Fuel Conditioning System

FCM One Operating Instructions

System Manual
Lit. Code 200001446-1-EN-GB
Manual No. 9013906 02 V. 2
Published by
Alfa Laval SpA
Product Development FCS & Modules
Via Pusiano 2
20900 Monza (MB), Italy

The original instructions are in English

© Alfa Laval Corporate AB 2020-02

This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.
Contents
1 Operator Panel...........................................................................................................5
1.1 Manual Controls........................................................................................................ 5
1.2 HMI Panel..................................................................................................................6
1.2.1 Overview Matrix........................................................................................... 7
1.2.2 Tab Control...................................................................................................8
1.2.3 Control Bar...................................................................................................9
1.2.4 User Login Dialog...................................................................................... 10
1.2.5 Pop-up Keyboard and Numerical Pad........................................................11
1.2.6 Main Tab 1: FCM One Process..................................................................12
1.2.7 Main Tab 2: Alarms and Events................................................................. 17
1.2.8 Main Tab 3: Trends.................................................................................... 18
1.2.9 Main Tab 4: System Information................................................................ 19
1.2.10 Main Tab 5: Timers and Counters.............................................................. 22
1.2.11 Main Tab 6: Parameters 1..........................................................................23
1.2.12 Main Tab 7: Parameters 2..........................................................................24
1.2.13 Main Tab 8: Parameters 3..........................................................................25
1.2.14 Main Tab 9: Parameters 4..........................................................................26
1.2.15 Main Tab 10: Programmable I/O................................................................ 26

2 Normal Operation...................................................................................................27
2.1 Before Start............................................................................................................. 27
2.2 Manual Start............................................................................................................ 28
2.3 Automatic Start (Recommended)............................................................................ 30
2.4 Stop......................................................................................................................... 32
2.5 Pumps Operation.....................................................................................................33
2.6 Pumps Stand-by Function....................................................................................... 34
2.7 Fuel Operating Modes.............................................................................................35
2.7.1 Fuel Control Type.......................................................................................36
2.7.2 Blending Mode........................................................................................... 37
2.8 Changeover.............................................................................................................38
2.8.1 MGO to HFO..............................................................................................42
2.8.2 HFO to MGO..............................................................................................45
2.9 Automatic Filter........................................................................................................48
2.10 Mixing Tube Aeration...............................................................................................48
2.11 Variable Frequency Drive (VFD)..............................................................................49
2.12 Remote Control....................................................................................................... 49
2.13 Automatic Start-up After Power Failure................................................................... 50
2.14 Regular Checks on the System...............................................................................50
2.15 Emergency Stop......................................................................................................51
2.15.1 Optional External Emergency Stop, EPC Mode........................................ 51
 2.15.2 Optional External Emergency Stop, Manual Mode.................................... 51
2.16 Logs Export............................................................................................................. 52
2.17 Standard Log Export................................................................................................53
2.18 Parameters Export and Import................................................................................ 54

3 GPS................................................................................................................................. 55
3.1 Communication Settings..........................................................................................55
3.2 Settings in FCM One............................................................................................... 55
3.3 Transferred Data..................................................................................................... 55

4 Manual Operation...................................................................................................57
4.1 Manual Operation of Main Components..................................................................58
 EN

1 Operator Panel
FCM operator panel is placed in the control cabinet upper part and it is
composed of several switches for manual control and by a touchscreen
interface for automation control.

1.1 Manual Controls

The switches for manual control are located in the bottom part of the operator
panel and allow the operator to manually handle the main components and
functions.

The main component switches are only enabled if the main system switch
is set in manual position.

The main component switches allow to the operator to Start (ON) or to

Stop (OFF) the supply pumps, circulation pumps and automatic filter and to
control haters (SRV or electric heaters according to the installation).

Pipes heat tracing selector is always enabled and allows to the operator to
select Start (MAN), Stop (OFF) or to leave the control of heat tracing to
EPC (AUTO).

In case that an Automatic/Automatic Alfa Laval Moatti filter has been instal-
led, the automatic filter selector is always enabled and allows to the opera-
tor to select the operating filter.

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1.2 HMI Panel

The touchscreen HMI panel is placed in the upper part of the operator panel
and it is the interface between the operator and the control system.

The HMI is a 7” touch screen panel with a software program (available option
15”); simply tap the panel with a fingertip to operate on it.
The HMI program includes many different screens. The operator can scroll
and navigate among them via the Overview Matrix or using the Tab Control.

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1.2.1 Overview Matrix

In order to get an overview about the available HMI screens, tap the Overview
button in the lower right corner of the screen.

The screens are organized in a matrix of rows and columns.

On the top of each column the main tab is located, while in the left of each row
it is possible to easily find the sub-tab.

Main tabs are numbered from left to right and sub-tabs are numbered from top
to bottom.
When the operator taps an icon in the overview matrix, the HMI program
automatically goes to that screen viewing the selected menu.

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1.2.2 Tab Control

The current main tab and sub-tab are highlighted, as shown in figure below:

In order to navigate through other screens, simply tap a sub-tab or main tab.

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1.2.3 Control Bar

The control bar is shown and it is available at the bottom of each screen.

The following buttons for controlling the FCM One are available in all modules:

Start button: tap the button to start the FCM system.

The green outline around the button flashes when the system is in the start-up sequence
and becomes solid when the start-up sequence has been completed.
When in manual mode, the button is enabled only if pumps are in running mode.

Stop button: tap the button to stop FCM system.

When the system is in idle mode, the button icon is grey coloured: the button functionality is
disabled.

Fuel button: tap the button to select a fuel.

The green outline around the selected fuel button flashes when the changeover is in pro-
gress and becomes solid when the changeover process has been completed.

Manual button: the button icon is shown when the system switch has been set in manual
position.

Remote button: tap the button to enable the remote control.

As the button is selected, the green outline will appear around the button.
If system switch is set in manual position, the remote control will be automatically disabled.

The buttons at the right side of the control bar are related to HMI itself:

The Utilities button opens a menu with Backlight and Print screen buttons.

Insert a USB memory stick in the USB port of the HMI panel and then tap the Print button.
This stores a screenshot of the currently displayed screen on the memory stick.

Enable Tooltip button to activate the component tags.

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Tap the Login button to display or to hide the user login dialog box at the top of the screen.

Tap the Overview button to enter or to leave the screen overview matrix.

1.2.4 User Login Dialog

The current access level is displayed in the upper part of all screens.
To enable the user login dialogue box, press the login button on the control
bar. The user login dialogue box is shown below.

Select a user name from the drop down menu then tap the empty password
input field to open the pop-up keyboard.
Type the required password followed by the ‘enter’ key.
There are four user levels to choose from the drop down menu:
Table 1: FCM One User Password

User Password Description

Operator 2821 Access to password protected variables limits
AdvOperator 3584 Access to advanced features
Alfa Laval Service Engineer level: access to advanced settings and
ALSE **** configuration
Alfa Laval Engineers level: this access level is reserved for product
ALE **** development only

By tapping the Logout button the Login level will be changed to ‘Guest’ that
gives access to the normal system operation.

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1.2.5 Pop-up Keyboard and Numerical Pad

When typing alpha-numeric characters, for example passwords, the on-screen
keyboard pop-up on the screen.

When entering numerical values as setpoints and parameters, the numerical

pad automatically pop-up on the screen.

It is possible to catch the keyboard or numerical pad by the inactive area to

move it to a different position on the screen.
Tap the escape button (Esc) to close the keyboard or numerical pad pop-up.

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1.2.6 Main Tab 1: FCM One Process

The Main Tab 1 enables the FCM One Overview screen and the other detail
process screens:

Table 2: FCM One Process

Animated overview of FCM One system.

FCM One Overview
Process values and status are displayed with coloured outlines.

Fuels and changeover details with information about:

• Fuel consumption
Changeover
• Changeover valves position
• Blending (if installed)

Supply Pumps details with information about:

• Supply pumps status
Supply Pumps • Supply pressure PT1
• VFDs (if installed)
• Automatic deaeration valve (if installed)

Automatic Filter details with information about:

• Running filter
Filter
• Differential Pressure Switch
• Sludge Removal Pump (if installed)

Circulation Pumps details with information about:

• Circulation pumps status
Circulation Pumps
• Circulation pressure PT2
• Automatic deaeration valve (if installed)

Temperature and Viscosity control details with information

about:
• Actual temperature TT2
• Actual viscosity VT
• Temperature set point
Temperature control
• Viscosity set point
• Heater/Cooler in use
• SPV cooler (if installed)
• Mixing tube inlet temperature TT1 (if installed)

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1.2.6.1 FCM One Overview

The FCM One Overview screen is the main screen to operate the FCM One
system. It is identified by the control cabinet icon.

The overview screen is composed of an upper part showing the process tiles
and by a lower part showing the main sensors and variables.

Process Tiles
Overview process tiles outline indicates the status of a specific process.

The outline flashes green when a process is starting and becomes solid green
when it is correctly running.

The outline flashes red if an alarm occurs in a process.

The tile outline turns off when a process has been stopped.

Tap a process tile to enter the Process overview screen.

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Main Sensors
The main process sensors are shown in the overview screen together with
heat tracing and mixing tube level switch status.

Manual Release
Manual release button is used to disable all the manual control overrides of
the components.

The button is only enabled if any component manual control has been
activated; tap on the button to release them. A pop-up dialog box will ask for
confirmation.

WARNING
Manual control overrides of components could seriously
compromise the FCM One standard functionality.

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1.2.6.2 Process Overview Screens

The main FCM One functions are split in five Process Overview screens:
1. Changeover
2. Supply pumps
3. Filter
4. Circulation pumps
5. Temperature control
Each Process Overview screen is composed of a simplified process flow
chart, that shows the status of involved components and variables, and by an
information box that summarize the status of the main components and allow
quick access to process parameters and counters.

Animated outline
The outline on the equipment or on the device indicates the status of the
equipment/device.
In the example below the outline flashes when it is starting/stopping or
opening/closing.

When the equipment or the device is completely started/stopped or open/

closed, the online colour stops blinking and becomes solid.

Overlay icons
Some of the components show the Faceplate icon in the top left cor-
ner.
Tap the equipment to open the faceplate, which may contain additional information about the equipment or the
manual control function.
The Manual control icon is available at the bottom left corner of the
component when a manual override of the component has been forced.

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WARNING
Manual control override of components could seriously compromise
the FCM One standard functionality.

The Alarm icon appears at the bottom right corner of a component that is in
fault or of a component that is generating an alarm.

The Warning icon appears, instead, when a component has been disabled.

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1.2.7 Main Tab 2: Alarms and Events

The Main Tab 2 enables the screens related to the system alarms.
Table 3: FCM One Alarms and Events

Alarm List List of active alarms

Alarm History List of historical alarms

Event Log List of user interactions with the HMI (audit trail)

Alarm Acknoledge
Before operating the FCM One system, make sure that all active alarms have
been acknowledged by the operator.

The presence of any active alarms is indicated by a red alarm icon at main tab
2.
The red alarm icon flashes until all active alarms have been acknowledged.

A grey icon means no active alarms.

Unacknowledged alarms have a red background colour:

Acknowledged alarms have a yellow background colour:

When the alarm condition is no longer fulfilled, acknowledged alarms

disappear from the alarm list.

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In order to acknowledge an alarm, select it tapping on alarm line and then tap
Ack Selected button.

In order to acknowledge all active alarms, tap Ack All button.

Old alarms are stored and they are shown in Alarm History screen 2.2.

1.2.8 Main Tab 3: Trends

The Main Tab 3 shows the main values trend screen.

Table 4: FCM One Real Time trend

Real time trend of main values:

• Supply pressure PT1
Real Time Trend • Circulation pressure PT2
• Viscosity VT
• Temperature TT2

Trend Legend
It is possible to toggle the trend legend status between ‘trend legend
displayed’ and ‘trend legend hidden’ by tapping the trend button.

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1.2.9 Main Tab 4: System Information

The Main Tab 4 enables the screens related to EPC configuration, Modbus
communication setup and logs export.

Table 5: FCM One System information

EPC hardware configura- EPC hardware configuration and installed modules

tion

Modbus Modbus TPC/IP or RTU configuration parameters

2Touch & Controller Info 2Touch & Controller info and software release

HMI Settings HMI settings, backup and restore

Logs and Parameters export to USB and Dynamic I/O configu-

Export to USB ration

Service Flow Meters configuration and screen cleaner functionality

PLC Modules
The complete list of installed PLC modules is shown on screen 4.1.
If any PLC module is detecting an error or a fault, or it is not correctly
configured, the Alarm Icon will appear at the bottom of each module.

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Modbus configuration
Modbus TCP/IP address and Subnet Mask are available on screen 4.2.

In order to change the IP address or Subnet Mask, write the new values and
then tap Update button.
Even Modbus RTU parameters are available in screen 4.2.
Please refer to Parameter list for further details.

Date and Time set

System Date and Time can be set on screen 4.4.
Set Time, Date and Regional settings in HMI and then tap Synchronize
System Time button to synchronize with PLC.

NOTE
If HMI and PLC time and date are not synchronized, the log function
will not work correctly.

HMI IP setting
Local and remote HMI IP address can be modified on screen 4.4.
Tap on Edit IP Address button; a pop-up dialog box will appear.
Edit the new IP address and Subnet Mask; then press Ok.

The default IP addresses are listed below.

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Table 6: FCM One Default IP Address

Default IP Address
Local HMI 192.168. 250.10
Remote HMI 192.168.250.11

Subnet Mask 255.255.255.0

WARNING
Inserting not valid IP address will stop the communication between
HMI and PLC causing FCM system loss of control!

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1.2.10 Main Tab 5: Timers and Counters

The Main Tab 5 enables the screens related to Timers and Counters.

Table 7: FCM One Timers and counters

Operating Timers 1:
• Machine run time
Operating Timers 1 • Supply pumps run time
• Circulation pumps run time
• Timers for automatic pumps switch

Operating Timers 2:
• Deaerations counter
Operating Timers 2
• Automatic filters run time
• Automatic filter drains counter

Flow Counters • Fuel flow counters

All timers and counters are available as Total and Trip counter.
Total counter can only be reset by Alfa Laval Service Engineer; trip counters
can, instead, be reset with any login level.
In order to reset a counter, login with the required login level and tap on the
Reset button.
A pop-up dialog box will appear to ask for confirmation.

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1.2.11 Main Tab 6: Parameters 1

The Main Tab 6 enables the first set of screens related to parameters.

Table 8: FCM One Parameters 1

System and Main parameters set including:

• Remote control type
System Parameters
• Start-up sequence
• Power failure action

Configure programmable I/O parameters:

• Digital Input
Programmable I/O
• Digital Output
• Analog Outputs

Changeover parameters including:

Changeover Parameters • Number of fuels
• Changeover valve type

Time parameters for changeover valves:

• CV1
Changeover Valves
• CV2
• CV3

Parameters for blending definition:

• Blend type
Blending Parameters
• Fuels selection
• Blend PID controller

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1.2.12 Main Tab 7: Parameters 2

The Main Tab 7 enables the second set of screens related to parameters.

Table 9: FCM One Parameters 2

Fuel 1 Parameters including:

• Fuel grade
• Fuel density
Fuel 1
• Control type
• Viscosity set point and limits
• Temperature set point and limits

Fuel 2 Parameters including:

• Fuel grade
• Fuel density
Fuel 2
• Control type
• Viscosity set point and limits
• Temperature set point and limits

Fuel 3 Parameters including:

• Fuel grade
• Fuel density
Fuel 3
• Control type
• Viscosity set point and limits
• Temperature set point and limits

Fuel 4 Parameters including:

• Fuel grade
• Fuel density
Fuel 4
• Control type
• Viscosity set point and limits
• Temperature set point and limits

Blend Fuel Parameters including:

• Fuel grade
• Fuel density
Blend Fuel
• Control type
• Viscosity set point and limits
• Temperature set point and limits

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1.2.13 Main Tab 8: Parameters 3

The Main Tab 8 enables the third set of screens related to parameters.

Table 10: FCM One Parameters 3

Supply pumps parameters including:

• Number of pumps
Supply Pumps • Pump in operation
• Automatic switch
• Supply pressure set point

Variable Frequency Drives configuration:

Supply Pumps VFDs • Pumps nominal data
• PID controller

Circulation pumps parameters including:

• Number of pumps
Circulation Pumps
• Pump in operation
• Automatic switch

Moatti automatic filter configuration:

• Filter position and type
Automatic Filter
• Drain interval
• Sludge removal pump

Mixing tube and flow meter configuration:

• Flow meter type
Mixing Tube
• Analog output range for fuel consumption
• Deaeration valve type

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1.2.14 Main Tab 9: Parameters 4

The Main Tab 9 enables the fourth set of screens related to parameters.

Table 11: FCM One Parameters 4

Temperature control hardware configuration:

• Heaters type
Temperature Control • Cooler type
• Temperature sensors
• Heat tracing

Time parameters for changeover valves:

Temperature Control Changeover • CV4
Valves
• CV5

Temperature control hardware configuration:

Temperature Control • Ramp speed
• Electric heaters PID

Viscosity transmitter configuration:

Viscosity Transmitter • Type
• Range

Time and PID parameters for temperature regulating valves:

Temperature Regulation Valves • SRV
• CRV

1.2.15 Main Tab 10: Programmable I/O

Alarms delay and pressure limits can be set through Main tab 10.
Table 12: FCM One List of programmable I/O

I/O Configuration — 1 Set programmable I/O

I/O Configuration — 2 Set programmable I/O

I/O Configuration — 3 Set programmable I/O

I/O Configuration — 4 Set programmable I/O

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2 Normal Operation
2.1 Before Start
The following procedures assume that the system pipelines and the valves arrangement are set for
operation (open valves and secured pipework). Moreover, they consider that the commissioning
actions described in the Installation System Reference booklet have been successfully performed.

CAUTION Breakdown hazard

Make sure that the pumps are filled with oil before start, otherwise the pumps shaft seal will be
damaged. For pumps startup recommendations, see chapter 4 in the Installation System
Reference booklet.

CAUTION Breakdown hazard

Make sure that all pipe lines have been flushed before start, otherwise all main components will
be damaged. For first startup procedure, see chapter 4 in the Installation System Reference
booklet.

1 Set heat tracing switch to “Auto” position or

ensure that, if installed, electric trace heating
thermostat is set to 65°C; in this way pipes
heating is switched off when the oil has been
warmed up.

2 Turn all the main switches inside the frontal

panel of the control cabinet to ON position.

3 Turn all the main switches inside the lateral

panel CP1 – SP1 and CP2 – SP2 section to
ON position.

4 Turn the two main switches on the cabinet

right and left side to ON position.

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2.2 Manual Start

The manual start procedure is listed below.

1 Move system switch to manual position.

2 Move supply pump switch to ON position to

start the required supply pump.

3 Move automatic filter switch to ON position.

4 If required, manually open deaeration valve

until the mixing tube level is high.

5 Move circulation pump switch to ON position

to start the required circulation pump.

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6 Move stand-by pump switch to ON position to

enable automatic stand-by function.

7 Tap start button on HMI; a pop-up dialogue

box will appear to ask for confirmation.

NOTE
In manual control, the Start button is only
enabled when pumps are in running
mode.

8 Move system switch to automatic position.

9 Move all pumps and filter switches to OFF

position.

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2.3 Automatic Start (Recommended)

The recommended automatic start procedure is listed below.

1 Move the system switch to automatic

position.

2 Tap start button on the HMI; a pop-up dialog

box will appear to ask for confirmation.
Pumps and heating system will be started
according to default starting sequence:
• Supply pump selected by P401 will be
started.
• If an automatic filter has been installed in
cold side position, the filter will be started.
• If the mixing tube level is low, the operator
has to manually deaerate the mixing tube
until fuel level is high.
• In case that automatic deaeration valve
has been installed, the valve automatically
opens until mixing tube level is high.
• Once supply pressure is above A405 PT1
Limit Low and mixing tube level is high,
the system waits for the amount of
seconds set in P100.
Then the circulation pump selected by
P501 will be started.
• If automatic filter has been installed in hot
side position, the filter will be started.
• When the circulation pressure is above
A504 PT2 Limit Low, the system waits for
the amount of seconds set in P101.
Then temperature control will be started.
• A temperature ramp will start according to
P962/P963 starting from actual fuel
temperature to the selected fuel
temperature set point.
• Once the temperature ramp is over, the
system will switch to the selected control
type.

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NOTE

During start-up procedure, low pressure alarms are disabled for the amount of seconds
related to P456/P556 or until the pressure value is above low pressure limits.

Figure 1: FCM One Automatic start (recommended)

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2.4 Stop
By stopping the system as described in the procedure below, no alarms will be activated.
The system is designed so that the pumps cannot be stopped from EPC controller even if an error
occurs in the controller.
Due to safety reasons, the EPC can only start or switch the pumps but never stop them; this action
has to be performed manually.

1 Tap stop button on the HMI screen; a pop-up

dialog box will appear to ask for confirmation.
Temperature control will be stopped; if
installed, SRV will be completely closed.
A pop-up dialog box will appear with the
message stop the pumps manually.

2 Move system switch to manual position.

NOTE
Wait until the system cooled down before
stopping the pumps.

3 Move all pumps and filter switches to OFF

position.
NOTE
To increase the life-span of the pumps
seals and to avoid clogging, it is
recommended to stop the pumps on light
oils.

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2.5 Pumps Operation

In order to switch the running pump(s) during automatic operation, P401 and
P501 have to be changed (see Parameter list booklet for alternatives).

NOTE
To increase the life-span of the pumps seals, it is recommended to
minimize the number of starts and stops on Heavy Fuel Oil.

The control unit can be set to change pumps (running to stand-by) at preset
intervals during operation according to P451/P551.
Alternatively, the control unit can be set to indicate when the time to change
over pumps is past.

NOTE
Since the pumps shaft seal has to be lubricated, a small amount of
oil will drop from the pump housing. About 10 drops per hours is
considered normal. If the leakage is greater, the shaft seal should be
replaced immediately to avoid additional damages. See Oil Feed
Pumps booklet for details.

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2.6 Pumps Stand-by Function

The pumps stand-by function is always active when the system is running in
automatic mode (system switch in automatic mode and green overlay around
the start button).

NOTE
When a stand-by pump is started due to a fault or due to low
pressure alarm, the faulty pump is disabled in parameter P401/P501.
If the pump is disabled, the stand-by function for the set of pump is
disabled. It is necessary to restore stand-by function for the pump
using parameter P401/P501.

NOTE
If power supply is missing for stand-by pump, an alarm is shown and
the stand-by function is temporary disabled. When power supply is
back, the stand-by function is automatically restored.

Automatic switch of pumps always changes the selected running and stand-by
pump in parameter P401/P501.
If a fault occurs in one pump (e.g. one of the supply pumps) the stand-by
function for the other set of pumps (e.g. circulation pumps) continues to be
active.
Stand-by function has two different time delays:
• When a pump failure occurs there is a delay defined by parameter G3
before the stand-by pump contactor closes.
• When a low pressure alarm occurs the time before the stand-by pump
starts is defined by parameter G1.

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2.7 Fuel Operating Modes

The controller is able to handle up to four different fuels and an additional
blend mode, according to the hardware installation.

Each fuel, including blend mode, can be configured with dedicated name,
specifications, set points and alarm limits (see Parameter list booklet for
details).

The selected fuel is indicated by a green overlay around the respec-

tive button on HMI.

NOTE
Only installed fuels are available for configuration and shown in HMI
control bar.

In connection with bunkering, it may be necessary to adjust some fuel

parameters. This is certainly when changing to a different grade fuel.
Some of the following parameters may have to be changed:
• Density parameter: changing to a fuel with different density, the respective
parameter has to be updated in order to obtain a most accurate viscosity
measurement. The fuel density value, in fact, is used in viscosity
measurement process.

CAUTION
Wrong settings of density parameter may cause inaccurate viscosity
measurement.

• Temperature set point parameter: the new fuel may be heated to a different
temperature to obtain the same viscosity set point.

NOTE
Wrong temperature set point may cause undesired behaviour during
the changeover process.

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2.7.1 Fuel Control Type

During standard operation, each fuel, includ-
ing blending, can be controlled in three differ-
ent ways:

• Viscosity control: Viscosity set point is used to control heating and cooling
systems.
Even if viscosity control is set, high and low temperature alarms are always
active.
Temperature control is always used during change overs temperature ramp
and during start-up.

NOTE
Wrong temperature set point may generate temperature alarms
when viscosity control is used.

Viscosity control is recommended for Heavy Fuel Oil.

• Temperature Control: Temperature set point is used to control heating and

cooling systems. Even if temperature control is set, high and low viscosity
alarms are active.
Temperature control is recommended for Diesel Oil.

• Temperature with viscosity feedback: with this hybrid control system,

temperature set point is used to control heating and cooling systems.
Viscosity set point is anyway used to automatically modify temperature set
point parameter in case of viscosity set point is not matched.
Temperature with viscosity feedback is recommended for light oils to avoid
low viscosity issues.

The control mode for each fuel is set by parameters.

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2.7.2 Blending Mode

A blend of two different fuels can be handled as an additional fuel that has its
own parameters set and regulations.

WARNING
Blending not compatible fuels may cause system instability and
clogging! Perform a compatibility test before blend fuels.

The blended fuel can be defined specifying the required final sulphur
content or the percentage of each original fuel composing the blend.
The blend definition mode is selected by parameter P310.

The two fuels used to specify blending are selected by parameters

P311 and P312.

The required final sulphur content is set by parameter P308 and it is

calculated using theoretical sulphur content of each blended fuel.

The theoretical sulphur content of each fuel is set by P304, P305,

P306 and P307 parameters.

NOTE
Set the theoretical sulphur content of each fuel according to bunker
delivery receipt. The theoretical sulphur content must be updated
after a new bunkering.

The required percentage of each fuel is set

by parameters P313 and P314.

Fuel percentage of each fuel is calculated measuring mass flow of each fuel
with dedicated mass flow meters.
The actual sulphur content of blended fuel is calculated using measured mass
flow of each fuel and its theoretical sulphur content specified by parameters.
Inlet three way changeover valves are driven according to the measured mass
flow; the valves are moved using a dedicated PID controller.

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2.8 Changeover
The different properties and working conditions of bunkered fuels, make the
fuel changeover one of the most important and critical function in the booster
systems. Particular attention must be paid to fuel incompatibility, temperature
gradient, changes in viscosity.
The fuel incompatibility
The risk of incompatibility between residual fuel and low-sulphur distillates is
considered higher than what is typically associated with mixing different types
of residual fuel. Introducing distillate may cause the asphaltenes in the
residual fuel to precipitate as heavy sludge. This may result in filter clogging
and, in extreme cases, may cause fuel starvation in the engine and
subsequent engine shutdown. Another associated issue may be sticking of the
injection pump due to deposits between the plunger and the barrel.
Compatibility tests may be carried out either on board during bunkering or via
an independent laboratory.
The temperature gradient
The effect of large and rapid changes in fuel oil temperature on the injection
pumps could result in a seizure of the pump cylinder liner and the plunger due
to the varying thermal expansion properties of the liner and the plunger.
Generally, engine manufacturers recommend a gradient of no more than 2 °C
per minute. For this reason, fuel changeover can take considerable time from
initiation to completion.
The changes in viscosity
The optimum operational viscosity of a residual fuel at the engine fuel pump is
usually within the range of 10–20 cSt; to achieve parameter, fuel oil must be
heated up around 130/140 °C. Distillates viscosity is much lower; it is usually
in the range within 2 and 6 cSt at 40 °C and often requires fuel cooling to
achieve it. Engine manufacturer normally require to maintain viscosity above
the minimum viscosity of 2 cSt to avoid both lubrication issues and excessive
leakages within components that can lead to lack of performance and, in same
situation, to seizure.
Changeover time
Another important factor to be considered during a changeover is its duration:
a long changeover time requires a bigger consumption of light fuel.
Anyway there are two sides to the changeover process that must be
considered; one is the practical side to get the correct viscosity into the
engine; the other side is to be in compliance with MARPOL Annex VI with
0.10% maximum sulphur value. Compliance with regulations takes longer than
just changing over from one fuel to the other.
The time needed will depend on:
• Fuel system design, how much oil is within the system
• Sulphur values of the fuels
• Consumption of the engines

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1. Tap the required fuel button on the HMI; a pop-up dialog box will appear to
ask for confirmation.

2. If manual changeover valve CV1 has been installed, move the valve to the
new fuel. If automatic changeover valve has been installed the valve will
immediately start to move towards the new fuel position.

NOTE
If more than one changeover valve have been installed, the controller
will perform position check on other changeover valves and, if
required, will move them to the required position before starting to
move the valve involved in changeover procedure.

NOTE
If automatic changeover valve has been installed, changeover time
for each valve and for each direction can be set by parameters. The
right time is function of temperature ramp, fuel consumption and
total fuel volume and may vary for each installation and running
conditions.

NOTE
Different engine loads may require different valve changeover times
to ensure the viscosity to stay within specified limits.
As general rule, a longer valve switch over time is required with high
fuel consumption; a shorter valve switch over time is required with
low fuel consumption.

Valves time can be adjusted as below:

• Changeover from HFO to MGO:
• If viscosity increases too much, reduce valve time.
• If viscosity decreases too much, increase valve time .
• Changeover from MGO to HFO:
• If viscosity increases too much, increase valve time.
• If viscosity decreases too much, decrease valve time.
If SPV Cooler has been installed, as soon as changeover valve leaves MGO
position, changeover valve CV5 moves towards by-pass position.

3. Temperature ramp will immediately start with temperature variation ac-

cording to P962/P963.
The temperature ramp starts from actual fuel temperature to the re-
quired fuel temperature set point.

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NOTE
Temperature high and low limits change together with temperature
ramp. Viscosity high and low limits are fixed during changeover
procedure.

NOTE
If viscosity goes above HFO set point or below MGO set point,
temperature ramp is frozen and the temperature is maintained until
viscosity is again within the acceptable range.

4. After the time set by parameter, changeover valve gets to the new fuel posi-
tion.
If SPV Cooler has been installed, as soon as the changeover valve reaches
MGO position, CV5 moves toward SPV cooler position.
5. If both heating and cooling systems have been installed, EPC is able to auto-
matically switch from heater to cooler and vice versa operating on changeover
valve CV4.
The controller will move the CV4 if the difference between actual temperature
and set point temperature is bigger than P912 (°C) for more than P913 (s)
time.
The valve changeover time is set by parameters P921/P922.

NOTE
If required, the controller is able to switch from heater to cooler and
vice versa even if changeover process is not started.

6. The changeover procedure is finished when changeover valve reaches the

new fuel position, temperature is in accordance with the requested set point
and viscosity is within set limits.

NOTE
The delay for total fuel replacement in the loop depends on the
engine consumption and the total fuel volume (Mixing tube, FCM
circulation pipes, pipes from FCM to engine and return line from
engine to FCM).

WARNING
Mixing not compatible fuels may cause system instability and
clogging! Perform a compatibility test before a fuel changeover.

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Alarms are activated if:

• The valve does not reach the final position within required time
• The valve does not leave current position when a changeover is started
• The valve leaves current position when changeover is not started

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2.8.1 MGO to HFO

The light fuel is normally controlled with temperature set-point around 40 °C to guarantee a viscosity
around 2–3 cSt. The target fuel is an heavy fuel oil controlled with viscosity set-point around 14 cSt.
Usually this viscosity requires a temperature around 140 °C.

1 System running in MGO.

• System is completely filled with MGO.

• The temperature transmitter TT signal the
PLC continuosly.
• The PLC continuosly control the cooler to
maintain the required temperature.

2 Changeover started.

• CV1 starts to move towards HFO position.

• Some HFO starts to enter in the supply
side; circulation side is still filled with
MGO.
• Temperature ramp starts.
• The PLC continuosly control the cooler to
increase the temperature as required by
temperature ramp.
• As consequence, viscosity decreases.

3 Viscosity decreases.

• CV1 continuos to move towards HFO

position.
• Circulation side is still filled with MGO.
• If the viscosity is close to MGO low limit,
temperature ramp stops.
• The PLC continuosly control the cooler to
maintain the temperature stable and avoid
further viscosity decrease.

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4 HFO enters in the circulation side.

• CV1 reached HFO position.

• Some HFO starts to enter in the circulation
side.
• The viscosity starts to increase;
temperature ramp starts again.
• The PLC continuosly control the cooler to
increase the temperature as required by
temperature ramp.

5 From cooler to heater.

• When the temperature cannot increase

anymore just regulation the cooler, CV4
starts to move towards heater position.
• During CV4 switch, temperature ramp
stops.
• Both heater and cooler are stopped.

6 Changeover ongoing.

• CV4 reaches heater position.

• Temperature ramp starts again.
• The PLC continuosly control the heater to
increase the temperature as required by
temperature ramp.
• Circulation side is still filled with a blend of
MGO and HFO.

7 Changeover ongoing.

• Temperature reached HFO setpoint.

Temperature ramp is finished.
• The PLC continuosly control the heater to
maintain the HFO temperature setpoint.
• The MGO part of the blend is continuosly
reduced by the engine consumption.
• As consequence, the viscosity slowly
increase.

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8 Changeover finished.

• When viscosity is above HFO low viscosity

limit, the system switches to viscosity
control.
• The MGO part of the blend can be
considered negligible.
• The PLC continuosly control the heater to
maintain the required viscosity.

Changeover from MGO to HFO. The complete procedure took more than three hours. this is the effect
of the combination of long run time for CV1 and low engine load.
The HFO takes a lot of time to reach the circulation side; if temperature starts to increase, the
viscosity will be too close to the low limit. For this reason the temperature ramp starts some minutes
later than the procedure.
It is even possible to see that CV4 moves too fast, creating some turbulence in temperature and
viscosity during the transition. A longer run time can give smoother results.

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2.8.2 HFO to MGO

The heavy fuel is normally controlled with viscosity set-point around 12cSt that usually means a
working temperature around 140°C.
The target fuel is a light fuel oil controlled with temperature set-point around 40 °C.

1 System running in HFO.

• System is completely filled with HFO.

• The viscosity transmitter VT signal the
PLC continuosly.
• The PLC continuosly control the heater to
maintain the required viscosity.

2 Changeover started.

• CV1 starts to move towards MGO position.

• Some MGO starts to enter in the supply
side; circulation side is still filled with HFO.
• Temperature ramp starts.
• The PLC continuosly control the heater to
decrease the temperature as required by
temperature ramp.
• As consequence, viscosity increases.

3 Viscosity increases.

• CV1 continuos to move towards MGO

position.
• Circulation side is still filled with HFO.
• If the viscosity is close to HFO high limit,
temperature ramp stops.
• The PLC continuosly control the heater to
maintain the temperature stable and avoid
further viscosity increase.

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EN 2 Normal Operation

4 MGO enters in the circulation side.

• CV1 reached MGO position.

• Some MGO starts to enter in the
circulation side.
• The viscosity starts to decrease;
temperature ramp starts again.
• The PLC continuosly control the heater to
decrease the temperature as required by
temperature ramp.

5 From heater to cooler.

• When the temperature cannot decrease

anymore just regulating the heater, CV4
starts to move towards cooler position.
• During CV4 switch, temperature ramp
stops.
• Both heater and cooler are stopped.

6 Changeover ongoing.

• CV4 reaches cooler position.

• Temperature ramp starts again.
• The PLC continuously control the cooler to
decrease the temperature as required by
temperature ramp.
• Circulation side is still filled with a blend of
HFO and MGO.

7 Changeover ongoing.

• Temperature reached MGO setpoint.

Temperature ramp is finished.
• The PLC continuously control the heater to
maintain the MGO temperature setpoint.
• The HFO part of the blend is continuously
reduced by the engine consumption.
• As consequence, the viscosity slowly
decrease.

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8 Changeover finished.

• When viscosity is lower than MGO high

viscosity limit, the changeover is
considered finished.
• The HFO part of the blend can be
considered negligible.
• The PLC continuously control the cooler to
maintain the required temperature.

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2.9 Automatic Filter

Alfa Laval Moatti automatic filter requires very little attention during operation.
In automatic mode, the filter motor is automatically started by
the EPC together with supply pumps when installed in cold
side or together with circulation pumps when installed in the
hot side.

NOTE
If Automatic-Automatic filter has been installed,
choose the filter in operation through automatic filter
selector.

An automatic drain at regular intervals can be enabled by pa-

rameter: the drain length is set by parameter too.
The automatic drain will be activated even in case the differen-
tial pressure drop increases too much:
• Differential pressure switch will be activated
• The system starts to drain for P604 seconds and increased
Automatic Drain counters
• If after P604 seconds the pressure drop is still high, an
alarm will be activated and the automatic drain will be
closed

NOTE
After a differential pressure drain has been activated,
at least one hour is required before the system starts
the next drain.

See Operation chapter in the filter component booklet for fur-

ther information.
If Sludge Removal Pump is installed, it will be automatically
started after every filter drain.

2.10 Mixing Tube Aeration

If the mixing tube needs venting during operation, an alarm
will be activated.
If automatic deaeration function is installed, the mixing tube
will be automatically deaerated.
Automatic deaeration valve closes when mixing tube level is
high again.

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2.11 Variable Frequency Drive (VFD)

Variable frequency drives can be used to modulate the supply
pumps speed. They allow to improve energy efficiency and to
cut maintenance costs.
The VFD hold the set supply pressure through an embedded
PID controller that accelerates and decelerates the supply
pumps.
Parameters and variables communication is performed via
Powerlink connection, while start and stop signals are per-
formed via hardwired connections. If Powerlink connection is
missing, the VFD sets the pumps speed to the nominal speed.
Process parameters and variables can be respectively
changed and monitored through supply pumps screen on
HMI.

2.12 Remote Control

FCM One remote control can be performed through:
• Digital I/O;
• Remote HMI;
• Modbus TCP/IP;
• Modbus RTU
For further information, see chapter 3 of the Installation System Reference
book.

Select the required remote control type through parameter P0.

Tap Remote button on HMI to enable remote con-

trol.
During remote operation, all local HMI buttons
and parameters will be disabled and local HMI
might only be used for monitoring purposes.

NOTE
Remote control button is only enabled in automatic mode and after
the first start-up of the system.

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Tap again the remote button on local HMI to disable the remote control.

NOTE
If system switch is moved to manual position, remote control will be
automatically disabled.

2.13 Automatic Start-up After Power Failure

The module can be set to be automatically restarted after a power failure by
parameter; see the Parameter List booklet for further details.
When the power supply will be restored after a power failure, the supply pump,
circulating pump and heater will be restarted (after delay time set by
parameter P103). The same pumps that were running before the power failure
will be restarted. If, however, the power to the EPC is not interrupted, the
standby pump will be started and alarm activated when power to the pumps
will be restored.

WARNING Automatic start up

Electric motors and heater system will be automatically restarted after
power failure: always shut off the machine before perform any
maintenance activity!

2.14 Regular Checks on the System

Regularly check the process values to note any unusual changes.
Also, regularly check the automatic filter pressure drop indicator.
If SRV position (or instantaneous electric heater power in the case of electric
heater) changes dramatically, this could be an indication of heater clogging.
When the outside ambient temperature is high, regularly check the internal
control panel temperature. This should be max 65°C.

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2.15 Emergency Stop

In order to stop the system in emergency mode, switch off the red and yellow
main power switches on the control cabinet side panels.

2.15.1 Optional External Emergency Stop, EPC Mode

If the optional external emergency stop button is being pushed while the
system is running in EPC mode, all pumps will be stopped. Alarm A9
‘Emergency Stop Button Activated’ will be shown on the display. The EPC
switches off outputs for all pumps. The EPC switches off the heaters.
When the emergency stop button is released the Fuel Conditioning Module
has to be restarted by pressing the alarm reset button and the start button on
the EPC.

2.15.2 Optional External Emergency Stop, Manual Mode

If the optional external emergency stop button is being pushed while the
system is running in manual mode, all pumps will be stopped. Alarm A9
‘Emergency Stop Button Activated’ will be shown on the display.

CAUTION
When the emergency stop button is released in manual mode, the
pumps will start again.

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2.16 Logs Export

FCM One can export logs through USB stick. Two different ways can be used in order to export logs:
• Tamper proof logs related to fuel changeover and blending according with IMO legislation; every 4
minutes the system registers and saves:
• GPS position;
• fuel parameters: type of fuel, sulphur content, fuels grade and density;
• process conditions: used fuel, system temperature, viscosity, consumption and density,
calculated sulphur content, consumption of each fuel, valves position;
• alarms, start and stop of the system.

NOTE
Before connecting USB drive in PLC, check that CF led on CPU is green. Never insert USB if
the CF led is red (CF card Failure)!

In order to export IMO logs from the software, proceed as follow:

1 Ensure that a USB stick has been inserted in

the PLC USB port

2 Tap the Export IMO log button on screen 4.5;

a pop-up dialog box will open

3 Events or Process variables can be exported

• Standard log: every 5 seconds the system
records all process variables.
• GPS position;
• All the process variables;
• All the alarms including starts and
stops;
• Feedback from chimney.

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2.17 Standard Log Export

In order to export standard logs from the software, proceed as follow:

1 Ensure that a USB stick has been inserted in

the PLC USB port.

2 Tap the Export Standard log button on screen

4.5; a pop-up dialog box will open.

3 Events, Process variables and Alarms can be

exported.

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2.18 Parameters Export and Import

CAUTION
Before connecting USB drive in PLC, check that CF led on CPU is green. Never insert USB
if the CF led is red (CF card Failure)!

In order to export or import parameters through USB, proceed as follows:

1 Ensure that a USB stick has been inserted in

the PLC.

2 Tap the Parameters Backup button on screen

4.5 to export parameters.

3 Tap on Parameters Restore button to load

parameters from a previously exported file.

NOTE

If exported file Parameter.cvs is

opened with a standard personal
computer, the system will not be able
to restore it.

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3 GPS
With a GPS receiver providing the data, vessel position and UTC/GMT-time
can be logged into the PLC.
The GPS receiver is not part of Alfa Laval scope of supply.
The GPS receiver must comply with protocol NMEA-0183, ver. 4.00. it should
be connected to PLC on dedicated I/O module.
Connection example is shown in the wiring diagram. Max cable length allowed
between PLC and the GPS receiver is 1200 m.

3.1 Communication Settings

In order to get a communication with GPS, use the following settings:
• Serial RS422
• 4800 baud
• 8 bit
• 1 stop bit
• No parity

3.2 Settings in FCM One

In order to enable communication with the GPS receiver parameter P3 must
be set to ‘Yes’.

3.3 Transferred Data

The FCM One internal clock will be synchronized with the UTC/GMT data from
the GPS receiver once communication has been established.
Position data can be decoded from three different telegrams in the NMEA-
protocol:
• RMC- Recommended Minimum Navigation Information.
• GGA- Global Positioning System Fix Data, Time, Position and fix related
data for a GPS.
• GLL- Geographic Position Latitude/Longitude.

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4 Manual Operation
The manual operation is provided in the unlikely event that the EPC is out of
order.
System components can be manually operated under the direct supervision of
the operator.

WARNING
No automatic regulation is available in manual operation: wrong
system handling may damage component or generate dangerous
events!

The module is equipped with visual indicators like thermometers, pressure

indicators and position indicators that can be used to monitor the process.
In order to enable manual operation, move the system switch to manual
position.

If EPC is still available, tap start button on HMI to enable system alarms.

NOTE
In manual control, start button is only enabled when pumps are in
running mode.

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4.1 Manual Operation of Main Components

Pumps
Pumps can be manually operated by switching the re-
quired pump switch to ON position.

To enable pumps stand-by function, move stand-by

pumps switches to ON position.

NOTE
In manual operation, automatic stand-by function is only used in
case of pump failure.

WARNING
Even if EPC is switched off or stop working during automatic
operation, the running pumps will continue to run but stand-by
function is not available. Once EPC is restored, it will take control
again.
In case it is not possible to immediately restore EPC, it is
recommended to switch the system in manual mode.

Temperature Control
Heating media regulation valve can be controlled di-
rectly using the SRV switch.
A hand lever is also available on valve actuator.

Electric heaters can be controlled with the dedicated

selector switch.

Electric heater can have up to four different steps (it depends by heater size).
To increase or decrease heating power, modify the number of active steps.

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NOTE
Even if the number of steps can vary according to electric heater
size, the selector always expected four steps. Only the available
steps will be activated.

Cooling media control valve must be operated using the hand lever available
on valve actuator.

Automatic Filter
The Alfa Laval Moatti automatic filter can be
operated moving the Automatic Filter switch to
ON position.

The filter needs to be manually drained at reg-

ular intervals by pushing the Filter Manual Dis-
charge button.

The filter can also be manually drained by using the by-pass valve.
Perform a daily check of the pressure drop visual indicator available on the
filter: if pressure drop exceeds 0.2 bar higher than standard operation, a
manual discharge should be performed.

See Operation chapter in the filter component booklet for further information.

Change over valves

The change over valves can be managed with hand lever available on valves
actuator.

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