Fresh water Generator on Ships

Fresh Water production from sea water for domestic and auxiliary purposes
is an essential requirement on board ships.

A considerable amount of water is consumed in a ship . On an average a

crew member consumes 100 litres of water perday.

Water consumption on steam ships can be relatively very high.

The quality of potable taken from ashore is sometimes very poor , so it has
become a normal practice to distillate sea water for all needs on board .

It is a statutory requirement to have a distillation plant on board , where

sufficient stowage space is absent.

The production of Fresh water from seawater is known as Fresh Water

Generator.

Various type of fresh water generator used on board are mainly :

1. Submerged tube type fresh water generator.[Low Pressure type]

2. Plate type fresh water generator [ low pressure type ] , and

3. Reverse Osmosis Plant.

Note : Nos. 1 & 2 – also called Vacuum Distillation Plants

Low-pressure vapor type is most widely used in commercial ships because

it utilizes waste HEAT from engine jacket water or steam while sailing. The
engine jacket water and steam can be utilized as a heat-source, and Shell &
Tube type and Plate type are available.
 2
The seawater is heated by various heat-sources under the vacuum state, and
then vaporized accordingly. The vaporized seawater is desalinated in separate
filtering unit before condensed, and then fresh water is produced. Meanwhile,
a salinity of produced fresh water shall remain at 0~10 ppm .
Fresh Water Generator is comprised of vaporizer, condenser, demister,
salinometer, distillate pump, ejector and steam injector.
Multi-stage Fresh Water Generator can achieve high efficiency when large
amount of fresh water is required.

Submerged tube type fresh water generator.

A fresh water generator consists of parts such as; heat exchanger,
demister or a mesh separator, ejector pump, ejectors for brine and air ,
condenser ,distillate pump, salinometer, solenoid v/v , sea water pump,
orifice , water flow meter and control panel. For both plate and shell type
fresh water generator; everything remains the same other than heat
exchanger /condenser. A plate type heat exchanger is used with plate type
water generator; while a shell and tube heat exchanger being used with
shell type fresh water generator.

---------------------------------------------------------------------------------------------------
Working Principle :

Basic principle of all low pressure Fresh Water Generator , is that the
Boiling Point of water can be reduced by reducing the pressure of the
atmosphere within the confines of the FWG . By maintaining a low
pressure , water will boil at a corresponding low temperature say 50
degrees Celsius.
 3

The source of heat for the FWG could be waste heat recovery from Main
Propulsion engine jacket cooling water / OR STEAM [ EMERGENCY when
main propulsion are idle ] .

Working Principle
The main engine jacket cooling water circulates the outside of the vertical
tube in heating section[ Heat Exchanger ] and the sea water to be distilled is
sent to the bottom cover of this section through the tubes .

The shell is brought under vacuum condition. Accordingly the sea water will
start boiling at that temperature prevalent inside the shell due to the heat
source received [ normally between 40 to 50 degrees Celsius.]

[The ‘Vapour pressure’ of a fluid is the pressure at which the fluid will boil at
ambient temperature]

Some of the sea water is converted into vapour when it goes up through the
heated tubes.

Water spray and droplet are partly removed from the vapor by the deflector
mounted on top of each evaporator and partly by a built-in demister.

The separated water droplets fall back into the brine, which is extracted from
the lower part of the unit by means of the ejector

The desalted vapour passing through the demister, will be sucked into the
condenser where it will be condensed by the cold incoming sea water. The
resultant distillate is led to the suction of the distillate pump.

In the meantime the non-condensable gases and brine are extracted and
discharged to overboard by the combination ejector.
 4

The condensate will be monitored by a Salinometer , to check the salinity level

is within range .

If the salinity exceeds preset level , the solenoid valve on the discharge line is
automatically activated and the salty distillate is dumped into the drain.

The Salinometer has a built –in- alarm connected to the control panel for
remote sounding.

A simple diagram

Manual Starting Procedures For Fresh Water Generator

Proper steps to be followed in correct sequence; take in consideration of
the environmental factor such as port or at sea.
It is a common practice not to use fresh water generator while at port; as it
generally contains waste products and harmful chemicals. A fresh water
generator is usually started at 20 nautical miles away from the nearest
shore [ normally after full away]. This not only provide protection against
sewage and industrial waste; but also ensure we get high temperature
jacket water.
 5
12 Key Steps to remember
1. Check and ensure that the jacket water temperature is constant and is
not below 70 degree Celsius.
2. Open the vent valve of the generator shell while closing the drain valve in
the bottom if opened.
3. Line up the sea water pump line by opening its suction and discharge
valve and the overboard discharge valve.
4. Start the sea water pump and slowly close the vent valve on the
generator shell.
5. Maintain the sea water pump pressure at 3 to 5 bars with ejector pump
pressure at 4 to 5 bar.[ as per standard instructions ]
6. Wait for another 10 to 15 minutes till you get a 90% vacuum condition in
the generator shell.
7. Once achieved; slowly open the valve to the jacket water inlet to
evaporator. Complete this process by giving one turn to the outlet valve;
followed by another turn on inlet valve.
8. Watch through the sight glass to confirm evaporation of water; followed
by a sudden drop in vacuum pressure, rise in temperature and fall in
feed water level .
9. As the system stabilize itself; open the cooling sea water valves to the
condenser.[ depends on the piping circuitry ]
10. Start the distillate pump and salinometer to check quality of feed
water.
11. Cross check the output water with salinometer reading; to ensure it is
not salty and fit for consumption.
12. Open necessary valves to start discharging produced water to the
fresh water tanks.

Demister
A demister is a thickened layer of mesh structure; fitted in between the
evaporator and the condenser element. This is used to separate sea water
from the steam vapour. A demister can be made of nickel, monel metals,
copper, stainless steel and synthetic fibers; such as Polypropylene and
PVC. Typically; demisters made of monel metal are used for fresh water generator.
What really happens is; when the water evaporates it carry over some fine
little molecules of water along with the rising steam[vapour].
 6
When the source of such water is sea; it can considerably increase the
salinity of output water. So to maintain salinity as low as 5 to 10 ppm; we
use demisters which restrict the passage of mist and pass dry steam.
The restricted mist latch on the demister surface which then combined with
other mist particles; it became heavy enough to fall off by the gravity. For
efficient results it is placed as close as possible from the final steam outlet
point. This allows for the larger heavier water particles to fall by itself;
before ever reaching to the demister.
A demister is a light weight simple structure used to separate mist from dry
steam. It is installed in system where the quality of steam required is very
high. Some of the salient features of demister are its high separating
efficiency; easy installation, corrosion resistance, long life and low pressure
drop.

3 ) Eductors / Ejectors --- Ejector Pump

Eductors
 7

 The high pressure motive fluid (P1) is passed through a specially shaped
nozzle (orifice) which increases the fluid velocity and decreases the fluid
pressure. By passing the motive fluid through a nozzle the static pressure
energy within the fluid is converted into kinetic energy which increases the
fluid velocity and decreases the static pressure.

This is process is known as the venturi effect.

 As the high velocity stream exits the motive nozzle (orifice), at the point of
maximum velocity, the vena contracta, an area of low pressure is
generated. This low pressure area is equal to or less than the secondary low
pressure fluid (P2), the suction fluid, so allowing it to enter the eductor body.

In maritime industry specially with marine engineers; the sea water pump
supplying operating water to these ejector are many a times also
considered as ejector pump. An ejector is similar to that of eductors with
no moving parts.
It consists of parts such as; a nozzle, throat and a diffuser [ convergent to
divergent]; and use under pressure water for its pumping action. The pump
takes its operating water from sea water pump and discharge overboard;
with the sucked brine or air. Working on the principle of venturi effect; the
sea water flow through a nozzle followed by a diffuser to create suction
pressure.
When a constant velocity fluid flowing through a pipe encounters a sudden
narrow path; its velocity thin a short time interval. Now to maintain its flow
rate and overall energy; the lost energy in form of velocity is then converted
to pressure energy. It is this pressure energy that is used to suck air and
brine out of the fresh water generator.
The air ejector is connected to the upper most part of the generator shell’
while the brine ejector to the bottom most part. The air ejector is used to
build up vacuum within the shell; of at least 90 percent in eight to twelve
minutes. Brine ejector on other hand tends to continuously pump out the
sea water; that were not evaporated in the process.

4 ) Distillate Pump
A distillate pump is a normal centrifugal pump located at the lower most
part of the fresh water generator. It takes suction from the condensate; and
discharge to the drinking water tank on ship.
 8
The output pass through a salinometer which checks for the salt content in
the output water.
The average salt content in the water is maintained at 10 ppm; but should
never exceed more than 15 ppm. If the salt content exceeds the limit it is
dumped to the bilges or send back to the generator shell with an alarm.
These pumps are preferred over others; for their ability to pump high flow
rate at variable dynamic head.
The pump is usually kept at much lower position to nullify the effects of
vacuum condition; providing sufficient head for the pump to perform. The
process also helps avoid the hassle to prime distillate pump; as it is self
primed by the flowing distilled water under the effect of gravity.

5 ) Salinometer
A salinometer is the device installed on fresh water generator;
capable of detecting even the slightest of salt content in the
sampling water. It is connected to the distillate output just before
the solenoid operated three way valve. The salinometer output is
feed to the control panel; which then based on required salt limit
will send fresh water for storage or back to generator.
A salinometer works on the simple principle that pure water do not
conduct electricity; and its conductivity increase with increase in
dissolved impurities and salts. The whole salinometer instrument
consists of parts such as; temperature compensator, sensitive
multi meter, relay and potentiometer.
The both electrodes of salinometer is dipped in the sampling
water; conducting electricity between them. The circuit is
connected as such the conducting current pass through the
actuating relay. Now as the current increase with increase in
salinity; the actuating relay actuates at desired value.
This close the alarm circuit raising alarm with a negative
feedback; back to the fresh water generator control panel.
 9

6 ) Sea Water Pump / Ejector Pump

Since both ejectors works on the principle of venturi effect; you need
something to provide them with the operating water. This is where the sea
water pump come into play; it not only pass through the ejector creating
suction pressure but also provide feed water for the fresh water generator
to produce steam(vapour).
A sea water pump is a centrifugal pump that takes; suction from the sea
water through sea chest followed by the strainer.
The output to the generator is controlled by the pump pressure along with
correct orifice plate along the feed line. A spring loaded diaphragm plate is
specially fitted into the generator feed inlet; to avoid flooding of shell when
the generator is on stand by. On other hand the ejectors receive operating
water as discharged by the sea water pump( ejector pump ).

7 ) Control Panel
A control panel is what that makes it easier and possible to control and
operate any machinery including fresh water generator. It is what that
automate the starting and stop procedures; letting us just to monitor and
see if its all well. It just makes it easier for us to start, stop, test alarms, test
salinometer and set desired ppm level.
In simple terms a control panel is a set of dials, toggles, buttons, and
bulbs that helps; operate and monitor the working of associated system
even with remote position. Such automation along with remote position
control is vital for operation; during the periodic unmanned engine room
periods.
 10

In order to get better suction head , the distillate pump is placed at the lowest
possible location in the FWG Plant. This is because the FWG shell is at a
lower pressure.
Distillate pump gets maximum NPSH suction head with the height of the
condensate column in the suction line .
Provisions of Thermometers for control of sea water to the condenser and
JCW to the heat exchanger. They permit control of both the cooling and
heating of these units.
The salinometer is connected to a remote alarm so that any high salinity is
immediately registered at the engine control panel.
 11

A detailed line diagram of a tube type fresh water generator on

board ship is shown below.

Plate Type Fresh Water Generator

Working principle of the plate type FWG is same as that of the shell
and tube type.

Only difference is the type of heat exchangers used. The plate type are
used for the evaporator and the condenser unit.
Heat from the Main propulsion source (JCW) is usd to evaporate a small
fraction of the sea water feed in the plate type evaporator.
Unevaporated water is passed off as Brine ( by combined brine and air
ejector) .
 12
The evaporated water [ steam /vapour] passes through the demister , onto
the plate type condenser .
Here after condensation , the condensate is discharged to the feresh water
storage tank , vide a distillate pump .
During the whole operation , , the feed rate to the evaporator[ heat
exchanger is fixed by the orifice plate at the feed inlet to the evaporator .
Atypical plate type freshwater generator line diagram is shown below.
 13
Plate type Fresh Water Generator
In the event of the salinity of fresh water exceeding value of more than 10 ppm ,
The solenoid controlled dump valve diverts the flow back to the shell .
This prevents contamination of the made water.
Reasons for excess salinity can be due to following reasons :
1. Leakage of sea water from condenser.
2. Priming of evaporator.
3. Malfunctioning of Demister .
. Other reasons.
Note : Air is not condensable and the ejectors have to perform to optimum , so
that the vacuum is maintained at all times and meeting requirements to boil
water at low temperatures .
Materials of Construction for FWG

 Shell : Fabricated steel or Non-ferrous metal ; internals shot blasted

and given a protective coat of epoxy rubber [ sheet rubber ] which is
rolled and bonded to the surface and hardened afterwards by heat
treatment.
 These coatings should be inert and prevent corrosion.
 They must resist the effect of acid cleaning and water treatment
chemicals.
 They should form a firm bond with the metal.
 Shell & Tube type – tubes made of aluminium brass and tube end
plate made of muntz metal.
 In plate type , the plate is made of titanium.
 Demister is made of knitted wire of monel metal.

Fresh Water Generator Starting Procedure

1. Make sure sea water ejector pump suction , discharge and overboard valves
are open .
2. Start the ejector pump . Pressure at the ejector must be atleast 4~5 Bar or
More.
3. Wait for Vacuum to build up to at least 92 % , inside the shell.
 14
4. Open feed water valve to the evaporator , adjust the feed pressure as stated.

5. Open Main JCW inlet and outlet to/from the evaporator gradually .
6. Purge out any air in the evaporator - hot source [jcw].
7. Switch on salinity alarm panel for measuring purity of made water.
8. Through sight glass provided in the evaporator shell , observe flashing of
Water.
9. Also check brine level . It should not be too high or too low.
10. Shell temperature to be around 40 ~ 50degrees Celsius.
11. When Plant is ON , slight drop in vacuum occurs .
12. Monitor the sight glass at the suction to the distillate pump. If content
Shows condensate level , start the distillate pump.Open discharge to
storage tank.
13. Check salinity of Fresh water produced.
14 . Check all running parameters in order.
Note : The capacity of the FWG can be varied by reducing or increasing the
amount of JCW to the evapoarator [ done vide a by-pass v/v provided ].

During very low seawater temperatures, evaporation temperature can falls to

a lower value. In that case, adjust vacuum adjusting valve to control vacuum
inside the shell. Cooling seawater quantity to the condenser also can be
reduced to increase the evaporator temperature. During high seawater
temperatures, evaporation temperature can go up. In that case, increase the
quantity of seawater to the condenser for reducing evaporation temperature.

[ for particular circuits only ]

Too high temperatures causes scale formation in side the tube surface ,
effecting proper heat exchange , and overall performance.

Too low a temperature results in seawater carry over which will eventually
increase the salinity of the fresh water produced .

During operation , it is desirable to throttle the distillate pump discharge , to

prevent pump running dry.
 15

The rate of distillate pump discharge and rate fresh water produced in the
condenser should match.

When the distillate pump is not able to draw fresh water at the rate of
production , level of fresh water increases in the condenser and effective
cooling area of the condenser reduces . This results in reduced evaporation
quantity.

Fresh water Generator Stopping Procedure

When a ship approaches port , shallow water , it is desirable to shut off the
FWG.

Reason , sea water contains harmful bacteria .

Procedure for shut down :

1. Slowly open by-pass v/v of Main JCW.

2. Ensure JCW temperatures within limits.
3. Close JCW inlet and outlet valves to the evaporator.
4.Close feed water chemical dosing valve.
5. Stop distillate pump and shut discharge valve.
6. Switch off salinity meter.
7. Shut off filling valves to fresh water storage tanks.
8. Wait for evaporator shell temperature to drop below 50 degrees Celsius.
9. Close the feed water valve to evaporator.
10. Stop Ejector pump . Shut off FWG overboard discharge valve .
11. Open vacuum breaker valve and bring shell pressure back to
atmospheric conditions.
12. Open drain valve of the evaporator to drain out all seawater
 16
How Scale formation occurs in Fresh Water Generator

The performance of the FWG reduces with the formation of scales ,

because of reduction in heat transfer efficiency.
Three common scales normally found in Fresh Water Generators are:

 Calcium Carbonate, CaCO3

 Magnesium Hydroxide, Mg(OH)2
 Calcium Sulphate, CaSO4

Calcium carbonate and magnesium hydroxide scale formation mainly

depends on temperature of operation .

Cacium sulphate scale formation mainly depends on the density of

the evaporator contents or brine .

The reaction takes place when sea water is heated are :

Ca(HCO3)2 ————> Ca + 2HCO3

2HCO3 ————> CO3 + H2O + CO2

If heated up to approx. 80 degree Celsius

 CO3 + Ca ————> CaCO3

If heated above 80 degree Celsius

 CO3 + H2O ————> HCO3 + OH

 Mg + 2OH ————> Mg(OH)2

Hence if the sea water in the Fresh Water Generator is heated to a

temperature below 80 degrees Celsius , Calcium carbonate
predominates.
If seawater temperature is heated above 80 degrees Celsius , then
magnesium hydroxide scale is deposited.

If the density of evaporator contents is in excess of 90000 ppm , Calcium

sulphate scales are formed .
 17
FWG , brine concentrate is normally 80000 ppm and less .
Hence scale formation due to calcium sulphate is not a problem.

Hence it is recommended to operate FWG at rated capacity , not more.

More production of water than rated capacity means higher concentration

of Brine and more scale formation. Similarly higher shell temperatures
resulting in the formation of hard scales which will be difficult to remove .
All this will reduce the plant efficiency drastically.

How to Minimize Scale Formation

Scale formation in FWG can be controlled / minimized by continuous

chemical treatment .
Polysulphate compounds like Sodium polysulphate with anti foam is
preferred and extensively used on board ships.
Trade name :
1. Vaptreat. – Unitor
2. Ameroyal – Drew Chemicals.
These chemicals minimize calcium carbonate scale formation and
possibility of foaming .
The compound is non-toxic , non-acidic .
It is continuously fed into the feed line using a metering pump or by gravity.
Amount of chemicals dosed , depends on the capacity of FW produced .
Effective only in low pressure evaporators [FWG]
Typical faults in FWG are :
Loss of vacuum or over-pressure of shell
The shell pressure of the fresh water generator rises and rate of
production reduces. The Reasons are :
1. Air leaks into the Evaporator Shell in large quantities and air ejector
is unable to cope up.
 18
2. Malfunctioning of the air-ejector.

3. The cooling water flow is reduced through the condenser or the

cooling water temperature is high. This causes saturation temperature
and hence saturation pressure within the condenser to rise.
4. Flow rate of the heating medium increased and excess water vapour
is produced. Since excess vapours cannot be condensed , shell
pressure increases or vacuum drops .

Salt Water Carry Over ;

Called Priming . General reasons for priming to take place are:

1. Level of salt water inside the shell is high. Agitation takes place . This is due to
when boiling occurs and salt water may be carried over along with the vapours.

2. When salt water brine density is too high , agitation of salt water occurs which
results in priming.

3. Increased Evaporation rates. Gradual increase in Brine Level.

Note :- For satisfactory operation of the FWG , a constant level of brine to be

maintained in the shell.
-Brine is concentrated sea water after liberation of vapours .
-This Brine is gradually extracted from the shell by the combined brine-air
Ejector.
-Any fault in the ejector or brine extraction pump ( in some models)
increase the brine level.

Increase in Salinity of Freshwater

Possible causes :
1. Brine level inside shell too high.
2. Leaking condenser tubes or plates
3. Operation of evaporator near shore with contaminated feed water.
4. Shell temperature and pressure too low .
5. Increased solubility of CO2 generated from salt water due to reduced
sea water temperature . This dissolved CO2 makes water acidic and
conductivity of water increases . Hence salinometer shows increased
salinity which is a measure of conductivity and not presence of salt.