ALL ABOUT FRESH WATER GENERATOR

QUESTION 1: Why distillate pump of fresh water generator is placed on lowest possible
plateform?

ANSWER: In order to get better suction head, distillate pump is placed at the lowest possible
location in the fresh water generator plant. This is because the fresh water generator shell is at a
lower pressure. Distillate pump get maximum net positive suction head with the height of liquid
column in the suction line. 

QUESTION 2: What is the salinity maintained by the solenoid of FWG

ANSWER: In the event of salinity of fresh water exceeding a predetermined value (maximum
usually 10 ppm) the solenoid controlled dump valve diverts the flow back to the shell.

QUESTION 3: Why air ejector are provided in fresh water generator?

ANSWER : What cannot be condensed at the condenser are called ‘incondensable gases’ like
air and these gases are continuously ejected out by air/brine ejector. This way the shell of
fresh water generator is maintained at high vacuum, a must requirement to boil water at low
temperatures.

QUESTION 4: What is the material of construction of tube metal, plate metal and demister in
FWG?

ANSWER : Heat exchangers use aluminium brass tubes and muntz netal tube plate in the case
of tube type fresh water generator. For plate type, titanium plates are used for condenser and
evaporator. Demister is made of layered knitted wire of monel metal.

QUESTION 5: What is starting procedure of fresh water generator?

ANSWER : Fresh water Generator Starting Procedure 

• Make sure seawater ejector pump suction, discharge and overboard valves are open. Start
the ejector pump. Seawater pressure at the air ejector must be 3 bar or more.

• Close the vaccume breaker valve provided on the top of FWG.

• Wait for vacuum to build up inside fresh water generator shell. (About 92 % vacuum).

• Open the feed water valve to feed seawater to the evaporator. Adjust the feed water pressure.
Normally marking is provided on the pressure gauge for desired feed water pressure.

• Open main engine jacket cooling water inlet and outlet to the evaporator gradually.

• Open the air vent clock at the top of the evaporator to make sure the evaporator is filled with
 jacket cooling water. Air must be purged out if any.

• Switch on the salinity alarm panel for measuring purity of the freshwater produced.

• There will be a sight glass provided at the suction line for the distillate pump. Make sure
condensed water is coming to the suction line. Now start the distillate pump and open
discharge valve to lead generated water to specified storage tanks.

• Do checks While Running Fresh water Generator

• Through the sight glass provided in the evaporator shell, observe flashing of water.

• Also check for the brine level inside. It should not be too high or too low.

• Shell temperature must be around 50 deg cel.

• Make sure shell vacuum is more than 90% from the vacuum gauge.

• Check seawater inlet and outlet temperature to the condenser.

• Ensure seawater pressure at air ejector inlet more than 3 bars.

• Check for distillate pump pressure and water flow meter.

• Check salinity of fresh water produced.

• Check level and flow of dosing chemical.

• Check ampere of ejector pump and distillate pump motor.

QUESTION 6: How production of fresh water can be controlled in FWG?

ANSWER: Capacity of a fresh water generator means the quantity of fresh water produced by
it per day. The capacity of fresh water generator can be varied by reducing or increasing the
amount of jacket cooling water to the evaporator. The quantity of jacket cooling water to the
evaporator can be adjusted by adjusting the bypass valve provided. When the temperature of
jacket cooling water is comparatively low, the quantity to the evaporator to be increased a bit. At
the same time cooling seawater pressure to the condenser also to be regulated accordingly.

QUESTION 8: What happens if seawater temperature is high or low as compared to the normal
value?

ANSWER: 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.

Too high evaporation temperature causes scale formation in the heat exchanger. On the other
hand, too low evaporation temperature results in seawater carry over which increases salinity of
fresh water produced.

QUESTION 9 : What is fresh water generator stopping procedure

ANSWER:
• Slowly open bypass valve for main engine jacket cooling water.

• Ensure that main engine jacket cooling water temperature is within normal limits.

• Close jacket cooling water inlet and outlet valves for the freshwater generator respectively.

• Close the feed water chemical dosing valve.

• Stop the distillate pump and shut discharge valve.

• Switch off salinity meter.

• Close filling valve to freshwater tanks.

• Wait for evaporator shell temperature to drop below 50 deg cel.

• Close the feed water valve to evaporator.

• Stop ejector pump. Shut fresh water generator overboard valve.

• Open the vacuum breaker valve to make shell side pressure equal to atmospheric pressure.

• Open the drain valve of the evaporator to drain all the seawater from the fresh water
generator.

QUESTION 10 :What precautions will u take for operating the FWG

ANSWER:
• Seawater pressure at the inlet of air ejector must be 3 bar or more.

• The pressure at ejector outlet should not exceed 0.8 bar.

• Never start fresh water generator distillate pump in dry condition.

• Feed water to be supplied for a few minutes to cool down the evaporator before stopping.

• Never open the drain valve of evaporator before opening vacuum breaker. Otherwise
atmospheric pressure causes seawater inside to hit the deflector.

QUESTION 11: How scale formation take place in FWG?

ANSWER :
The performance of fresh water generator reduces with the formation of scales because of
reduction in heat transfer efficiency. Three scales which are 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 the
temperature of operation. Calcium sulphate scale formation depends mainly on the density of
the evaporator contents or brine. The reaction takes place when sea water 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 degree
Celsius, calcium carbonate scale predominates. If sea water is heated above 80 degree Celsius,
magnesium hydroxide scale is deposited.

If the density of evaporator contents is in excess of 96000 ppm, calcium sulphate scales are
formed. But fresh water generator brine density is normally 80000 ppm and less. Hence scale
formation due to calcium sulphate is not a problem.

Hence it is recommended to operate fresh water generator at its rated capacity, not more. More
production of water than rated capacity means higher concentration of brine and more scale
formation. Similarly higher shell temperatures result in formation of hard scales which will be
difficult to remove. All these together will reduce the plant efficiency drastically.

QUESTION 12 : How to minimise scale formation?

ANSWER :
Scale formation in fresh water generator can be controlled and minimized by continuous
chemical treatment.
Polysulphate compounds (like sodium polysulphate) with anti foam is preferred by marine
engineers and is extensively used on ships. Their trade name is different, like:

1. Vaptreat (by “UNITOR”)

2. Ameroyal (by “DREW CHEMICALS”)

QUESTIONS 13 What can be fault of FWG

ANSWER : Faults in fresh water generator reduces performance of the system, thereby reducing
quality and quantity of freshwater produced on ships. These irregularities must be identified and
rectified immediately to ensure that the optimum performance of the fresh water generator is
achieved.

Typical faults in fresh water generator are:

Loss of Vacuum or Over-pressure of Shell

The shell pressure of the fresh water generator rises and rate of freshwater produced reduces.
The reasons are:

• Air leaks into the evaporator shell in large quantities and air ejector cannot cope.

• The cooling water flow through the condenser is reduced or cooling water temperature is
high. This cause saturation temperature and hence saturation pressure within the condenser
to rise.

• Malfunctioning of the air ejector.

• Flow rate of the heating medium increased and excess water vapour produced. Since this
excess vapours cannot be condensed, shell pressure increases or vacuum falls.

Salt Water Carry Over

• Level of salt water inside the shell is high. When water level is high agitation due to boiling
occurs and salt water may carry over along with the vapours.

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

• Increased evaporation rate.

Gradual Increase in Level of Brine

For the satisfactory operation of the freshwater generator, a constant level of brine to be
maintained in the shell. Brine is the concentrated sea water after liberation of water vapours.
This brine is gradually extracted from the shell. Usually this is achieved by the combined air-brine
ejector. It extracts air as well as brine from the shell. Any fault in the ejector or brine extraction
pump (in some models) cause increase in the brine level.

Increase in Salinity of Freshwater

Possible causes are:

• Brine level inside shell too high.

• Leaking condenser tubes or plates.

• Operation of evaporator near shore with contaminated feed water.

• Shell temperature and pressure too low.

• Increased solubility of CO2 generated from the 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 ans not
presence of salt.

QUESTION 14 : Draw a diagram of FWG

ANSWER
Last modified: 20 Oct 2019