a period longer than 14 days.

• Open front covers and clean unit inside with freshwater.

• Let the unit dry out completely, before closing covers.

Please observe “Maintenance of separator vessel”.

18 Opjwe00.fm
 Maintenance

3.0.0 Why you need to perform regular maintenance duties

Regular maintenance of the plant will improve performance and availability.

The maintenance schedule on the following pages will tell you how often service
should be performed on the main components.

As the actual operating conditions of the plant are of major influence on the life time,
the overhaul dates are not obligatory but only recommended intervals.

When the plant has been in operation for a longer period of time and experience has
been established as to the actual performance, it will be possible to adapt the main-
tenance schedule.

For service on minor components please refer to component instructions.

3.1.0 Overhaul Intervals

Component Operating Action

Hours

Evaporator section As required Clean in inhibited acid bath

Condenser section As required Clean with pure freshwater and

brush

Combined ejector/cooling 8000 h Measure seal ring and impeller.

water pump with motor Examine mechanical shaft seal,
Hot water ciculating pump cooling water pipe passage.
Megger-test electric motor.
Clean pump thoroughly before
reassembly.

Freshwater extraction 8000 h See above

pump with motor

Combined air/brine ejector 8000 h Measure nozzles and diffuser

and compare to measurements
in technical specification.

MV-valves 4000 h Disassembly and inspect for

damage.

Demister 8000 h Clean in inhibited acid bath

Madpue01.fm 19
Maintenance

Component Operating Action

Hours

Manometers 8000 h Adjust with control manometer

Salinometer See separate in- See separate instructions

structions

3.2.0 Maintenance of Separator Vessel

The separator vessels and the pressure plates for the heat exchanger sections
(evaporator and condenser) are made of stainless steel with a special chemical
treatment. This treatment will reestablish normal surface oxidation after work- up at
the factory. The preparation is a natural protection of the stainless steel.

CAUTION

To preserve this natural protection DO NOT scrape or scratch the inside

surface of the separator vessels.

Further, there are isolating layers on the separator inside walls, where the heat ex-
changer sections are mounted.

Whenever the sections are dismantled, these isolating layers must be checked for
defects. Repair any defects according to the maintenance guide for glass flake coat-
ing.

Whenever the separator vessel is opened,

• check that the anodes are functioning

If the anodes are not functioning and/or worn, replace them.

NOTE

If the unit is stopped for a longer period than 14 days.

• Open separator covers and clean unit inside with freshwater.

• Let the unit dry out completely, before closing covers.

20 Madpue01.fm
 Maintenance

3.3.0 Maintenance of Evaporator Section

Clean evaporator as follows:

1. Remove bolts in front cover, and open.

2. Loosen the 6 nuts in plate stack gradually, so that no nut is carrying the entire
load alone

3. Remove plate stack.

NOTE

If some of the gaskets come loose on removing plate stack, please see
section 1.5.2

4. Submerge plates completely in a hot, inhibited acid bath at maximum 50ºC. For
further instructions see “Chemical dosing of scale control chemicals”.

WARNING

Always follow carefully the suppliers instructions when using inhibited ac-
ids.

Remember to neutralize according to suppliers instructions.

5. Examine plates and gaskets for possible damage, and remove damaged plates
and/or replace damaged gaskets.

6. If a defective plate is found, remove the plate together with one of the adjacent
plates.

NOTE

The assembly measurements must be reduced with 5.4 mm per plate, if

plates are removed from plate stack.

Madpue01.fm 21
Maintenance

CAUTION

The ES and EE plate cannot be removed but must always be replaced, with
a corresponding plate.

7. Reassemble evaporator section in accordance with assembly scheme.

8. Tighten plate stack to measurements stated in technical specification.

9. Pressure test evaporator section before closing front cover.


The evaporator section is pressure tested by letting hot water circulate through
the section with bypass valve for hot water in normal running position.

10. When the evaporator section is found to be tight, close front cover and tighten
bolts.

11. Retighten, when vacuum has been reestablished.

3.4.0 Maintenance of Condenser Section

Clean condenser as follows:

1. Remove bolts in front cover, and open.

2. Loosen the 6 nuts for SWC-unit / 12 nuts for CL-unit in plate stack gradually,
so that no nut is carrying the entire load alone.

3. Remove plate stack.

NOTE

If some of the gaskets come loose on removing plate stack, please see
section 1.5.2

4. Scrub plates with a soft brush and plain hot water at maximum 50°C.

5. Examine plates and gaskets for possible damage, and remove damaged
plates and/or replace damaged gaskets.

6. If a defective plate is found, remove the plate and one of the adjacent plates.

22 Madpue01.fm
 Maintenance

NOTE

The assembly measurements must be reduced with 5.4 mm per plate, if

plates are removed from plate stack.

CAUTION

The ES and EE plate cannot be removed, but must always be replaced,

with a corresponding plate.

7. Reassemble condenser section in accordance with assembly scheme.

8. Tighten plate stack to measurements stated in technical specification.

9. Pressure test condenser section before closing front cover.

The condenser section is pressure tested by letting sea water from the com-
bined cooling water/ejector pump circulate through the section.

CAUTION

Before starting the combined ejector/cooling water pump, the feed water
must be sealed off.

10. When the condenser section is found to be tight, close front cover and tighten
bolts.

11. Retighten, when vacuum has been reestablished.

3.5.0 Renewal of Plate Heat Exchanger Gaskets

3.5.1 Removal of Old Gaskets

Pull the old gaskets out of groove.

If the gasket cannot come off directly, heat the back of the gasket groove with a
hot-air blower or butane gas burner.

Madpue01.fm 23
Maintenance

Pay attention not to overheat the plates.

You will obtain a suitable temperature, if the flame is held 10 to 15 cm behind the
plate.

WARNING

DO NOT use acetylene gas

3.5.2 Cleaning
Charred or loose glue and rubber remains must be removed, e.g. using a rotating
stainless steel brush. The width should be adapted (Ø40-50 mm, width 8-10 mm).
Thin layers of glue which are difficult to remove, may remain.

Clean the gasket groove with a clean cloth, dipped in a solvent (acetone, methyl eth-
yl ketone, trichlorethylene etc.).

WARNING

Be careful when handling these solvents, as they may be hazardous to

your health. Observe suppliers’ instructions.

Gaskets, that have loosened, can be glued on. Clean gasket groove carefully with a
sharp tool. Then clean the loose part of the gasket with emery cloth or sandpaper.
Finally clean groove and gasket with a solvent, and glue.

3.5.3 Preparation of new Gaskets

Dry new gaskets with a clean cloth that has been slightly moistened with a solvent.

3.5.4 Fitting new Gaskets

1. Apply a thin layer of glue to both gasket and groove.

2. Let the glue dry for 10-15 minutes.

3. Fit new gasket into groove.

Gaskets may sometimes be slightly short or long.

24 Madpue01.fm
 Maintenance

Short gaskets should be stretched before being fitted into the groove.

Long gaskets should be fitted into the grooves at the plate ends first and then
gradually be pushed into the groove towards the middle.

If necessary, tape gasket into groove.

Madpue01.fm 25
 Pressure Test

4.0.0 Pressure Testing Separator

If there are leaks in the system, it will be necessary to carry out a pressure test in
order to identify the leak:

1. Close valve on discharge side of combined cooling water/ejector pump.

2. Close discharge valve on overboard line from combined brine/air ejector.

3. Close valve on discharge line to freshwater tanks.

4. Open air screws on the separator vessel in order to vent the vessel, when sup-
plying water for pressure test.

5. Supply water (sea or freshwater) at the socket for the connection of feed water
treatment.

CAUTION

Maximum pressure on the separator vessel is 150 kPa (1.5 kp/cm²) (21
PSI).

Prdpue00.fm 26
 Chemical Dosing of Scale Control Chemicals

5.0.0 Prevention of Scaling

During the evaporation of sea water there is always a risk of scaling on the heating
surfaces. This will lead to a reduction of the K-values of the heating surface and de-
creasing freshwater production and reduction of plant efficiency.

In order to effectively prevent scaling the operators must be aware of the factors in-
fluencing the scale formation.

5.1.0 Feed Water Ratio

The feedwater ratio is an extremely important factor. It is defined by the relationship
between the feedwater amount fed into the plant and the produced amount of fresh-
water.

If the feedwater ratio is reduced, the concentration will rise in the plant subsequently
resulting in scale formations.

Two things may shift the feedwater ratio: first of all direct adjustment of the feedwater
system, and secondly exceeding the maximum freshwater production laid out for the
plant. The operators must observe the following rules at all times.

CAUTION

DO NOT adjust feedwater system. Feedwater pressure min. 3.0 max. 4.0
bar g.

5.2.0 Chemical Dosage

In order to control scale formations on the heating surfaces and continuously ensure
long operation periods without acid cleaning the plant, it is absolutely necessary to
dose scale control additives to the feedwater. The operators must follow the instruc-
tions for chemical dosing given by the chemical supplier carefully.

Cdgnpe00.fm 27
Chemical Dosing of Scale Control Chemicals

CAUTION

If the distiller is operated at boiling temperatures above 45°C without chem-

icals, frequent cleaning of the evaporator will be necessary.

We recommend that you do not operate the freshwater distiller without rec-
ommended chemical dosage at boiling temperatures above 45°C. Even at
lower temperatures it can be recommended.

5.2.1 Scale Inhibitor Dosage Equipment for Feed Water

Please refer to drawing, see “FWG Order Specification”.

• When adding chemicals mix thoroughly to ensure a homogenous blend of

chemicals and water.

Use a fully soluble scale inhibitor, e.g. on polymer basis. The following products can
be recommended:

NALFLEET Evaporator treatment 9-913

AMEROYAL EVAPORATOR TREATMENT

HEXAMETHAPHOSPHATE

1. Mix the required quantity for 24 hours operation in the tank according to mak-
er’s instructions.

2. Adjust flowmeter to cover the maximum freshwater output from the distiller.

3. Flush the dosage system regularly.

28 Cdgnpe00.fm
 Chemical Dosing of Scale Control Chemicals

5.2.2 Safety Precautions with the use of Chemicals

WARNING

1 USE eye protection and gloves. Avoid direct skin contact, eye contact
or contact with clothes. 

2 CLEAN empty containers before disposal. 

3 If chemicals are spilled on clothes, rinse with water and dispose off
clothes. 

4 If chemicals are spilled on the floor, rinse with water and suck remain-
ing chemicals off with sand. Clean the spot immediately afterwards. 

5 Scale inhibitor is hazardous, if consumed in a concentrated solution.

If consumed by mistake.
IMMEDIATELY SEEK MEDICAL ATTENTION. 

6 If eyes get in contact with the chemicals, rinse for at least 20 minutes.
IMMEDIATELY SEEK MEDICAL ATTENTION.

Cdgnpe00.fm 29
 Trouble-Shooting

6.0.0 Test Sheet

Before taking any action, please fill in a test sheet to find possible causes of malfunc-
tions.

Test sheets can be found in the back of this binder.

Trw26e03.fm 30
 Trouble-Shooting

6.1.0 Trouble Shooting Table

Problem Cause Action

Drop in production. Partially blocked feed water Dismantle evaporator section,

orifice and/or sludge deposits and clean evaporator and ori-
on hot water side. fice.

Sludge on the heat exchanger Dismantle condenser section,

plates on the sea water side. and clean.

Inlet channel in evaporator/ Dismantle evaporator/ con-

condenser plate stack denser section, and clean.
blocked, e.g. with rust scales,
gasket fragments etc.

Too low ejector pump pres- See instructions for “Low Sea
sure. Cooling water/Ejector pump
flow / pressure”, below.

Leakages Carry out a pressure test at

max. 150 kPa (1.5 kp/cm²)
(21.8 PSI).a

Foreign bodies in ejector noz- Inspect nozzles, and clean.

zles. Replace nozzles, if damaged.

Too high back pressure on Check overboard pipe and

ejector outlet side. Max 60 valves for blocking / function-
kPa (0.6 kp/cm²) (8.7 PSI). ability.

Non-return valve in air extrac- Replace non-return valve.

tion pipe defect.

Hot water temperature too Reduce to specified tempera-

high. ture.

Defective water clock. Examine water clock. Let the

produced water flow through
water clock into a 10 l pail, and
check production with a stop
watch.

Trw26e03.fm 31
Trouble-Shooting

Problem Cause Action

Low Sea Cooling water/Ejector Too low ejector pump pres- Clean, or replace pressure
pump flow / pressure. sure. gauge.
Minimum pressure 300 kPa
(3.0 kp/cm²) (43.5 PSI). Suction strainer blocked. Clean suction strainer.
At inlet side of ejector.
Valves on suction or pressure Examine and overhaul defec-
pipe defect. tive valves.

Leakage from suction pipe to Repair.

pump.

Impeller / seal ring defective. Check pump maximum clear-

ance See “Maintenance of
Ejector Pump”

Clocked up condenser plate Dismantle condenser plate

stack. stack and clean.

Pump rotating in wrong direc- Interchange phases.

tion.

Sight glass overflow. Normal Suction pipe leakage. Check suction pipe especially
back pressure for freshwater unions and connections. Re-
pump is 120 - 160 kPa (1.2 - pair.
1.6 kp/cm²) (17.4 - 23.2 PSI).
Except for JWP-16-C40 gener- Mechanical seal in freshwater Replace mechanical seal.
ator type, where the max. back pump defect.
pressure is 80 kPa (0.8 kp/cm²)
(11.6 PSI). Impeller / seal ring in freshwa- Check pump maximum clear-
ter extraction pipe defect. ance See “Maintenance of
Freshwater Pump”

Pump rotating in wrong direc- Interchange phases.

tion.

Valves to freshwater tank Check all valves.

closed.

Inlet filter for water clock Clean filter.

blocked.

Salinity too high (more than 2.0 Demister not fitted correctly. Check that demister is fitted
ppm). against baffle and front cover.

Front cover gasket defect or Replace front cover gasket.

not fitted correctly.

Insufficient brine extraction. See separate instructions for

insufficient brine extraction,
below.

Electrode unit defective or Examine electrode unit for

dirty. cracks. Check that it is fitted
correctly. Clean, if necessary.

32 Trw26e03.fm
 Trouble-Shooting

Problem Cause Action

Leakage in condenser sec- Open distiller and pressure test

tion. condenser. Max. 600 kPa (6.0
kp/cm²) (87 PSI). If there is a
defective plate, remove togeth-
er with adjacent plate assem-
ble plate stack according to
new plate number with re-
duced assembly measure-
ments. Check plate gaskets
and replace, if necessary.

Insufficient brine extraction - Ejector pump pressure too See special instructions for
brine level in sight glass higher low. “Low Sea Cooling water/Ejec-
than 20 mm. tor pump flow / pressure”,
above.

Foreign bodies in ejector noz- Check nozzles, and clean. Re-

zles. place damaged nozzles.

Too high back pressure down- Examine overboard pipe and

stream of ejector. valves.

Wrong dimension of feedwa- Examine orifice dimension -

ter orifice. check technical specification.

Non-return valve in brine suc- Examine valve and repair, or

tion pipe of ejector defect. replace.

Frequent refill of freshwater Leakage in evaporator sec- Open distiller and pressure test
expansion tank due to loss of tion. condenser. Max. 600 kPa (6.0
hot water. kp/cm²) (87 PSI). 
If there is a defective plate, re-
move together with adjacent
plates assemble plate stack
according to new plate number
with reduced assembly mea-
surements. Check plate gas-
kets and replace, if necessary.

Abnormal amperage con- Ejector nozzles defective. Replace nozzles.

sumption of ejector pump mo-
tor. Wrong dimension of feedwa- Check dimensions on spare
ter inlet orifice. parts list, See List of spare part
drawings”, and replace if nec-
essary.

Bearings in motor defective. Examine with stetoscope, and

replace bearings, if defective.

Contactor defective. Examine and replace contactor

set, if defective.

Breaking of phases. Max. 5% difference in amper-

age between phases.

Trw26e03.fm 33
 Maintenance of Freshwater Pump

7.0.0 Maintenance of Freshwater Pump Types PVVF 1525-1532-2040

The following instructions must be carefully observed whenever it becomes neces-
sary to overhaul or repair the freshwater pump.

Please refer to drawing for item references in the text.

7.1.0 Overhaul of the Pump

1. Remove the nuts 14 on the pump casing 1.

2. Lift motor with pump cover 4 and impeller 2 clear of pump casing 1.

3. Unscrew countersunk screw 20 (right hand thread).

4. Remove impeller. Normally, it can be removed without using dismantling tools.

5. Remove key 19.

6. Remove the mechanical shaft seal 22.

7. Inspect the ceramic ring, the carbon ring and the spring.

8. Replace mechanical shaft seal, if necessary. It is recommended to grease the

shaft and seat for the ceramic ring with glycerine in order to make it easier to
assemble the mechanical shaft seal. Please also observe separate instruc-
tions for mechanical shaft seal delivered together with the seal.

Mapvfe00.fm 34
 Maintenance of Freshwater Pump

9. Fit carbon ring, spring and spring holder on pump shaft.

10. Inspect impeller and the drilled sealing water channel for clogging, and clean.

11. Remember to replace gasket 3.

12. Reassemble in reverse order.

7.1.1 Clearance
In connection with the inspection be sure to measure the impeller and wear ring 17
in order to secure that the clearance is no more than 0.5 mm on the diameter.

CAUTION

The pump shaft 11 must only be dismantled, if pump shaft or electric mo-
tor bearing has to be replaced.

In this case carefully observe “Dismantling pump shaft”.

7.1.2 Dismantling Pump Shaft

1. Dismantle the pump as described above.

2. Unscrew pointed screws 11.

3. Carefully insert two screw drivers behind the pump shaft, and loosen it.

If the pump shaft does not come loose, use the special dismantling tools shown
below.

The tool is not Alfa Laval Desalt supply.

Mapvfe00.fm 35
Maintenance of Freshwater Pump

The tool consists of a pipe (A), a disc (B) with hole for the screw (C) and a nut
(D), washer (E).

Please note that the length L must be longer than the length l.

Place pipe around the shaft. Fasten the screw with nut and washer into the
threaded hole (M12) on the shaft end.

Loosen shaft by tightening the nut while holding on to the screw.

CAUTION

DO NOT grind the motor shaft.

4. Mount the new pump shaft on the motor shaft.

5. Make sure that the pump shaft fits the motor shaft without any obstructions, be-
fore final shaft fitting as follows:

• Tap onto the end of the pump shaft slightly with a RUBBER hammer.

6. Tighten pointed screws 11 as follows:

36 Mapvfe00.fm
 Maintenance of Freshwater Pump

NOTE

The torque should be 5 Nm (0.5 kpm) and the maximum wobble 60 .m.

7. Check the wobble of the pump shaft with a dial indicator.

8. Assemble the pump as described above.

Mapvfe00.fm 37
 Maintenance of Ejector Pump

8.0.0 Maintenance of Ejector Pump

(If supplied from Alfa Laval)

The following instructions must be carefully observed whenever it becomes neces-

sary to overhaul or repair the above mentioned pump. Please refer to drawing for
item references in the text.

8.1.0 Overhaul of the Pump

1. Remove the set screws 19 in pump cover 2.

Motor with motor bracket 6, pump cover 2, and impeller 5 can now be lifted
clear of the pump casing 1.

2. Unscrew the screw 22 (right-hand thread).

3. Remove impeller.

Macnle00.fm 38
 Maintenance of Ejector Pump

NOTE

Normally, the impeller can be removed without using dismantling tools.

If not, you can fit dismantling screws into the two threaded holes in the im-
peller.

4. Remove the key 26 and the mechanical seal 8 (including spring holder, spring
and carbon ring).

5. Inspect the ceramic ring, the carbon ring and the spring. Replace, if necessary

If mechanical seal has to be replaced, proceed as follows:

• Unscrew set screw 20 to remove pump cover 2 from motor bracket 6 in

order to gain access to ceramic ring.

In order to make it easier to assemble the mechanical seal, the shaft and ring
seat may be greased with glycerine. Please also refer to separate instructions
for mechanical seal delivered together with the seal.

• After fitting the ceramic ring, fit pump cover 2 to motor bracket 6.

• Fit carbon ring, spring and spring holder.

6. Clean drilled cooling water channel in pump cover 2.

7. Inspect impeller and threaded holes for clogging.

8. Remember to change the O-ring 7.

9. Reassemble in reverse order.

8.1.1 Clearance
In connection with the inspection, the impeller 5 and wear rings 10 are measured in
order to secure that the clearance is not larger than stated in the diagram below.

Macnle00.fm 39
Maintenance of Ejector Pump

Wear ring Ø Clearance maximum Clearance minimum

100 mm 0.5 mm 0.15 mm

150 mm 0.6 mm 0.2 mm

200 mm 0.7 mm 0.25 mm

250 mm 0.8 mm 0.28 mm

300 mm 0.85 mm 0.3 mm

350 mm 0.9 mm 0.3 mm

If the clearance is too big, replace wear rings as follows:

1. Unscrew countersunk screws 25.

2. Pull out wear (seal) rings.

3. Fit new wear rings and tighten countersunk screws.

CAUTION

The pump shaft may only be dismantled, if pump shaft or bearings, in the
electric motor have to be replaced.

Carefully observe instructions for “Dismantling pump shaft”.

40 Macnle00.fm
 Maintenance of Ejector Pump

8.1.2 Dismantling Pump Shaft

If the shaft 4 has to be dismantled due to a defect or if electric motor bearing has to
be replaced, proceed as follows:

1. Unscrew pointed screws 16.

2. Remove shaft 4. Normally this can be done without using dismantling tools.

CAUTION

DO NOT grind the motor shaft.

3. Fit shaft 4.

4. In order to make sure that the coupling is fitted correctly, tap slightly at the shaft
end with a RUBBER hammer.

5. Tighten pointed screws 16 with a torque of 35 Nm (3.5 kpm).

Macnle00.fm 41
 Salinometer

9.0.0 Salinometer Type DS-20

9.1.0 Technical Specification

Function Measuring (Dot Bar) and supervising salinity of

freshwater produced by seawater desalination.

Supply voltage 90-120 V or 200-240 V AC.

Frequency 50/60 Hz

Power consumption Salinometer 10 VA.

Relay contacts Max. load 100 VA.

Salinity display 0,5 - 20 ppm (Dot Bar).

Temperature correction Automatic in the range 5 - 85°C.

Alarm level Can be set to any value between 0,5 - 20 ppm.

Test Can be checked by test switch, 10 ppm.

Output 4-20 mA Current Loop.

Max. ambient tempera- 55°C.

ture
Protection degree IP 54.

9.2.0 Installation (for DS-20)

1. Open front cover.

2. Select correct voltage select according to the main supply voltage 115 V or 230
VAC.

3. Screw salinometer on to bulkhead with six nuts.

4. Connect necessary cables to the terminals.

5. Close front cover.

6. Test salinometer function (see instructions for use).

Salise00.fm 42
 Salinometer

9.3.0 Instructions for use

1. Switch on mains.

2. Switch on sec. alarm.

Green pilot LED should light up. Dot. Bar displays the measured salinity.

9.3.1 Testing the Instrument

WARNING

The salinometer must be tested at least once a month, and the electrode
unit must be cleaned.

Push TEST switch on.

The Dot Bar should read 10 ppm.

If the alarm level is less than 10 ppm, the salinometer will give an alarm.

9.3.2 Adjustment of Alarm Level

1. Switch “MAINS” on.

2. Push sec. alarm off.

3. Adjust Alarm Set to desired alarm level by using the switches.

4. Switch “Sec. Alarm” on.

The salinometer is now ready for use.

If the salinity exceeds the alarm level,

• The two red alarm LEDS flash.

• Solenoid valve is activated.

• Buzzer (if fitted) and external alarm system is activated.

Cancel buzzer and external alarm system by switching “Sec. Alarm” off. Solenoid
valve is not affected.

Salise00.fm 43
Salinometer

Switch “Sec. Alarm” on as soon as the salinity is normal again; i.e. when the two red
LEDS are off.

9.3.3 Maintenance

CAUTION

Remove electrode unit and inspect/clean after every 1000 hours of opera-
tion. Use a clean and dry rag. Avoid touching the electrodes with the fin-
gers.

44 Salise00.fm
 Spare Parts

10.0.0 Ordering Spare Parts

When ordering spare parts please always state:

1. Serial number.

2. Capacity.

3. Designation.

4. Spare parts drawing number.

5. Position number.

6. Article number.

In order to identify article numbers, please refer to FWG Order Specification and oth-
er drawings.

When ordering parts for pumps proceed as follows:

1. Find article number in the list of drawings.

2. Check spare part drawing and item list with corresponding article number to
identify the item to be ordered.

10.1.0 Alfa Laval Service

The Alfa Laval group is represented in all major ports of the world.

DO NOT hesitate to contact your Alfa Laval representative if you have any ques-
tions, problems or require spare parts.

Spmare01.fm 45
Spare Parts

46 Spmare01.fm
 Index

A
Adjustment of alarm level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
Adjustment of hot water flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16
Adjustment of sea cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Alfa Laval service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45

C
Chemical dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39
Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16

D
Dismantling pump shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41

E
Ejector Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15

F
Feed water ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27
Fitting new gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Freshwater Pump Types PVVF 1525-1532-2040 . . . . . . . . . . . . . . . . . . . . . . . . page 34
Freshwater Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12

I
Installation (for DS-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42
Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43

L
Long term standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18

M
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
Maintenance of condenser section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
Maintenance of ejector pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
Maintenance of evaporator section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
Maintenance of Freshwater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34
Maintenance of freshwater pump types PVVF 1525-1532-2040 . . . . . . . . . . . . . page 34
Maintenance of separator vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20

ON-016442IX.fm 47
Index
O
Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45
Overhaul intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Overhaul of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38

P
Perform regular maintenance duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Preparation of new gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Pressure testing separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26
Prevention of scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27

R
Removal of old gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23
Renewal of plate heat exchanger gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23

S
Safety instructions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Safety precautions with the use of chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29
Salinometer type DS-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42
Scale inhibitor dosage equipment for feed water . . . . . . . . . . . . . . . . . . . . . . . . page 28
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
Starting and stopping procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
Stopping the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17

T
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42
Telefax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Test sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30
Testing the instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 43
Trouble shooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31

W
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Why you need to perform regular maintenance duties . . . . . . . . . . . . . . . . . . . . page 19
Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11

48 ON-016442IX.fm
Document: 985 20424-R01
General description, DPU-2-36-C(AS)100/125 (MDPC No.: 9.2.4.1)

Application

Conversion of seawater into freshwater by vacuum distillation, for drinking, process water, and
domestic
Use on ships and rigs, and in small power stations. Max. salinity 2 ppm.

Capacity

The D-PU-2-36-C(AS)100/125 covers capacity range from 20 to 75 m3/24h, depending on the

heating
medium and seawater temperature. The capacities shown below are at a seawater temperature of
32°C.

Working principle

The seawater to be distilled evaporates at a temperature of about 70°C as it passes between the
hot
Plates in the heat exchanger. The boiling temperature corresponds to a vacuum of about 70%,
which is maintained in stage one by a brine/air ejector.
The steam generated passes through a demister where any drops of seawater entrained in the
steam are removed and allowed to the bottom of the distiller chamber.
The steam is then led through a connecting pipe to the lower heat exchanger in stage two where it
is condensed into fresh water. During condensation, the heat of evaporation is transferred to the
feed water (brine) obtained from stage one. The brine boils at a temperature of about 45°C,
corresponding to a vacuum of about 90%, which is maintained in stage two by the combined
brine/air ejector.
As in stage one, the generated steam passes through a demister to remove any entrained
seawater, which is collected at the bottom of the distiller chamber of stage two.
The steam then continues to the upper heat exchanger in stage two where it is condensed into
fresh water.
The heat transferred to seawater used for cooling the condenser is utilized by employing a part of
the condenser outlet water as feed for stage one.

Article no 985 20424-R01 Page 1 of 2

Illustrations, indications of material, dimensions and weights etc. herein, do not constitute any commitment on our part. We reserve

the right to change such specification when necessary.

December 20, 2011 49 985 20424 R01 – 9.2.4.1.fm

Basic equipment

Titanium plate heat exchanger in evaporator and condenser.

Stainless steel separator and stainless steel demister, front cover and pressure plates.
Seawater pipes in CuNi.
The freshwater generator is equipped for jacket water heating and with a combined condenser and
ejector water system. Furthermore the freshwater generator is equipped with dump valve, water
clock, automatic feed water regulator, combined brine/air ejector, instruments, freshwater pump
with electric motor, internal piping and bed frame.

Options

Flanges: DIN, JIS and ANSI

Power/control: 3 x 380 V 50 Hz 100/110/220 V

3 x 440 V 60 Hz 100/110/220 V
3 x 460 V 60 Hz 110 V (ul)

Additional equipment necessary for operation

- Ejector pump/electric motor

- Control panel with motor starters and salinometer
- Feed water treatment

Optional equipment/design

- Steam heating system type CAS and CS

- Hot Water Loop Module for steam boosting of jacket water
- Salinometer
- Manual motor starters and salinometer
- Remote start/stop
- Water clock by-pass
- Return pipe to brine sump
- Electric panel build-on the unit
- Optional spares kit for 1, 2 or 5 years of operation
- Steel box for spares kit
- Class test certificate
- Freshwater treatment equipment

Article no 985 20424-R01 Page 2 of 2

Illustrations, indications of material, dimensions and weights etc. herein, do not constitute any commitment on our part. We reserve

the right to change such specification when necessary.

December 20, 2011 50 985 20424 R01 – 9.2.4.1.fm

Document: 985 20427-R01
Technical data, DPU-2-36-C(AS)125 (MDPC No.: 9.2.4.2-3)

Power consumption

(MHFWRUDQGIUHVKZDWHUSXPS
+] +]
N: N:
Pressure

 EDUJ ,EVLQ
0D[MDFNHWZDWHUSUHVVXUH  
0D[EDFNSUHVVXUHWRIUHVKZDWHUWDQN  
0D[VHDZDWHUSUHVVXUHWRLQOHWFRQGHQVHU  
0LQVHDZDWHUSUHVVXUHWRHMHFWRU  
0D[EDFNSUHVVXUHDWHMHFWRURXWOHW  
0D[EDFNSUHVVXUHIRUVDIHW\YDOYHRQVWHDPHTXLSPHQW  
0D[VWHDPSUHVVXUHIRUVWHDPHTXLSPHQW  
1RUPDORSHUDWLRQIRUVWHDPHTXLSPHQW ± 
%DFNSUHVVXUHWRFRQGHQVDWHZHOOIRUVWHDPHTXLSPHQW ± ±

Temperature

6HDZDWHUWHPSHUDWXUH±ƒ& -DFNHWZDWHUWHPSHUDWXUH±ƒ&
Flow

6HDZDWHUIORZPK -DFNHWZDWHUIORZ±PK
Materials

6HSDUDWRU 6WDLQOHVVVWHHO
)URQWFRYHU 6WDLQOHVVVWHHO
%HGIUDPH 6WHHOKRWGLSJDOYDQL]HG
3LSHIRUEULQHGLVFKDUJH 6*LURQKRWGLSJDOYDQL]HG
(YDSRUDWRUFRQGHQVHUSODWHV 7LWDQLXP
'HPLVWHU 6WDLQOHVVVWHHO
3LSHIRUVHDZDWHU &X1L
3LSHIRUIUHVKZDWHU &X1L
&RPELQHGEULQHDLUHMHFWRUKRXVLQJ 5HGEUDVV
&RPELQHGEULQHDLUHMHFWRUQR]]OH 6WDLQOHVVVWHHO
)ODQJHIRUHYDSRUDWRUFRQGHQVHU 6*LURQKRWGLSJDOYDQL]HG
6WHDPHTXLSPHQWW\SH-:63DQG63 
3LSH 6WHHOKRWGLSJDOYDQL]HG
6WHDPLQMHFWRUKRXVLQJ 6*LURQSDLQWHG
6WHDPLQMHFWRUQR]]OH 6WDLQOHVVVWHHO
Shipping data

)UHVKZDWHUJHQHUDWRUFRPSOHWHZLWKHMHFWRUSXPSHOHFWULFDOSDQHOGRVLQJXQLWDQGVWDQGDUGVSDUHV

:HLJKW 1HWNJJURVVNJ
'LPHQVLRQV O[Z[K[[PP
9ROXPH P


Article no 985 20427-R01 3DJHRI
,OOXVWUDWLRQVLQGLFDWLRQVRIPDWHULDOGLPHQVLRQVDQGZHLJKWVHWFKHUHLQGRQRWFRQVWLWXWHDQ\FRPPLWPHQWRQRXUSDUW:HUHVHUYH

WKHULJKWWRFKDQJHVXFKVSHFLILFDWLRQZKHQQHFHVVDU\

December 20, 2011 51 985 20427 R01 – 9.2.4.2-3.fm

December 20, 2011 52 985 20427 R01 – 9.2.4.2-3.fm
Document: 985 20461-R01
Technical data, Pump and Motor for DPU-2-36-C(AS)125 (MDPC No.: 9.2.4.2-4)

9.2.4.2-4 Technical data,

Pump and Motor for D-PU-2-36-C(AS)125

No. of plates NE/NK 50/50/50-58/58/58

Pump function *Freshwater Ejector
Pump type PVVF-2040 CNL 80-80/200
Motor type 71 B 160 L
Nom. Flow x pressure m3/h x mwc 2.1 x 28 88 x 38
Impeller size 50 Hz: mm ø149 ø192
Impeller size 60 Hz: mm ø128 ø168
Rotating speed 50 Hz: RPM 2820 2915
Rotating speed 60 Hz: RPM 3360 3515
3 x 380 V 50 Hz
Rated output power kW 0,55 18,6
Consumed power kW 0,67 18,2
Current (full load) A 1,4 33,5
Current (start) A 7 211
3 x 440 V 60 Hz
Rated output power kW 0,75 21,4
Consumed power kW 0,75 18,2
Current (full load) A 1,6 33,5
Current (start) A 7 211
3 x 460 V 60 Hz
Rated output power kW 0,75 21,4
Consumed power kW 0,75 18,2
Current (full load) A 1,5 32
Current (start) A 7 211
* Unit are equipped with two freshwater

Article no 985 20461-R01 Page 1 of 1

Illustrations, indications of material, dimensions and weights etc. herein, do not constitute any commitment on our part. We reserve

the right to change such specification when necessary.

December 20, 2011 53 985 20461 R01 – 9.2.4.2-4.fm

December 20, 2011 54 985 20461 R01 – 9.2.4.2-4.fm
Document: 985 17373 R03
Flow Chart (incl. options), DPU-36-C125 (MDPC No.: 9.2.4.3-5)

December 20, 2011 55 985 17373 R03 – 9.2.4.3-5.fm

December 20, 2011 56 985 17373 R03 – 9.2.4.3-5.fm
Document: 985 17326-R01
Equipment specification, DPU-2-36-C(AS)125 (MDPC No.: 9.2.4.4-2)

Equipment supplied by Alfa Laval:

Tag no Description Article no Connection

 8QLW  
(:(6 (MHFWRU 6HHVSHFLILFDWLRQ 
)*(6 )ORZVLJKWJODVV  ò´%63
)*(6 )ORZVLJKWJODVV  ò´%63
),)5 :DWHUPHWHU  ô´%63
),)7 )ORZLQGLFDWRU  ¶¶%63
2&)( 2ULILFH 6HHVSHFLILFDWLRQ 
3,(6 3UHVVXUHJDXJH  ó´%63
3,( 0DQRYDFXXPJDXJH  ´%63
3,( 0DQRYDFXXPJDXJH  ´%63
3,)5 3UHVVXUHJDXJH  ó´%63
38)5 )UHVKZDWHUSXPS 6HHVSHFLILFDWLRQ 
38)5 )UHVKZDWHUSXPS 6HHVSHFLILFDWLRQ 
386& (MHFWRUSXPS 6HHVSHFLILFDWLRQ 
47)5 (OHFWURGHXQLW  
7,(6 7KHUPRPHWHU  ò´%63
7,( 7KHUPRPHWHU  ò´%63
7,( 7KHUPRPHWHU  ò´%63
9$(6 1RQUHWXUQYDOYH  '1
9$(6 1RQUHWXUQYDOYH  ò´%63
9$(6 1RQUHWXUQYDOYH  ò´%63
9$( $LUVFUHZ  ´%63
9$( 6DIHW\YDOYH  ´%63
9$( $LUVFUHZ  ó´%63
9$( 6DIHW\YDOYH  ´%63
9$)( 6SULQJORDGHGYDOYH  '1
9$)5 6ROHQRLGYDOYH 6HHVSHFLILFDWLRQ 
9$)5 6SULQJORDGHGYDOYH  ³%63
9$)5 1RQUHWXUQYDOYH  ´%63
9$)5 1RQUHWXUQYDOYH  ´%63
9$)5 9DOYH  ò¶¶%63
9$)5 9DOYH  ò¶¶%63
9$)5 9DOYH  ¶¶%63
9$)5 9DOYH  ¶¶%63
9$)7 1RQUHWXUQYDOYH  ´%63
9$)7 9DOYH  ´%63
9$)7 9DOYH  ò¶¶%63
 &RQWUROSDQHO  6HHVSHFLILFDWLRQ 

 1RUPDOO\VXSSOLHGE\$OID/DYDO
 7\SH&$6 

Article no 985 17326-R01 3DJHRI

,OOXVWUDWLRQVLQGLFDWLRQVRIPDWHULDOGLPHQVLRQVDQGZHLJKWVHWFKHUHLQGRQRWFRQVWLWXWHDQ\FRPPLWPHQWRQRXUSDUW:HUHVHUYH

WKHULJKWWRFKDQJHVXFKVSHFLILFDWLRQZKHQQHFHVVDU\

December 20, 2011 57 985 17326 R01 – 9.2.4.4-2.fm

 

 Steam arrangement**  
,666 6WHDPLQMHFWRU 6HHVSHFLILFDWLRQ 
3,66 0DQRYDFXXPJDXJH  ¶¶%63
7,66 7KHUPRPHWHU  ò´%63
7,66 7KHUPRPHWHU  ò´%63
9$66 %XWWHUIO\YDOYH  '1
9$66 6DIHW\YDOYH 6HHVSHFLILFDWLRQ 
9$66 %DOOYDOYH  ´%63
9$66 6HDWHGYDOYH  ô¶¶%63
9$66 %XWWHUIO\YDOYH  '1


Article no 985 17326-R01 3DJHRI

,OOXVWUDWLRQVLQGLFDWLRQVRIPDWHULDOGLPHQVLRQVDQGZHLJKWVHWFKHUHLQGRQRWFRQVWLWXWHDQ\FRPPLWPHQWRQRXUSDUW:HUHVHUYH

WKHULJKWWRFKDQJHVXFKVSHFLILFDWLRQZKHQQHFHVVDU\

December 20, 2011 58 985 17326 R01 – 9.2.4.4-2.fm

Document: 985 17330 R04
Dimensional drawing - DPU-2-36-C125

December 20, 2011 59 985 17330 R04.fm

December 20, 2011 60 985 17330 R04.fm
Document: 985 17495-R00
Vertical Plant Positioning, JWP-16/26 and D-PU-(2)-36 (MDPC No.: 9.2.8.1)

December 20, 2011 61 985 17495 R00 – 9.2.8.1.fm

December 20, 2011 62 985 17495 R00 – 9.2.8.1.fm
985 15915
64 985 15915 R02.fm
984 70207
985 20129
Document: 985 15583 R00
Lifting brackets for DPU-2-36

December 20, 2011 67 985 15583 R00.fm

December 20, 2011 68 985 15583 R00.fm
Document: 985 23202 R00
Ejector assembly drawing

December 20, 2011 69 985 23202 R00.fm

December 20, 2011 70 985 23202 R00.fm
 Bill Of Material
Parent item no.: Description: Date:
985 23202-19 R: 00 EJECTOR DN100 2 AIR, DIN 20111220 Page 1 of 1
Drawing no.: 30,2/45,6/49,9/53,4 Ini
985 23202 DKSOJBNA

December 20, 2011

BUBL QTY U/M DESCRIPTION DRAWING NO. ARTICLE NO. MATERIAL REMARKS
1 1.000000 EA LIQUID JET PUMP HOUSING DN100 985 21758 985 21758-01 CuSn5ZnPb5 (RG5)
2 2.000000 EA O-RING 88,50 X 3,53 NBR 985 00087-55 NBR
SHORE 70
3 1.000000 EA NOZZLE ONE DN100, ID=30.2 985 22192 985 22192-01 AISI 329 (duplex)
LIQUID JET PUMP DN100
5 1.000000 EA MIXING CHAMBER/DIFFUSER Ø95 985 23200 985 23200-02 CuSn5ZnPb5
LIQ. JET PUMP L=14.1 , D=53.4
6 16.000000 EA SCREW M8 X 30 DIN 912 A4 985 00087-57 A4
Document: 985 23202-19 R00

7 1.000000 EA FLANGE DN100 DIN - LOOSE 985 21828 985 21828-01 S235JR
LIQUID JET PUMP
8 1.000000 EA INTER MEDIATE HOUSING EJECTOR 985 22187 985 22187-01 CuSn5ZnPb5
2 STAGE
9 1.000000 EA NOZZLE THREE DN100, ID=49.9 985 22202 985 22202-01 AISI 329 (duplex)
Ejector DN100 2 AIR, DIN, Parts List

LIQUID JET PUMP DN100

10 1.000000 EA NOZZLE TWO DN100, ID=45.6 985 22197 985 22197-01 CuSn5Zn5Pb5
EJECTOR DN100

71
Alfa Laval Copenhagen A/S Bank: SEB, Landemarket 10, Copenhagen
BIC/SWIFT ESSEDKKK
Maskinvej 5
DK-2860 Søborg, Denmark Accounts: DKK IBAN Acc. DK5752950010008069
CVR/VAT/EORI No. DK10134285 EUR IBAN Acc. DK4552950013000735

985 23202-19 R00.fm

Phone/Fax: +45 3953 6000 / +45 3953 6568 USD IBAN Acc. DK4252950015000929
December 20, 2011 72 985 23202-19 R00.fm
 6 5 4 3 2 1

D D

December 20, 2011

4
Solenoid valve - NO/230V

1
Drawing: 985 22018 ver. 00

C C

73
B B

obligation on our part.

Rev.
Revision text Date Drawn Cheked Appr.
No.
Title
SOLENOID VALVE

Project no. Project type Project name

Dimensions Without Tolorances: Location:

A Size A
ISO 2768-M or ISO 13920-B A3 Alfa Laval Copenhagen A/S
Date Drawn ISO
Denmark
Scale
23-04-2009 Method E Drawing No. Rev.
AHNA

985 22018.fm
1:1
Reviewed Approved Matr:

or used for purposes not expressly permitted by us.

PLD JNN 985 22018 00
6 5 4 3 2 1
December 20, 2011 74 985 22018.fm
984 23490-00
76 984 23490-00 R01.fm
Drawing: 985 21511 version 00
Fresh water pump type PVVF-2040 Assembly drawing

December 20, 2011 77 985 21511 v01.fm

December 20, 2011 78 985 21511 v01.fm
984 10253-00
80 984 10253-00 R02.fm
Document: 985 21012 ver. 00
Outline drawing for motor 71B

December 20, 2011 81 985 21012.fm

December 20, 2011 82 985 21012.fm
Document: 985 19815-R02
Feedwater treatment 130 L build-on DPU-36-C(AS)100/125 (left side) 
(MDPC No.: 9.2.9.1-13)

December 20, 2011 83 985 19815 R02 – 9.2.9.1-13.fm

December 20, 2011 84 985 19815 R02 – 9.2.9.1-13.fm
Document: 985 20435-R01
Technical data, Control panel for Freshwater Generator (MDPC No.: 9.2.6.1-4)

General

&RQWUROSDQHOIRUVLQJOHDQGWZRVWDJHIUHVKZDWHU
JHQHUDWRUV,QFOXGHVWDUWVWRSRISXPSVDQGVDOLQLW\
VXSHUYLVLRQ7KHSDQHOLVLQWHUQDOO\FRQQHFWHGDQGQHHGV
RQO\WREHFRQQHFWHGWRPDLQSRZHUDQGWRWKHHOHFWULFDO
FRPSRQHQWVRQWKHIUHVKZDWHUJHQHUDWRU
Standard Design

6WDQGDUGGHVLJQFRQVLVWVRIDER[ZLWKWKHIROORZLQJ
FRPSRQHQWVEXLOWLQ

0DLQVZLWFKORFNVSDQHOLISRZHULVRQ
3XVKEXWWRQIRUIUHVKZDWHUHMHFWRUDQGHMHFWRUSXPS
- 6WDUWJUHHQ
- 6WRSUHG

6LJQDOODPSIRUIUHVKZDWHUDQGHMHFWRUSXPSUXQQLQJJUHHQ
6LJQDOODPSIRUVRXUFHRQZKLWH

7KHUPDOUHO\DQGFRQWUDFWRUIRU
- )UHVKZDWHUSXPSV
- (MHFWRUSXPS

2SHUDWLQJWUDQVIRUPHU
6DOLQRPHWHU
)XVHV
1DPHSODWHLQVLGHSDQHO
3DLQWLQJ5$/',1

Electrical Design

6XSSO\YROWDJH
[9+][9+]RU[9+]

&RQWUROYROWDJH
RU9

3HUPLVVLEOHWROHUDQFHV
9ROWDJH
)UHTXHQF\

,QWHUQDOZLUH
&ODVVƒ&

([WHUQDOFRQQHFWLRQV
5HPRWHDODUPWKHUPDORYHUORDGIUHVKZDWHUSXPS±12
5HPRWHDODUPWKHUPDORYHUORDGHMHFWRUSXPS±12
5HPRWHVWDUWVWRSIUHVKZDWHUSXPS

Article no 985 20435-R01 3DJHRI

,OOXVWUDWLRQVLQGLFDWLRQVRIPDWHULDOGLPHQVLRQVDQGZHLJKWVHWFKHUHLQGRQRWFRQVWLWXWHDQ\FRPPLWPHQWRQRXUSDUW:HUHVHUYH

WKHULJKWWRFKDQJHVXFKVSHFLILFDWLRQZKHQQHFHVVDU\

December 20, 2011 85 985 20435 R01 – 9.2.6.1-4.fm

 

5HPRWHVWDUWVWRSHMHFWRUSXPS
&RQWDFWVHWIUHVKZDWHUSXPSUXQQLQJ1&

&RQWDFWVHWIUHVKZDWHUSXPSUXQQLQJ±12
&RQWDFWVHWHMHFWRUSXPSUXQQLQJ±1&
&RQWDFWVHWHMHFWRUSXPSUXQQLQJ±12

([WHUQDOFRQQHFWLRQVVDOLQRPHWHU
([WHUQDOPHWHU
(OHFWURGHXQLW
([WHUQDODODUPFRQWDFW±1&
([WHUQDODODUPFRQWDFW±12
%X]]HU
6ROHQRLGYDOYH±1&
6ROHQRLGYDOYH±12

Other Data

3URWHFWLRQGHJUHH,3
0D[DPELHQWWHPSHUDWXUHƒ&
'LPHQVLRQV[[PP
:HLJKWDSSUR[NJ

Options

2SWLRQ$LQFOXGHVVWDQGDUGDQG
- $PPHWHUIRUHMHFWRUSXPS
- 5XQQLQJKRXUPHWHUIRUHMHFWRUSXPS
- 0LQLFLUFXLWEUHDNHUWRSURWHFWIUHVKZDWHUSXPS
- 5HOD\IRUWKHUPDORYHUORDG1&

%R[IRUUHPRWHVWDUWVWRS
6XSSO\YROWDJH[9+]XO

Article no 985 20435-R01 3DJHRI

,OOXVWUDWLRQVLQGLFDWLRQVRIPDWHULDOGLPHQVLRQVDQGZHLJKWVHWFKHUHLQGRQRWFRQVWLWXWHDQ\FRPPLWPHQWRQRXUSDUW:HUHVHUYH

WKHULJKWWRFKDQJHVXFKVSHFLILFDWLRQZKHQQHFHVVDU\

December 20, 2011 86 985 20435 R01 – 9.2.6.1-4.fm

Document: 985 17533-R04
Dimensional drawing, Control panel for Two-stage FWG (MDPC No.: 9.2.6.2-5)

December 20, 2011 87 985 17533 R04 – 9.2.6.2-5.fm

December 20, 2011 88 985 17533 R04 – 9.2.6.2-5.fm
Document: 985 20884-R0
Electrical diagram, Control panel for Two-stage Freshwater Generator
(MDPC No.: 9.2.6.3-5)

December 20, 2011 89 985 20884 R0 – 9.2.6.3-5.fm

December 20, 2011 90 985 20884 R0 – 9.2.6.3-5.fm
December 20, 2011 91 985 20884 R0 – 9.2.6.3-5.fm
December 20, 2011 92 985 20884 R0 – 9.2.6.3-5.fm
December 20, 2011 93 985 20884 R0 – 9.2.6.3-5.fm
985 20884 R0 – 9.2.6.3-5.fm 94 December 20, 2011
List of external cables
Terminal row:
X1
1R 7 HUP &RQQHF WLRQ 3DJH /LQH
985 20884 R0 – 9.2.6.3-5.fm 95 December 20, 2011
List of external cables
Terminal row:
X1
1R 7 HUP &RQQHF WLRQ 3DJH /LQH
985 20884 R0 – 9.2.6.3-5.fm 96 December 20, 2011
List of external cables
Terminal row:
X1
1R 7 HUP &RQQHF WLRQ 3DJH /LQH
985 20578-R00
98 985 20578-R00-1.fm
Document: 98520577_v00
Thermometer straight w.pocket

December 20, 2011 99 985 20577_v00.fm

December 20, 2011 100 985 20577_v00.fm
 Installation and instruction
manual for Ejector pump

Instructions manual for CNL pumps size 160 and 200

Alfa Laval Freshwater Generators
Instructions for installation,
operation, maintenance and repair of
CNL pumps size 160 and 200.

Alfa Laval Copenhagen A/S

– December 20, 2011 101 985 22205 rev. 00

Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for
improvement of this publication would be gratefully appreciated. 
Copies of this publication can be ordered from your local Alfa Laval Company. 

Published by: Alfa Laval Copenhagen A/S 

Maskinvej 5 
DK-2860 S¯borg 
Denmark 
© Copyright Alfa Laval Copenhagen A/S.

102 Revision number

1 General

Should you need further clarification regarding this manual, do not hesitate to contact
your local Alfa Laval representative - or call Alfa Laval Copenhagen A/S directly.

Telephone +45 (for Denmark) 39 53 60 00

Telefax +45 (for Denmark) 39 53 65 66

1.1 Introduction
This instruction manual contains relevant information on installing, operating and
maintaining the pump.

The pump is configured for the specific customer requirements. The specific pump
type is described in the enclosed documentation

The personnel in charge of installing, operating and maintaining the pump must be
properly qualified and trained to carry out the operations described in this manual. Alfa
Laval recommends that you read this manual before you install and operate the pump
as this will minimize any risk of incorrect handling. Alfa Laval cannot be held respon-
sible for unauthorized use of the pump.

Alfa Laval does not provide any guarantee if working conditions are inappropriate. If
the working conditions differ from those given in the technical data sheet, please con-
tact Alfa Laval before putting the pump into operation.

1.2 Identification
Details of the pump identification (type, article number ect.) can be found in the tech-
nical data sheet. The Pump no. can also be found on the name plate on the pump.

General – December 20, 2011 103 985 22205 rev. 00

1.3 Directions & warning signs
Comply with all instructions located on the pump or motor, such as direction of rota-
tion, arrows, instruction signs, directions or warning signs and remember to keep this
information in readable condition.

1.4 Warning symbols

Important machine and safety-related instructions in this manual are illustrated with
symbols. It is essential that these instructions are followed to avoid accidents and dam-
ages to machines and/or personnel.

STOP!
This symbol is for all safety instructions which must be followed to
avoid accidental injuries and hazards to life. Observe these safety
instructions carefully and proceed with great care.

ELECTRIC POWER!
This symbol signals possible danger due to presence of electric power.
Only proceed if the operator is experienced with the pump and proce-
dures.

CAUTION!
This symbol is used for instructions of particular importance and sig-
nals a risk of damage to the pump or its components. Proceed only if
the parts or the pump have been assembled according to instructions.

1.5 General safety

The following safety instructions apply for both pumps and motors supplied by Alfa
Laval.

General – December 20, 2011 104 985 22205 rev. 00

 Please observe:

• The safety regulations

• Accident prevention regulations
• Country specific safety regulations
• Guide lines and acknowledged technical rules cited in this operating manual.

Non-compliance with safety regulations will result in danger to personnel and damage
to the unit, e.g:

• Danger to personnel through contact with voltages exceeding 42V.

• Failure to observe prescribed methods of transportation, assembly, maintenance
and repair of pump or motor.

CAUTION!
When working on the unit, please observe all valid accident prevention
regulations and generally acknowledged technical rules!

1.5.1 Electrical hazards

ELECTRIC POWER!
Do not carry out any installation or maintenance on the pump or motor
while it is operating or before it has been disconnected. Pumps with
motors must have appropriate connections. Amp ratings are given in
the technical data sheet and the power supply must be adequate.

1.5.2 Temperature hazards

STOP!
Before any maintenance is carried out, be sure to empty the pump of
liquid. If the pump has been pumping hot liquid, the pump should be
cooled to the surrounding temperature.
As a precaution, the hot parts of the machine should always be covered
to avoid accidental contact.

General – December 20, 2011 105 985 22205 rev. 00

 1.5.3 Chemical hazards

CAUTION!
The pump should always be cleaned before carrying out any mainte-
nance or repairs. This will prevent chemical reactions if the pump has
been pumping dangerous liquids.

1.5.4 Dry running

CAUTION!
If the pump is not supplied with a priming device, the pump must
never be put into operation before it has been filled with liquid. If the
pump is supplied with a priming device, dry running is permissible for
a short period while the pump is primed.

1.5.5 Noise level

STOP!
Under normal conditions the pump and the motor will produce a noise
level below 80 dB. The exact noise level depends on motor type, foun-
dation and environment. 

The operator must wear protective gear if the noise level becomes
harmful.

General – December 20, 2011 106 985 22205 rev. 00

2 Installation

2.1 Condition on delivery

The Pump is tested before delivery to ensure perfect running condition. A test run is
made of the pump using water to check the performance data stated in the technical
specifications.

2.2 Inspection on delivery

Check your shipment immediately upon arrival. Make sure that the parts and accesso-
ries received are in accordance with your order. In the event of damage, defects or defi-
ciency, immediately report the problem to the Transport Company and Alfa Laval.

The packaging must be examined to make sure that it is in good condition to guarantee
protection in storage.

The packaging may only be opened when:

• It is seriously damaged.
• The product is to be stored longer than originally planned.

In all other cases the packaging may only be opened at assembly. When the packaging
has been removed, the product must be examined for any deficiencies or defects.

2.3 Storage instructions

CAUTION!
The standard packaging protects the pump against corrosion during
transport and storage in dry conditions for at least 3 months. If the
pump is not installed immediately after receipt, it must be protected
against corrosion and frost and kept in a dry place.

Installation – December 20, 2011 107 985 22205 rev. 00

 2.3.1 Preservation procedure
1. Drain the pump through the bottom drain.
2. Flush the pump with hot fresh water (maximum 60 0C, 140 0F). Flushing can be
done through the manometer connections.
3. Let the pump dry out.
4. Flush the pump with 'Mobil Arama 25' or similar quality.
5. Mount drain plug and manometer connections.
6. Turn the pump shaft once a week to avoid damaging the mechanical shaft seal.

2.3.2 Restarting of Pumps

1. Fill the pump with hot fresh water through the manometer connections.
2. Mount the manometer connections.
3. Turn the pump shaft by hand to check for any obstructions.
4. Open valves and check that the mechanical shaft seal is not leaking (if leaking
starts the pump and let it run for 1 to 2 minutes, if still leaking the mechanical seal
must be replaced).
5. Start the pump and watch the operation of the pump and electric motor for approx.
10 minutes.

2.3.3 Preservation Procedure for Electric Motors

• Factory fitted bearings use a lithium based grease with a recommended shelf life of
two years. If stored for a longer period, grease may need to be replaced.
• Shielded bearings have a storage life of five years and a further two years opera-
tional life following the installation.
• To avoid static indentation during long term standstill, the area should be vibration
free.
• Where exposure to some vibration is unavoidable, the shaft should be looked.
Roller bearings may be fitted with a shaft locking device, which should be kept in
place during long term standstill.
• Shaft should be rotated by hand, one quarter of revolution weekly.

ELECTRIC POWER!
Where anti-condensation heaters have been fitted, it is strongly recom-
mended that they are energized.
In such case, prominent warnings of live terminals inside the terminal
box must be posted inside and outside the motor terminal box.

Where anti-condensation heaters are not fitted, the use of desiccant is recommended.

Installation – December 20, 2011 108 985 22205 rev. 00

 2.3.4 Restarting of Electric Motors
Before taking a motor into service, ensure that anti-condensation heaters (if fitted) have
been disconnected and isolate before starting the motor.

1. Check that no foreign matter is present.

2. Remove all surface dust and dirt.
3. Test the stator insulation resistance between phases and also to earth.
4. If an insulation resistance lower than one mega ohm at 20 oC (68 oF) is measured,
the windings must be dried out until a minimum of one mega ohm is obtained.
5. Start the motor.
6. Watch the operation of the electric motor for approx. 10 minutes.

2.4 Foundation

CAUTION!
The pump must be fixed to a rigid foundation which is substantial
enough to absorb vibrations and to take up stress from the hydraulic
strain and loads from the pipelines.
The pump should be installed with sufficient accessibility for inspec-
tion and maintenance. The surface of the foundation where the pump is
installed must be level and horizontal. Damage due to an inadequate or
faulty foundation is not covered by the guarantee.

Installation – December 20, 2011 109 985 22205 rev. 00

2.5 Environment conditions

CAUTION!
The pumps are intended for installing in dry rooms free from aggres-
sive atmosphere in temperatures between + 10 and 50 0C. Installing
the pump in other conditions is only allowed if this is stated in the tech-
nical data sheet.

2.6 Piping

CAUTION!
To keep pressure loss and flow resistance at a minimum, tight bends
and substantial size reductions in the piping system should be avoided.
Loss of pressure in the suction line must be kept at a minimum in order
to avoid cavitations in the pump. Static suction height + loss of pres-
sure in the suction line + NPSH value for the pump + steam pressure
must not exceed 10 mWC at sea level. Long suction pipes that make
air pockets possible should be avoided.
Suction and pressure lines must be connected to the flanges of the
pump, free from strain, as any stresses are taken up at fixed points, and
suitable compensators should therefore be installed in the pipe system.
The flanges between which the pump is installed must be absolutely
parallel.

Installation – December 20, 2011 110 985 22205 rev. 00

2.7 Piping connections

CAUTION!
Before installing the pump, the entire piping must be pressure and
leakages tested and flushed clean before it is connected to the suction
and discharge side of the pump. If the pressure test takes place with the
pump installed, the testing pressure must not exceed the testing pres-
sure of the pump, which is stamped into the pump, usually in the suc-
tion flange. The pump’s gaskets or flanges for the mechanical shaft
seal might otherwise be damaged.
Check that all connections to the pump are in working order and that
the various measuring equipment has been correctly connected. Take
care that no parts obstruct easy access to the pump for inspection or
replacement of important parts.

2.8 Electrical installation

ELECTRIC POWER!
Check that there is enough cable to allow the motor to be removed
without disconnecting the wires. A switch (emergency stop) must be
installed close to the pump.

2.9 Recommended accessories

As the pump, especially the mechanical shaft sealing, is designed to run with clean
water without sludge, a suitable filter must be installed in the suction line.

Installation – December 20, 2011 111 985 22205 rev. 00

3 Operation

3.1 Start-up procedures

CAUTION!
Ensure that the pump and motor are mounted according to instructions,
all connections are correct and the necessary screens and guards are in
order.

• Check the direction of rotation (marked with an arrow). The motor

must turn in the direction in which the arrow is pointing. If the
direction is wrong, the connections to the terminals of the electric
motor should be changed.

• Check that the pump can be turned by hand.

• Check that the motor has been lubricated with grease. (If applica-
ble)

• Make sure that the piping is clean and free from foreign objects.
Liquid should flow regularly into the pump.

• Check that the pump and suction pipe are filled with liquid. Any air
or gas must be carefully released before start-up.

• Check the pump for noise and vibrations immediately after starting.
At the normal head it should have a very steady motion without
unusual noise and vibrations after one minute.

• Check the seal housing for leakages.

Operation – December 20, 2011 112 985 22205 rev. 00

3.2 Starting the pump

CAUTION!
When the pump is ready, it is started with the discharge valve closed.
After starting, the discharge valve is slowly opened until the working
point is reached. If the pump runs with closed valves for a period, it
should be equipped either with temperature control equipment or recir-
culation. Running with the valves closed for a long period can damage
the pump.

3.3 Stand-by

CAUTION!
If the pump is going to be on stand-by for a long period, it must be
started or rotated at least once a week to avoid damage to the mechani-
cal seals.

3.4 Pump vibrations

CAUTION!
During operation, be aware that significant vibrations have a major
affect on the pump’s performance. If vibrations are significant the
pump should immediately be turned off to be able to locate possible
errors.

Operation – December 20, 2011 113 985 22205 rev. 00

4 Maintenance

4.1 Inspections

STOP!
Before any inspection and maintenance of the pump, the operator must
ensure that the pump cannot be unintentionally started. The pump must
be stopped, and all electronic contacts must be disconnected.
The system must be de-pressurized and the pump must be emptied of
liquid and washed. If the pump has been pumping hazardous liquids,
the liquid must be collected, and the pump should be flushed with
clean water or another suitable liquid. It is important to ensure that the
pump does not contain dangerous amounts of corrosive, toxic or simi-
lar substances when maintenance is taking place.

4.1.1 Three-month inspection

• Check suction and discharge pressure.
• Check for unusual noise, vibrations and leakages.
• Inspect the motor.
• The mechanical seal must be inspected for leaks. The seal must not leak either dur-
ing stand-by or during operation.

If any faults are found during inspection, they must immediately be corrected, since
any defects can be of major importance for the functioning of the pump and its useful
life.

4.1.2 Twelve-month inspection

Take the pump apart - See “Disassembly and assembly instructions”. The rotating parts
are checked and repaired if necessary. Normal clearance between the impeller and

Maintenance – December 20, 2011 114 985 22205 rev. 00

 casing wear ring is 0,45-0,50 mm. Maximum clearance is 0,8-1,0 mm. depending on
the size and capacity. See - “Centrifugal pump wear ring clearances”

4.1.3 Lubrication
The pump type CNL is without bearings and needs no lubrication. The motor bearings
are greased in accordance with the motor instructions.

4.2 Disassembly and assembly

4.2.1 Disassembly
1. Ensure that the pump is emptied of liquid
2. Unscrew bolts connecting pump casing and cover. Lift the disconnected part of the
pump comprising motor, bracket and pump cover.
3. The impeller will follow the removed part, enabling direct access.
4. Gentle disconnection is recommended to prevent any damage on the mechanical
seal.

NOTE!
Unless pump shaft and engine shaft are assembled with a flanged cou-
pling, do not remove the pump shaft from the motor shaft unless the
pump shaft or the motor has to be replaced.

4.2.2 Assembly
• Before reassembling clean the inside of the pump casing and paint with appropriate
coating.
• In order to make disconnection of the pump easier at a later stage, lubrication of all
bolts and assembling surfaces with “Never Seez” lubricant is recommended.
• Assemble motor, coupling and pump shaft. Note! Adjustment of the shaft will take
place later.
• Assemble the motor stool item 6 with the motor.
• Pump cover item 2 with the seat ring of the mechanical seal, has to be fitted gently
on the shaft and tightened to the motor stool item 6 by screws.
• The O-ring has to be fitted to the cover
• Adjust the distance (B) between the bottom of the shaft flange and the cover.

Maintenance – December 20, 2011 115 985 22205 rev. 00

 IEC size B (mm)
CNL -/160 90-160 4
CNL -/200 90-180 4
CNL -/200 200 14

• The rotating part of the mechanical shaft seal is placed carefully on the shaft.
• The casing wear ring and the impeller have to be fitted and tightened by screws.
• The rotating assembly can be fitted to the pump casing and tightened by screws.
• Before any start-up, the shaft has to be turned by hand in order to check for any
blockages.
• The pump has to be primed in order to prevent any dry running.

4.3 Fitting instructions for mechanical seals

A mechanical seal is a very high-precision product and should be treated with the
utmost care before and during fitting. Do not unpack until ready for use. The rotating
wear ring and the seat have been lapped to a high degree of accuracy.

Maintenance – December 20, 2011 116 985 22205 rev. 00

 Mechanical seals used for CNL pumps

Type 1 Type 2

4.3.1 Fitting instructions

1. Remove the protective packaging from the seal, check for damage, and wipe clean.
2. Make sure that the pump is ready and switched off.
3. The shaft should be clean and free of burrs, and the machined place where the seat
fits must be cleaned very carefully. Edges should be rounded so that they are not
sharp or penetrating.
4. Check that the shaft diameter corresponds with the dimension of the seal within a
tolerance of 0.05 mm.
5. The bore in the housing and the seat must be lubricated. Use only liquid soap,
soapy water or glycerine with ethylene-propylene elastomer. The elastomer must
also be lubricated on the inside where it slides on the shaft. Lubricants containing
silicone must never be used.
6. Press the seat into position with your fingers. If the space is tight, use a bush when
pressing the seat into position. Take care not to damage the surface of the seat. For
example, use a piece of plastic for protection between the bush and the seat. After
pressing the seat into position, make sure that it is fully in place by measuring the
depth with a depth calliper.
7. The compressed length after fitting must correspond to the working length of the
size of seal in question given in the table of measurements.
8. Be aware of changes that can occur when bearing arrangements and gaskets etc.
are replaced.
9. Before the pump is started it must be filled with liquid and the air allowed escap-
ing. Air should be bled frequently during the period after starting.

Maintenance – December 20, 2011 117 985 22205 rev. 00

 NOTE!
When fitting shaft seals, the instructions should be read carefully,
especially when the medium is dangerous (poisonous, hot, flammable
etc.)

4.4 Centrifugal pump wear ring clearance

In connection with the inspection, the impeller 5 and wear rings 10 are measured in
order to secure that the clearance is not larger than stated in the diagram below.

CAUTION!
The pump shaft may only be dismantled, if pump shaft or bearings, in
the electric motor have to be replaced.

Wear ring Ø Clearance maximum Clearance minimum

100 mm 0.5 mm 0.15 mm
150 mm 0.6 mm 0.2 mm
200 mm 0.7 mm 0.25 mm
250 mm 0.8 mm 0.28 mm
300 mm 0.85 mm 0.3 mm
350 mm 0.9 mm 0.3 mm

Maintenance – December 20, 2011 118 985 22205 rev. 00

 If the clearance is too big, replace wear rings as follows:

1. Unscrew countersunk screws 25.

2. Pull out wear (seal) rings.
3. Fit new wear rings and tighten countersunk screws.

Maintenance – December 20, 2011 119 985 22205 rev. 00

5 Spare Parts

5.1 Ordering
When ordering spare parts or requesting our assistance, please advise the following:

• Pump type
• Item numbers and descriptions of parts to be ordered (Check spare part drawing
and corresponding parts list with item numbers to identify the parts to be ordered)

5.2 Alfa Laval Service

The Alfa Laval group is represented in all major ports of the world.

DO NOT hesitate to contact your Alfa Laval representative if you have any ques-
tions, problems or require spare parts.

If you do the repairs yourself, you are requested to follow the instructions regarding
assembly and disassembly or to contact our service department.

5.3 Returning parts

Before returning parts to Alfa Laval, please note that all liquids must be removed and
parts should be cleaned and neutralized.

The sender is liable for damage suffered by the pump or other goods caused by leaking
of liquid during transport.

5.4 Decommissioning
Do not dump old or used parts. Metal parts should be recycled as scrap.

When decommissioning the pump, it should be neutralized and cleaned, and any haz-
ardous liquids, should be removed and sent to a recycling facility.

None of the materials in the pump can be considered hazardous, but we urge you to act
with care and to take the steps needed when decommissioning the pump or its parts.

Spare Parts – December 20, 2011 120 985 22205 rev. 00

5.5 Type CNL - table of materials
Table of materials with the total content calculated as percentage by weight.

Material %
Pump casing See. Parts list 54
Casing cover See. Parts list 10
Base Cast iron 11,5
Shaft AISI 316 2,5
Impeller See. Parts list 7
Motor base Cast iron 10
O-ring Viton 0,2
Mechanical seal Carbon/ceramics 0,3
Casing wear ring See. Parts list 1
Accessories Stainless steel 1
Coupling Cast iron 2,5

5.6 Spare parts drawing for CNL 160 and 200 with
flanged coupling

Spare Parts – December 20, 2011 121 985 22205 rev. 00

6 Trouble Shooting

6.1 Trouble Shooting Table

The diagram below describes the most common faults which can occur during opera-
tion of the pump unit. Should additional information be required, please contact Alfa
Laval.

Pump and motor cannot be actu- • Impeller or shaft blocked.

ated: • Motor fault.
Motor running but no pumping • Motor rotation is not transmitted through cou-
effect: pling.

• Discharge valve closed.

• Non-return valve or other valves are closed.

• Suction line closed.

• Air in pump casing.

• Suction line leaking.

• Shaft seal leaking.

• Bottom valve defective.

• Suction lift too high.

• Priming pump defective.

Trouble Shooting – December 20, 2011 122 985 22205 rev. 00

 Insufficient capacity: • Wrong direction of rotation.

• Number of revolutions too low.

• Counter-pressure too high.

• Suction line or impeller partly clogged.

• Air in pump casing.

• Air in pumping medium.

• Suction lift too high (inlet pressure too low).

• Cavitations.

• Suction line leaking.

• Shaft seal leaking.

• Pump worn out.

Pump pressure too high: • Number of revolutions too high.

• Impeller oversized.

• Too many pressure stages.

• Specific gravity of pumping medium too high.

• Viscosity of pumping medium too low.

• Inlet pressure too high.

• Manometer defective.
Capacity too large: • Number of revolutions too high.

• Impeller diameter too big.

• Counter-pressure too low.

Discharge head too low: • Number of revolutions too low.

• Impeller diameter too small.

• Too few pressure stages.

• Specific gravity of pumping medium too low.

• Viscosity of pumping medium to high.

• Manometer defective.

Trouble Shooting – December 20, 2011 123 985 22205 rev. 00

 Power consumption too large: • Motor too small.

• Motor fault.

• Capacity too large.

• Counter-pressure too low.

• Stuffing-box tightened too much.

• Shaft ends out of alignment.

• Electricity supply incorrect.

Pump output decreases or stops: • Suction line leaking.

• Shaft seal leaking.

• Increasing suction lift.

• Filter clogged.

• Cavitations.
Irregular running: • Bearings defective.

• Motor fault.
Increasing noise level: • Cavitations beginning.

• Air in pumping medium.

• Capacity too large.

• Clamping to base loosened.

• Base bolts loosened.

• Influences from pipe connections or base.

Leaks: • Cracks in pump casing.

• Faulty assembly of pump.

• Pipe connections leaking.

• Shaft seal leaking.

Trouble Shooting – December 20, 2011 124 985 22205 rev. 00

 Bearing temperature too high: • Faulty lubrication or wrong lubricant.

• Defective pump alignment.

• Influences from pipeline.

• Coupling distance wrong.

• Shaft bent.

• Foreign bodies or impurities in bearings.

Pump wears out quickly: • Wrong pump in relation to liquid.

• Cavitations.

• Stuffing-box tightened too much.

• Shaft bent.

• Defective alignment.

• Influences through pipe line.

Strong vibrations: • Impurities in pump.

• Worn or loose bearings.

• Operating the pump at a critical speed.

• Unbalanced motor or rotating components.

• Loose hold-down bolts or loose or damaged

parts.

Trouble Shooting – December 20, 2011 125 985 22205 rev. 00

7 Drawings and Part Lists

Drawings and Part Lists – December 20, 2011 126 985 22205 rev. 00
Drawing: 985 21657 ver. 00
Ejector pump assembly and spare parts drawing

December 20, 2011 127 985 21657.fm

December 20, 2011 128 985 21657.fm
Document: 985 13859 R02
Ejector pump, Pump curve CNL 80-80/200

December 20, 2011 129 985 13859 R02.fm

December 20, 2011 130 985 13859 R02.fm
Document: 985 17500-R04
Dimensional drawing, CNL 80-80/200 (MDPC No.: 9.2.5.2-3)

December 20, 2011 131 985 17500 R04 – 9.2.5.2-3.fm

December 20, 2011 132 985 17500 R04 – 9.2.5.2-3.fm
Document:
Test sheet for Single-stage Freshwater Generator