-
MODO OPERACION
PUMPBOMBA
ON
OPERATION MODE
AUTO
/ CALEFACCIONHEATER
ENTRADA
RECIRCULATIONRECIRCULACION
WATER OVERBOARDDESCARGA AL MAR
INLET
0
MAN
ALTA TEMPERATURAHIGH TEMPERATURE
OFF
ON
OIL DISCHARGEDESCARGA DE ACEITE
MEMBRANEMEMBRANA
BYPASS
CAMBIAR MEMBRANAREPLACE MEMBRANE
7309612001 CPSB-2_5B MKIII+EBM14x.doc/Rev.0 04/06
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Table of contents Page 1.
Safety..............................................................................................................................6
1.1. Risks that may be undergone during the operation of the
oily water separator...........6
1.2. Labelling of Advice in the Operating Instructions
........................................................6
1.3. Personnel Qualifications and
Training.........................................................................6
1.4. Security
Precautions....................................................................................................7
2. Introduction
.....................................................................................................................9
2.1.
Description...................................................................................................................9
2.2. Purpose
.......................................................................................................................9
3. General instructions
......................................................................................................10
3.1. Unit
Purpose..............................................................................................................10
3.2.
Recommendations.....................................................................................................10
4. General Description
......................................................................................................11
4.1.
Description.................................................................................................................11
4.2.
Elements....................................................................................................................11
5.
Installation.....................................................................................................................15
6. Start
Up.........................................................................................................................16
6.1. Previous
Verification..................................................................................................16
6.2. Filling of separator
.....................................................................................................16
6.3. Filling of the membrane module
................................................................................17
6.4. Start Up
.....................................................................................................................17
6.5. To Stop
......................................................................................................................18
7. Operating
Principles......................................................................................................19
7.1. Suction and Separation of the Oil-Water Mixture
......................................................19
7.2. Automatic Oil Discharge
............................................................................................20
7.3. Passing through the membrane
................................................................................20
7.4. Recirculation to bilge
system.....................................................................................20
7.5. Automatic and Manual Operation Modes
..................................................................21
8. Maintenance Instructions
.............................................................................................22
8.1. Plate Pack Cleaning
..................................................................................................22
8.2. Disposable membrane
replacement..........................................................................24
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8.3. Maintenance Schedule
..............................................................................................26
9. Trouble
Shooting...........................................................................................................27
10. Spare Part List
..............................................................................................................30
Appendix
Pump
Oil Monitor
Drawings and Bills of Materials
Certificates
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Table of Figures Page Figure 1 Frontal of control
panel................................................................................11
Figure 2 Elements
.....................................................................................................12
Figure 3 Opening vent and closing drains
.................................................................16
Figure 4 Opening water filling valve
..........................................................................17
Figure 5 Opening membrane
vent.............................................................................18
Figure 6 Discharge to the sea
..................................................................................19
Figure 7 Separation water-oil in the coalescent plates Facet
Mpack......................19 Figure 8 Oil-Discharge
..............................................................................................20
Figure 9 Flow through the membrane
.......................................................................21
Figure 10 Recirculation to bilge
.................................................................................21
Figure 11 Disassembly of pipes
................................................................................22
Figure 12 Opening the cover of the separator
...........................................................22
Figure 13 Removing the trough
.................................................................................23
Figure 14 Removing the plate pack from the
trough..................................................23 Figure
15 Cleaning the plate
pack.............................................................................23
Figure 16 Locating the plate pack into the
trough......................................................24
Figure 17 Membrane assembly
.................................................................................25
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Index of Tables
Page Table 1 Connections
.............................................................................................................................
13 Table 2 dimensions of Connection pipes
..............................................................................................
15 Table 2 Maintenance
Schedule.............................................................................................................
26 Table 3 Trouble Shooting
......................................................................................................................
27 Table 4 Spare Part
List..........................................................................................................................
30
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1. SAFETY These operating instructions contain basic
requirements to be observed during the installation, operation and
maintenance of the Separator. Therefore, the instructions must be
read by the operator responsible of the unit prior to assembly and
commissioning, and kept available at the operating site of the
separator at all times.
1.1. Risks that may be undergone during the operation of the
oily water separator
The separator has been fully tested and certified regarding
safety, if it were not properly set up or used, risks could arise
and result in damage of:
The personnels life or their body.
the separator and other installations on board.
the proper operation of the separator.
The personnel responsible for the installation of the separator
and/or its electrical and hydraulic systems must
be duly qualified to carry out their duties
strictly follow the instructions her explained
1.2. Labelling of Advice in the Operating Instructions
The following warnings are incorporated into these
instructions:
In these operating instructions safety advice whose
non-observance could lead to danger for life or limb is labeled
with the following text
Attention!!! Safety instructions whose non-observance could
jeopardize the machine and its functions are labeled by the word :
Caution!!!
Important! Indicates practical tips and other important
information.
Always comply with instructions mounted directly on the unit,
e.g.
o rotational direction arrow o fluid connection indicators
and ensure that the information remains legible.
1.3. Personnel Qualifications and Training
Personnel charged with operation, maintenance, inspection and
assembly must be in possession of the appropriate qualifications
for the tasks. The company operating the machine must define exact
areas of responsibility, accountabilities and personnel supervision
schemes. Personnel lacking the required skills and knowledge must
receive training and instruction. If necessary, the operating
company may commission the manufacturer/supplier to conduct these
training courses. Furthermore, the operating company must ensure
that the personnel fully understand the contents of the operating
instructions.
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1.4. Security Precautions
The following precautions must be taken for the security of the
personnel who operate the Separator:
1. Fire prevention measures will have to be taken if the
separated product requires it.
2. Precaution must be taken to keep the area around the
Separator clean to prevent accidents.
3. All product spills must be dried immediately with rags, and
these removed to a safe place.
4. Gloves must be used when parts are handled that have been in
contact with the fluids handled by the Separator.
5. If some of the handled fluids are flammable and volatile,
smoking must not be allowed near the Separator and accessory
equipment.
6. In these cases suitable fire-fighting equipment must be also
installed near the Separator before carrying out any type of
maintenance.
7. Avoid unnecessary contact of the skin and clothes with the
handled fluids.
8. After maintenance or working with the Separator, the hands
and parts that have been in contact with the fluids must be
thoroughly washed.
9. Immediate medical attention must be lent to cuts in the skin,
upset stomach, etc., due to possible contacts with the product or
to the inhalation of gases.
Attention!!! The equipment is normally fed voltages that can
cause damage if contact with these lines takes place. Precautions
must be taken when opening the Control Panel, since even if the
general switch is open there will be tension in the input terminals
of the control panel. As a precaution the line that feeds the
equipment should be disconnected.
10. If the Separator is in an area classified as security, the
necessary precautions
must be taken when working with the electrical equipment. In
these cases the control panel should not be opened with
tension.
Important !!! SECURITY AND ENVIRONMENTAL PROTECTION ARE THE
RESPONSIBILITY OF THE USER. FACET DOES NOT ASSUME ANY
RESPONSIBILITY FOR THE INADEQUATE USE OF THIS SEPARATOR OR ITS USE
OUTSIDE THE PARAMETERS FOR WHICH IT WAS DESIGNED
Important !!! The pump is positive displacement type. Operation
of the pump against an excessive pressure caused by closed valves,
by high pressure losses in the piping or by product sedimentation
will lead to the destruction of the pump, drive, pipe work and/or
downstream equipment., it is imperative to avoid the operation of
the pump with any obstruction at the disharge line.
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11. The separator must be securely installed on a stable,
horizontal surface. following it to tip over would endanger life
and limb.
Attention!! The separator works with a pump. Moving or working
parts must be protected against accidental contact.
Warning The separator can be heated (either electrically or,
e.g., by steam). Temperatures up to around 72 C. can then obtain in
the upper part, which could cause burns if touched.
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2. INTRODUCTION 2.1. Description
This manual describes instructions for installation, operation
and maintenance for Facet CPS BMKIII + EBM14X Bilge Water
Separators
2.2. Purpose
Provide the user with the necessary instructions for continuous
working without problems and the procedures and test for failure
detection and correction.
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3. GENERAL INSTRUCTIONS 3.1. Unit Purpose
Treat water-oil mixtures collected in the bilge of ships
according to international bilge water treatment rules and
regulations.
Emulsified and dissolved hydrocarbons can be separated with this
plant according to IMO Regulations MEPC 107(49)
Important! The plant (or pump) cannot be used to pump oil or
sludge. Ecologically dangerous!
3.2. Recommendations
3.2.1. The Inlet line should be provided with a coarse filter
and non return valve at the suction point
3.2.2. The oil discharge line must not have any valves connected
to it.
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4. GENERAL DESCRIPTION 4.1. Description
The bilge water separator FACET, Series CPS-B MKIII + EBM, is
delivered ready for operation and, basically, it's a horizontal and
very compact design.
4.2. Elements
4.2.1. One pump driven by an electrical motor, suctions oily
water from the bilge. It is located between the coalescing plate
pack separator unit and the membrane unit.
4.2.2. Coalescing plate pack separator unit containing Mpak
-coalescing plate packs for oil separation, removes oil from water.
A level control system for separated free oil that controls the
automatic discharge of the separated oil.
4.2.3. Membrane unit containing EBM disposable membrane breaks
oil-water emulsions
Figure 1 Frontal of control panel
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WATER OVERBOARDDESCARGA AL MAR
BILGE WATER INLET
ON
BOMBAPUMP
BYPASS
MEMBRANAMEMBRANE
REPLACE MEMBRANECAMBIAR MEMBRANA
RECIRCULACIONRECIRCULATION
ENTRADA AGUADE SENTINAS
OIL OUTLET
MODO OPERACION
AUTO
MAN
0
OPERATION MODE
SALIDA DE ACEITE
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4.2.4. A control panel, complete with:
A main switch with positions '0' - '1' Operation Mode selector
switch Auto - 0 - Manual. Manual Oil Discharge Pushbutton. Manual
Recirculation Pushbutton. Reset replace membrane sound alarm
pushbutton Level Relay for the oil level control.
The system also includes connections for:
4.2.4.1. Connections for a Level Switch to start the unit when
the level in the bilge is adequate
4.2.4.2. External Contacts for High Oil Content in effluent
alarm.
Figure 2 Elements 4.2.4.3. External contact for general
failure
PUMPBOMBA
NC SOLENOID VALVE
VALVULA SOLENOIDE NC
NO SOLENOID VALVE
VALVULA SOLENOIDE NA
NC SOLENOID VALVEVALVULA SOLENOIDE NC
HEATER (OPTIONAL)CALEFACCION (OPCIONAL)
CPS-B MKIII SEPARATORSEPARADOR CPS-B MKIII
OIL DISCHARGEDESCARGA DE ACEITE
OVERBOARDWATER OUTLET
DESCARGAAL MAR
BACK TO BILGE
RETORNOA LA SENTINA
CHECK VALVEVALVULA DE RETENCION
CHECK VALVEVALVULA DE RETENCION
PRESSURESWITCH
PRESOSTATO
MEMBRANEMEMBRANA
INLETENTRADA
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4.2.5. Test-cock on the top of the unit and Effluent sample cock
at the water outlet.
4.2.6. Vacuum and Pressure Gauge
4.2.7. Check Valves on the oil discharge line and the
recirculation line.
4.2.8. Two solenoid valves at the discharge of the pump to drive
the flow through the membrane (normally closed valve) or to bypass
it (normally open valve) according to the oil concentration of the
sample.
4.2.9. Solenoid Valve at the Overboard discharge line.
4.2.10. Solenoid Valve at Oil free Water Inlet line.
4.2.11. Oil Monitor. The equipment includes an effluent oil
content monitor that visualizes the ppm in a display and determines
depending on the effluent oil content, the use of the membrane or
the bypass depending on the oil content and the discharge to the
sea or the return to the bilge.
4.2.12. Pressure switch, to control disposable membrane life. It
is provided with an adjustable electrical switch for alarm
indication
4.2.13. Electrical Heater or Steam Coil for oil removed. All the
units can optionally take systems of heating in the dome of
separated oil
- Electrical heating
- Coil heating
4.2.14. All the units are provided with supports for anchor
bolting. And they have the following connections
Inlet Overboard Discharge Recirculation to Bilge Oil Discharge
Clean Water Inlet Vent Drains Sample Connections for Steam coil
(optional)
The size and type of these connections depend on the model of
the unit.
TABLE 1 CONNECTIONS Capacity (m3/h) 0,5
CPS-2.5B MKIII + EBM 14X1
1.0
CPS-5B MKIII + EBM 14X1
2.5
CPS-10B MKIII+ EBM 14X2
5
CPS-25B MKIII + EBM 314X2
10
CPS-50B MKIII+ EBM 314X3
Inlet DN32 1 DN32 1 DN32 1 DN65 2 DN65 2
Outlet 1 BSP 1 1 BSP 1 1 BSP 1 1 BSP 1 2 BSP 2
Oil Discharge DN25 1 DN25 1 DN25 1 DN50 2 DN50 2
Recirculation DN25 1 DN25 1 DN25 1 DN32 1 DN50 2
Clean Water Inlet BSP BSP BSP DN25 1 DN25 1
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4.2.15. The nameplate of each one contains relevant information
about the unit. Be sure to send this information to the nearest
representative of Facet International when ordering spare parts or
for additional information regarding technical support related to
the Facet Unit.
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5. INSTALLATION 5.1. Place the unit in its allocated place and
make sure that clearances are available as
indicated on the dimensional drawing.
5.2. All the pipes that arrive and leave the Separator must be
aligned as best as possible with the connections to avoid excessive
mechanical efforts on the connections or flanges. Make sure of the
use of correct gaskets between the flange connections. Tighten all
bolts securely and uniformly.
5.3. Secure anchor bolts to foundation.
5.4. The dimensions of the pipes cannot be smaller than those
indicated in the following table.
Important! Make sure of the correct identification of the inlet
and outlet connections of the separator before connecting it to the
system. It will not work correctly if the connections are
mixed.
TABLE 2 DIMENSIONS OF CONNECTION PIPES Capacity (m3/h) 0,5 1.0
2.5 5 10
water inlet DN32 1 DN32 1 DN32 1 DN65 2 DN65 2
water outlet 1 BSP 1 BSP 1 BSP 1 BSP 2 BSP
oil outlet DN25 1 DN25 1 DN25 1 DN50 2 DN50 2
back to bilge DN25 1 DN25 1 DN25 1 DN32 1 DN50 2
Oil-free water supply BSP BSP BSP DN25 1 DN25 1
5.5. Connect bilge water inlet to suction line from the bilge.
The suction height incl. losses due to friction in the pipes should
not exceed 7 m W.G.. A non return valve (foot valve") must be
fitted at the suction point in the bilge or well. A coarse filter
or strainer basket with approx. 3 mm perforations should also be
fitted.
5.6. Connect water outlet to overboard check valve (no Facet
supply). Setting of this overboard check valve is max. 0,2 bar.
5.7. Connect the back to bilge connection down to bilge.
5.8. Connect oil outlet to oil collection tank or slop tank
(funnelled connection). No valve in this line is allowed.
5.9. Make funnelled connection from the sample cocks down to
bilge and ppm alarm discharge line.
5.10. Connect the oil free water to the water filling points.
Connect the oil free water to the ppm alarm too.
5.11. Connect the power supply in accordance with the electrical
schema.
5.12. If a steam coil is mounted, connect low pressure steam
(max. 3.2 bar) to steam inlet and fit a steam condensate trap
(float operated) to steam outlet connection. Maximum allowed
temperature in the separator is 72C and in the oil collecting dome
80C.
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6. START UP After the installation according to Section 5, the
unit is ready for initial filling with oil-free water.
First, carry out the following pre-operational checks:
1. Check all bolted connections for loose bolts and tighten
them, if necessary.
2. For the pump, oil monitor and the other equipment see
relevant instructions in appendix.
6.1. Previous Verification.
After making all the connections and having installed the
accessories, a control is due before putting the Separator to test
with fluid:
1. Make sure that the anchorage bolts are properly
tightened.
2. Inspect all the flanged connections to make sure that the
gaskets are in place.
3. Check that the bolts of the flanges are tightened.
4. Check bolts and screws of all the accessories to make sure
that they are tightened.
Important! Prior to starting up the separator, ensure that all
pipelines are free from foreign bodies. Installation residues (such
as weld spatter, screws, steel chips etc.) will lead to damage of
the pump.
5. Look over pipes to verify that they have not been flattened
or bent. If a pipe is
damaged, replace it with a new one.
6. Check racords and sleeves to verify their tightness. Do not
over-tighten the threaded connections as this can give rise to
losses or dripping of fluid.
7. Verify that the(s) cover(s) of the Separator is/are properly
closed.
8. If the Separator has heat insulation be sure that such
isolation does not interfere with visual or operational functions
of the elements of control and instrumentation.
9. Remove all leftover materials, specially fuels, from the
working area of the Separator.
10. For the pump, monitor and other equipment, follow
instructions in the appendix.
6.2. Filling of separator
1. Close the valves located at the inlet of the separator
2. Open the cock on top of the unit.
3. Close the drain valves if supplied
Figure 3 Opening vent and closing drains
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4. Open the oil-free water filling valve.
5. Close the water filling valve and the cock when a steady
stream of water comes out of the cock.
6. Start the unit with the main switch in position "1" and
Selector Switch in position "Man". The oil-free water solenoid
valve will be opened to evacuate the rest of air out of the unit
via the oil outlet. After that, the pump will start automatically
while the water supply valve will be closed and the three way
valves will be in position of membrane bypass and overboard
discharge. If the vacuum/pressure gauge indicates a pressure less
than 0, the pump rotates in the correct direction. If not (if the
vacuum/pressure gauge indicates pressure) correct pump rotation
after stopping the unit.
7. Stop the unit by means of the Operation Mode Selector (Auto -
0 - Man) (Position "0").
6.3. Filling of the membrane module
Once the pump rotation is verified and if necessary corrected,
the membrane module must be filled.
1. Remove the plug located on the vent of the membrane
module
2. Open the oil-free water filling valve.
3. Start the unit with the main switch in position "1" and
Selector Switch in position "Man" and press Manual Recirculation to
force the pass of the water through the membrane. When a steady
stream of water comes out of the vent of the membrane, stop the
unit, close the water filling valve and place the plug on the vent
connection of the membrane.
4. The unit is now ready for operation.
Figure 4 Opening water filling valve 6.4. Start Up
Having done the pre-operational checks and the preparations for
start-up in accordance with the previous Section, the unit is now
ready for start-up and operation.
1. Close all drainage valves (if it has them).
2. Open the valves located in the inlet of the separator
3. Verify that there is no valve closed in the discharge lines
of the separator
Important !!! The pump is positive displacement type, it is
imperative to avoid any obstruction at the discharge line.
4. Open the ventilation valve or remove the vent plug.
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5. If the separator is equipped with electrical heater (only
very viscous fuels) turn the switch of the heater to position
"On"
Figure 5 Opening membrane vent 6. It is recommended to carry
out
a test-filling with clean water when starting the separator.
Turn the main switch in the Control Panel to position "1", the
operation mode selector to Automatic", and press the Manual
Discharge of Oil switch during the space of half a minute.
When releasing the switch, the system will begin normal
operation: if there is sufficient level in the bilge, the pump will
start automatically and the solenoid valve will open to discharge
overboard. If the level in the bilge is not adequate the system
will remain at rest and will start automatically once the required
level is reached.
The Facet CPS Separator is now completely operative.
MEMBRANE VENTVENTEO MEMBRANA
6.5. To Stop
1. Turn heater selector switch to position "Off" (if electrical
heater supplied).
2. Open the cock on top of the unit (only allowed when the pump
is running) and close it as soon as the pump stops.
3. Stop the unit as soon as the pump starts again (Operation
Mode Selector (Auto - 0 - Man) in position "0").
4. Close the valves in the inlet and outlet lines.
5. Keep the Drainage and Manual Vent valves closed.
6. The unit is now ready for future operation.
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7. OPERATING PRINCIPLES For purposes of the following
explanation please see flow diagram on the drawing list.
7.1. Suction and Separation of the Oil-Water Mixture
The pump draws the oil/water mixture from the bilge tank and
transfers it into the coalescing plate separator.
The pump is installed between the water outlet side of Plate
packs separator and membrane inlet, in order to minimize
emulsification of the oil/water mixture.
The coalescing plate separator contains a rectangular trough
which contains the coalescing plates.
The flange at the end of the tank separates the inlet from the
outlet compartment. The oil/water mixture inlet pipe splits into
two pipes which protrude into the side chambers alongside the
internal trough. The oil/water mixture will separate into two
streams upward almost vertical where most of the oil is sent to the
recovered oil area.
Figure 6 Discharge to the sea The water, now only containing a
low concentration of oil formed by small droplets, proceeds towards
the coalescing plates.
Figure 7 Separation water-oil in the coalescent plates Facet
Mpack The even pattern of the plates produces a regular flow with
very low turbulence (Reynolds number: 60-100 ). Within the plate
pack, oil droplets are deposited onto the oleophilic plate material
by gravity. Due to the velocity variations in the flow stream,
created by the modified sinusoidal flow path, small oil particles
are coalesced hydrodynamically by particles colliding into bigger
particles of oil, which then separate by gravity and are captured
by the oleophilic plates. Then, the oil collected in the plates is
allowed to "sweep" through the plates pack towards the
OPERATION MODE
MAN
MODO OPERACION
ON
PUMPBOMBA
AUTO
0
RECIRCULATIONRECIRCULACION
CAMBIAR MEMBRANAREPLACE MEMBRANE
MEMBRANEMEMBRANA
BYPASS
BILGE WATER INLET
DE SENTINAS
DESCARGA AL MARWATER OVERBOARD
ENTRADA AGUA
OIL OUTLETSALIDA DE ACEITE
- 19 - Facet Oil Water Separator CPSB MKIII + EBM14x
www.facetinternational.net www.facetusa.com
-
surface, where it is picked up and transferred to oil collection
dome. After coalescing separation and when a specific level of
emulsions are present in the plate pack separator outlet, the oil
monitor sends a signal and automatically the membrane line will be
opened and the bypass line closed, until bilge is empty.
In normal operation, the water leaving the separator contains
less than 15 ppm of oil free, and it is discharged outwards or
passed through the membrane module.
7.2. Automatic Oil Discharge
Oil-free water from the ship supply must be provided to
discharge the oil out of the unit. The minimum pressure required is
the necessary to pressure the oil into the reclaimed oil holding
tank (not supplied by FACET). A probe is installed in the oil
collecting area to control the oil discharge when sufficient oil is
accumulated.
This probe, through the control system and the Oil Monitor,
controls the "oil-free water supply" and the "clean water
discharge" valves. It is also sensitive to the presence of air
excess in the system, which may be similarly discharged.
This enables the recovered oil to be effectively evacuated out
of the unit. So, high concentrations of oil of up to 100% of sludge
are thus dealt with by a simple control system.
Figure 8 Oil-Discharge
OPERATION MODE
MAN
MODO OPERACION
ON
PUMPBOMBA
AUTO
0
RECIRCULATIONRECIRCULACION
CAMBIAR MEMBRANAREPLACE MEMBRANE
MEMBRANEMEMBRANA
BYPASS
BILGE WATER INLET
DE SENTINAS
DESCARGA AL MARWATER OVERBOARD
ENTRADA AGUA
OIL OUTLETSALIDA DE ACEITE
7.3. Passing through the membrane
When the oil concentration in the effluent exceeds the ppm limit
value, the intermediate solenoid valves located at the discharge of
the pump, automatically commute to membrane mode passing the fluid
through the membrane mode and the indicating lamp Bypass switches
off. The flow through the membrane goes on until the bilge is
empty.
7.4. Recirculation to bilge system
In operation mode described on paragraph 7.3, when the oil
concentration in the effluent exceeds the allowed limit value, the
system commutes to "Recirculation to Bilge" closing the outlet
solenoid valve of Overboard Water Discharge and cause the bilge
water to return to the bilge through the check valve.
After the trouble is located (see section 9) and corrective
action has been taken, the oil monitor will switch the system
automatically back to normal operation. If no action is taken, the
mixture will continue to re-circulate.
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Figure 9 Flow through the membrane
Using the "Manual Recirculation" Push button on the control
panel the unit will automatically re-circulate the bilge water to
the bilge independently of the Oil Monitor measure. This Push
button can be used for instance, for initial and periodic testing
purposes.
7.5. Automatic and Manual Operation Modes
The system is ready for two operation modes:
- Automatic mode: the unit starts automatically when the level
in the bilge is adequate.
- Manual mode: the unit starts independently of the level in the
bilge
.
Figure 10 Recirculation to bilge
OPERATION MODE
MAN
MODO OPERACION
ON
PUMPBOMBA
AUTO
0
RECIRCULATIONRECIRCULACION
CAMBIAR MEMBRANAREPLACE MEMBRANE
MEMBRANEMEMBRANA
BYPASS
BILGE WATER INLET
DE SENTINAS
DESCARGA AL MARWATER OVERBOARD
ENTRADA AGUA
OIL OUTLETSALIDA DE ACEITE
OPERATION MODE
MAN
MODO OPERACION
ON
PUMPBOMBA
AUTO
0
RECIRCULATIONRECIRCULACION
CAMBIAR MEMBRANAREPLACE MEMBRANE
MEMBRANEMEMBRANA
BYPASS
BILGE WATER INLET
DE SENTINAS
DESCARGA AL MARWATER OVERBOARD
ENTRADA AGUA
OIL OUTLETSALIDA DE ACEITE
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8. MAINTENANCE INSTRUCTIONS After 250 hours of operation, the
unit should be drained to remove the accumulation of solids. While
the separator is out of operation, open simultaneously one of the
drainage valves and the water filling valve to flush the solids out
of the tank into the slop tank.
After 2,000 hours of operation, the separator tank and the
plates should be cleaned. The sludge amount found in the plates
pack should be used as a basis to determine the next interval
before cleaning. If 20% or less of the passages between plates are
blocked with sludge, the interval should be extended, but if 60% or
more are blocked, the interval should be shortened. The plates pack
must be removed from the trough for its cleaning.
8.1. Plate Pack Cleaning
To take out the plates pack follow the next steps:
1. Remove all separated oil out of the oil collecting area as
follows:
2. Open test cock on the top of the unit (only allowed when the
pump is running) and close it as soon as the pump stops.
3. Stop the unit as soon as the pump runs again. Operation Mode
Selector (Auto - 0 - Man) on "0" position.
4. Open the water filling line for 2 min. with the separator out
of operation.
Figure 11 Disassembly of pipes 5. Drain the separator completely
opening the drainage valves and the test cock on
the top of the unit to permit the entry of air.
Figure 12 Opening the cover of the separator
6. Remove the pipe from CPS Outlet to pump suction
7. Remove the clean water pipe
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8. Loosen and remove the cover bolts or release the swing bolt
assembly
9. Remove vessel end cover and inspect the gasket
10. Pull out the trough by the handles in the front side
. Figure 13 Removing the trough
11. To take out the plates pack see the corresponding drawing.
Remove all the holding clamps of the plates packs, the top support
with gaskets and the PVC corrugated plate(s) between the plates
pack and the lateral wall of the trough.
Figure 14 Removing the plate pack from the trough
12. After this, take out the plates packs by carefully pulling
them out of the trough by hand. Take care not to damage the plates
or the plate sealing.
Notes: it is not necessary to dismantle the plates from the
packs.
13. Clean the plates pack by flushing with water from the side.
An 1-1/2" fire hose at 0,7 - 1 bar or a standard garden hose at
normal pressure 2 - 2,5 bar are effective cleaning tools.
In a similar manner, steam can also be used to flush plates pack
as long as the localised tip temperature in the area close to the
plates does not exceed 70C. Continue above procedure until all the
plates pack assemblies have been removed and flushed clean.
14. Flush the interior of the tank downward and allow all
sediments to leave by the drain valve.
15. Re-Assembly of the M-coalescing plate packs: to replace the
plates, follow the procedure described below (see corresponding
drawing).
Figure 15 Cleaning the plate pack
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16. For easier handling glue the gaskets on the bottom and
against the round plate of the trough as shown in the drawing.
17. Replace the bottom supports and plates packs and push them
against the round plate and the left side wall seen from the open
end of the trough.
18. Replace the PVC corrugated plate over the full length of the
trough between the plates pack and the right side wall of the
trough.
19. Be sure that they will rest on the bottom of the trough.
20. Replace the gaskets and top support with clamp according to
the drawing.
21. Replace the remaining clamps according to the drawing.
Figure 16 Locating the plate pack into the trough
22. Go through the pre-operational checks as outlined in Section
6 page 16 and put the unit in operation as outlined in that
Section.
8.2. Disposable membrane replacement
1 The disposable membrane replacement is indicated by the
control panel acoustic and indicating lamp. When this alarm happens
the unit stops.
Warning If filter is equipped with electrical heater, be sure to
turn off the heater before draining the unit.
2 Close the blocking valves in the inlet and outlet lines.
3 Open vent valves (or remove plug).
4 Open drain valves (or remove plugs).
5 Allow the unit enough time to vent and drain completely before
opening.
6 Loosen and remove cover bolts or release the swing bolt
assembly of the membrane vessel.
7 Remove cover using lifting handles.
8 Discard old cover gasket to a FIRE-SAFE place.
9 Remove nuts, lock washers, flat washer, gasket washers and end
caps from the centre rods.
10 Slide old disposable membrane from centre rods being careful
not to drop the centre seal from the assemblies. Discard all old
elements to a FIRE-SAFE place.
11 It is not necessary to remove the centre rods from element
adapters. If centre rods were removed from adapters, thread the
one-half inch jam nuts onto the centre rods until centre rods are
extending through the jam nuts. Screw centre rods into element
adapters until jam nuts are securely lock in place against element
adapters.
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Caution!!! Due to the toxic effect of some of the additives used
in liquid products, care should be exercised in handling all parts
that have been in contact with the liquid product.
Figure 17 Membrane assembly1
12 Clean all interior surfaces of the membrane vessel especially
the surfaces of the element mounting plate, element adapters,
centre rods and all small metal element mounting hardware.
CENTER RODVARILLA CENTRA
CARTRIDGE END CAPTAPA DE CARTUCHO
TORQUEPAR DE APRIETE 1.4kg m
STARLOCK WASHERARANDELA EN ESTRELLA
FLAT WASHERARANDELA PLANA
GASKETJUNTA
NUTTUERCA
TORQUEPAR DE APRIETE 0.7 kg m
NUTTUERCA
13 Slide new membrane onto centre rods.
Caution Membranes should be handled by end caps only to prevent
damage. Use only Facet replace elements. Do not mix membranes of
different manufacturer since they may have different pressure drop
and filtration characteristics.
1 Center seal is installed when more than one membrane element
is supplied
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14 Reassemble the end caps, gasket washers, flat washers, lock
washers and hex nuts to centre rods. Be sure to install centre
seals between the two deep or more element assemblies.
15 Tighten hex nuts with a torque wrench according to drawing
after it has been ascertained that the elements are seated properly
on adapters and seals.
16 Discard old cover seal to a FIRE-SAFE place. Install a new
cover seal and close cover.
Install cover bolts and tighten bolts evenly and securely to
ensure good sealing.
8.3. Maintenance Schedule
TABLE 3 MAINTENANCE SCHEDULE Item Interval Action
From time to time Clean fan cover Electric Motor
800 operating hours Clean bearings and replace grease
Bearing Box 800 operating hours Fill with grease
Pump 4000 operating hours Replace grease
Oil Monitor Weekly Clean measurement cell
Separator 250 operating hours
2000 operating hours
Drain tank to remove sludge
Clean shell and plates
When Replace membrane alarm activates
Disposable membrane
Recirculation continuously
Replace disposable membrane
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9. TROUBLE SHOOTING
TABLE 4 TROUBLE SHOOTING Trouble Possible Cause Diagnostic
Technique Corrective Action
Failure in the electricity supply
Check the circuit of electrical supply of the system
Open main switch in position 0
Place main switch in position 1
The protection switch of the control circuit inside the control
panel is open
Open the control panel and you rearm the switch of
protection
The protection motor breaker of protection inside the control
panel is open
Open the control panel and you rearm the motor breaker of
protection
The control system is not electrically fed
The system detects the signal of replace membrane
Replace membrane following the maintenance instructions
1 Pump doesnt work
and the pilot of the pump does not turn on
The equipment is not operative
The selector of "Operation Mode" is in position "0"
Put the selector of "Operation Mode" in Automatic or "Manual
position.
There is not enough level in the bilge for operation
Verify the level in the bilge
Check the connection and verify that the interconnection cable
is not cut or loose
2 The selector of " Operation Mode" is in "Auto" position and
the pump does not work
The control system does not receive the bilge level starting
signal The bilge level switch is
not connected
Verify the good operation of the level switch
The terminals of connection in the interior of the control panel
are not properly tight
Review the terminals and tighten them properly.
Problem in the electrical connection of the Control Panel to the
motor of the pump
The cable of connection to the motor is cut
Review the cable and change if necessary
The contactor of the motor does not work
Open the control panel and check that the contactor is not
energized
Change it for a new one.
3 The pump does not work but the pilot of the pump is on
The motor does not work
See appendix
Membrane is saturated Replace membrane 4 The processed water has
fuel.
Membrane is not working properly The membrane is not
mounted correctly Check the assembly of the membrane, verifying
that unit is mounted properly according the assembly drawing
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TABLE 4 TROUBLE SHOOTING Trouble Possible Cause Diagnostic
Technique Corrective Action
Check the electrical connection and the cable between the
electrodes and the Control Panel
Short circuit in the probes of the dome
Verify that water has not entered the connector of the
electrodes
The control system does not detect oil present in dome.
The level relay does not work correctly
Change it for a new one.
The plates are dirty
Clean the plates according to description in section 8.1 (page
22)
The plates are not working properly
The package of plates is not mounted correctly
Check the assembly of the package of plates verifying that all
the gaskets are placed properly according to the assembly drawing
in the appendix
There is no clean water supply.
Open the water supply.
The pressure of clean water supply is not enough
Check the pressure of clean water supply
Verify electrical connection from the control panel to the
solenoid valve
Some mechanical obstruction prevents the opening of the valve,
Disassemble clean.
5 The separator is permanently in oil discharge (pilot light on)
but does not discharge anything
Clean water is not entering the separator
The clean water solenoid valve inlet is not open
The coil of the valve is defective, change it for a new one
6 The separator carries out very frequent oil discharges
Air enters the separator
Some connection in the separator or the pipe is not
watertight
Review the connections and the pipes, tightening the connections
that are loose and, if necessary, change the gaskets
The cable of connection between the probes and the Control Panel
is cut or there is some loose cable
Verify the electrical connection
7 The separator is permanently in discharge of oil (pilot light
on) but discharges water
The electrodes are continuously detecting the presence of oil in
dome of oil collection
The electrodes are isolated by a film of fuel.
Remove the support of the electrodes (unscrew it), check and
clean the electrodes with solvent
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TABLE 4 TROUBLE SHOOTING Trouble Possible Cause Diagnostic
Technique Corrective Action
The level relay does not work correctly
Change it for a new one.
The timer of maximum time of oil discharge does not work
correctly
Verify the electrical connection and, if necessary, change it
for a new one
The coil of the solenoid valve is not energized
Verify the electrical connection from the control panel to the
solenoid valve
Some mechanical obstruction prevents the valve opening.
Disassemble and clean it.
8 The system is continuously re-circulating to bilge but the
Recirculation pilot light does not turn on
The discharge to sea solenoid valve is not open
The coil of the solenoid valve is energized but the valve is not
open
The coil of the solenoid valve is defective. Change it for a new
one.
It is not passing sample through the monitor of oil content
Verify the position of the valves in the line of sample
inlet
The monitor of oil content is detecting high content of ppm in
the sample The crystal of the sensor
is dirty Clean the crystal of the sensor
The control system does not receive correctly the signal coming
from the monitor of oil content
Review the electrical connection and verify that there is no cut
cable
9 The system is continuously re-circulating to bilge, the
Recirculation pilot light is on and the system is equipped with
monitor of oil content
The monitor of oil content is not detecting high content of in
the sample
The 15ppm alarm signal of the oil content monitor is not
properly adjusted
Readjust it
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10. SPARE PART LIST Spares Recommended
TABLE 5 SPARE PART LIST
Qty. Description Reference Code
1 Stator for Pump SI - 0,5 Dwg 106-001A2
(Pump) ITEM 601 55007314
1 Mechanical Seal for Pump SI - 0,5 Dwg 106-001A2
(Pump) ITEM 330 55007123
1 Set of Cover Gaskets CPS-2,5B MKIII + EBM14x1
Assembly Dwgs
ITEM 36 + 21
73007361
+
57012600
1 Level Relay Dwg 3137196 - ITEM RN 55032031
1 Cartridges CPS-2.5B MKIII + EBM14x1 97012143
When ordering spares, the serial number of the equipment and
description must be indicated.
Electrical Heater (Only if required)
VOLTAGE
EQ. DESCRIPTION 400 V 440 V 480 V SPECIAL
CPS-2.5B MKIII + EBM 14x1
(0.5 kW) 55050013 --- --- ---
When ordering spares, the serial number of the equipment and
description must be indicated.
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PPM Alarm (By Customer requirements)
DESCRIPTION MANUFACTURER CODE FACET
OMD 2005 DECKMA HAMBURG 79510005
SMART BILGE RIVERTRACE 79520010
BILGMON 488 BRNNSTRMS ELEKTRONIK AB 79560000
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Operating Instructions seepex Machine Safety
Dokument document Ausgabe issue Blatt sheet
OM.SAF.01e B / 21.04.99 1 (2)
2. Safety These operating instructions contain basic
require-ments to be observed during the installation, opera-tion
and maintenance of the machine. Therefore, the instructions must be
read by the mechanical fitter and by the technical
personnel/operator responsible for the machine prior to assembly
and commissioning, and kept available at the operating site of the
machine/plant at all times. Compliance is required not only with
the general safety instructions given in this section but also with
the detailed instructions, e.g. for private usage, given under the
other main headings in these operating instructions. 2.1 Labeling
of Advice in the Operating Instructions In these operating
instructions safety advice whose non-observance could lead to
danger for life or limb is labeled with the following general
hazard symbol:
safety symbol acc. to ISO 3864 - B.3.1 Warnings regarding
electric power are labeled with:
safety symbol acc. to ISO 3864 - B.3.6 Safety instructions whose
non-observance could jeopardize the machine and its functions are
labeled by the word
CAUTION Always comply with instructions mounted directly on the
machine, e.g. - rotational direction arrow - fluid connection
indicators and ensure that the information remains legible.
2.2 Personnel Qualifications and Training Personnel charged with
operation, maintenance, inspection and assembly must be in
possession of the appropriate qualifications for the tasks. The
company operating the machine must define exact areas of
responsibility, accountabilities and personnel supervision schemes.
Personnel lacking the required skills and knowledge must receive
training and instruction. If necessary, the opera-ting company may
commission the manufacturer/ supplier to conduct these training
courses. Further-more, the operating company must ensure that the
personnel fully understand the contents of the operating
instructions. 2.3 Dangers Resulting from Failure to Observe Safety
Instructions Failure to comply with the safety instructions may
lead to hazards to life and limb as well as dangers for the
environment and the machine. Non-obser-vance of safety instructions
can invalidate the right of claim to damages. The following are
just some examples of possible dangers resulting from failure to
comply with the safety instructions: - Failure of important
machine/plant functions - Failure of prescribed methods of service
and
maintenance - Danger to life and limb due to electrical,
mechanical
and chemical influences - Danger to the environment due to the
leakage
of hazardous substances 2.4 Safety-conscious Working Always
comply with the safety instructions listed in this document, the
existing national accident prevention regulations and any
company-internal work, operating and safety rules.
-
Operating Instructions seepex Machine Safety
Dokument document Ausgabe issue Blatt sheet
OM.SAF.01e B / 21.04.99 2 (2)
2.5 Safety Instructions for the Operating Company/Machine
Operator - Any potentially hazardous hot or cold machine parts
must be provided with protection against accidental contact at
the customers premises.
- Protective guards for moving parts (e.g. coupling)
must never be removed while the machine is in operation.
- Leakages (e.g. in the shaft seal) of hazardous
conveying liquids (e.g. explosive, toxic, hot) must be drained
in such a way that no danger arises for persons or for the
environment. Always observe the relevant statutory
requirements.
- The risk of exposure to electrical power must be
eliminated (for details, see the VDE regulations, for example,
or those of the local power supply company).
2.6 Safety Instructions for Maintenance, Inspection and Assembly
Work The operator must ensure that all maintenance, inspection and
assembly tasks are carried out by authorized and qualified
personnel who have studied the operating instructions closely and
become sufficiently familiar with the machine. As a basic rule, the
machine must be brought to a standstill before work is carried out.
Always comply with the de-commissioning procedure described in this
document. Any machiness or assemblies conveying media that are
detrimental to health must be decontaminated. Immediately following
completion of work, all safety and protective devices must be
replaced in position and, where applicable, re-activated. Before
re-starting the machine, observe the points listed under the
heading "Initial Startup". 2.7 Unauthorized Modification and
Manufacture of Replacement Parts Conversions or modifications of
the machine are permissible only in consultation with the
manu-facturers. Original manufacturer replacement parts and
manufacturer-approved accessories enhance the operational safety of
the machine. The usage of unauthorized parts may lead to the
nullification of the manufacturer's liability for any resultant
damages.
2.8 Impermissible Modes of Operation The operational safety of
the machines supplied is warranted only for employment in
accordance with the intended use as defined in Section 1 - General
- of these operating instructions. Never allow the threshold values
specified in the data sheet to be exceeded.
-
Operating Instructions Progressive Cavity Pump Service and
Maintenance
Dokument document Ausgabe issue Blatt sheet
OM.MAI.85e A / 04.04.03 1 (4)
These operating instructions are valid for range BW size 1 to 3
7. Service and Maintenance Contents 7.1 General Instructions 7.2
Service and Inspection 7.3 Dismantling 7.4 Re-assembly The
sectional drawing and parts list relevant for items 7.3 and 7.4 can
be found in item 9. 7.1 General Instructions A requirement for the
reliable operation of any pump is service and maintenance carried
out in compliance with instructions. Maintenance personnel must
therefore have access to these operating instructions and adhere to
them meticulously. seepex will accept no liability for damages
arising from non-observance of these operating instructions. 7.2
Maintenance and Inspection 7.2.1 Lubrication 7.2.1.1 Rotor and
Stator The rotor and stator are lubricated by the conveying
product. 7.2.1.2 Shaft Sealing Consult document OM.SEA.__ for
information on shaft sealing lubrication. 7.2.1.3 Pin Joint The pin
joints are filled with special grease and are lubricated for the
expected duration of service. The seepex joint grease specified in
the index of these operating instructions should exclusively be
used for any required maintenance work.
CAUTION Usage of other grease types will lead to premature joint
failure and excludes any right to claims under guarantee.
7.2.1.4 Bearing of the Pump/Drive Engine The bearing of the
rotating pump parts is effected by the drive engine. Lubrication
instructions are therefore included in the appended drive engine
operating instructions, item 10. 7.2.2 Lubricant Filling Levels
Details are specified in the index. 7.2.3 Drives and Optional
Extras For maintenance and inspection specifications, see the
appended manufacturer's documents, item 10.
7.2.4 Supervision during Operation 7.2.4.1 Shaft Sealing Consult
document OM.SEA.__. 7.2.4.2 Optional Extras To be monitored in
accordance with the separate documents, item 9/item 10. 7.2.4.3
Drive Engines To be monitored in accordance with the separate
manufacturer's documents, item 10. 7.2.5 Preventive Measures To
avoid expenses incurred by lengthy stop periods of the pump, seepex
recommends the acquisition of a set of wearing parts and a set of
gaskets. The scope is listed in document OM.WPS.85.
-
Operating Instructions Progressive Cavity Pump Service and
Maintenance
Dokument document Ausgabe issue Blatt sheet
OM.MAI.85e A / 04.04.03 2 (4)
7.3 Dismantling the seepex Progressive Cavity Pump Tools are
required for dismantling and re-assembly. These tools are listed in
document OM.SPT.01. The stator (601) and the rotating pump parts
can be exchanged at site. The rotating pump parts can be either
dismantled as a complete rotating unit (RTE) (item 7.3.4) or as
individual components (item 7.3.5). Before commencing the
dismantling of pump parts, protect the pump against tipping or
falling down by fastening it at the lantern (200) / drive
(ANT).
ANT200
7.3.1 Pressure Branch (700) - Dismantling Before dismantling
consider item 7.3.2
7.3.2 Stator (601) - Dismantling Easier assembly:
Disassembly of the stator can be made considerably easier by
first moistening the inner surface
of the stator with antiseize agent (soft or liquid soap). Before
removing the pressure flange (700), pour the antiseize agent into
the opening between rotor and stator on the pressure flange side.
Several clockwise (see item 6.2.5) revolutions of the rotor will
then distribute the antiseize agent over the inner surface of the
stator reducing the friction between rotor and stator
considerably.
Lock drive shaft against rotation. Disassemble stator (601).
7.3.3 Suction Casing (500), Casing Gasket (501) - Dismantling
Provide the rotor (600) with a protective cover (SH).
600 501500
-
Operating Instructions Progressive Cavity Pump Service and
Maintenance
Dokument document Ausgabe issue Blatt sheet
OM.MAI.85e A / 04.04.03 3 (4)
7.3.4 Rotating Unit (RTE) - Dismantling
CAUTION Before dismantling the rotating unit it is essential to
observe the specifications in document OM.SEA.__ Shaft Seal
Dismantling. Remove flushing connections at shaft seal
housing (SEA). Raise/shift splash ring (310) and eject plug-in
shaft pin (309) in horizontal direction. Remove rotating unit
(RTE)/plug-in shaft (307),
together with shaft seal (SEA) from output shaft of the drive
(ANT). See Document OM.SPT.01for tool
(W10) used for pulling off. Consult document OM.SEA.__, for
removal of the
shaft seal (SEA) from the plug-in shaft (307).
SEA 307 310 309
RTE ANT
7.3.5 Rotating Pump Parts - Dismantling 7.3.5.1 Rotor (600),
Coupling Rod (400) Detach the rotor (600) from the plug-in shaft
(307) by dismantling the joint (G) in accordance with item
7.3.6.
S
600 307 7.3.5.2 Plug-in Shaft (307) The plug-in shaft (307) is
removed in the same way as the rotating unit (RTE), acc. to item
7.3.4.
SEA307 310 309
ANT
7.3.6 Dismantling of Joint As described in document OM.PJT.__.
7.3.7 Shaft Sealing Consult document OM.SEA.__ for information on
dismantling the shaft sealing. 7.3.8 Lantern (200)/Drive (ANT) -
Dismantling
7.4 Re-assembly Before commencing the re-assembly, fasten the
lantern (200) in such a way that the drive and the pump components
cannot tip or fall down during the re-assembly.
7.4.1 Lantern (200)/Drive (ANT) - Assembly Clean flange bearing
surfaces (FLS), centering diameter and output pivot of the drive
(ANT).
200 ANT
-
Operating Instructions Progressive Cavity Pump Service and
Maintenance
Dokument document Ausgabe issue Blatt sheet
OM.MAI.85e A / 04.04.03 4 (4)
7.4.2 Rotating Unit (RTE) - Re-assembly The rotating unit (RTE)
has been assembled in accordance with the description in document
OM.PJT.__. Mount shaft seal (SEA) on plug-in shaft (307) as
described in document OM.SEA.__ . Moisten splash ring (310) and
plug-in shaft (307)
with joint grease (see index for type) and slide splash ring
(310) onto plug-in shaft (307), observing the fitting position of
the splash ring, (see lettering on the splash ring).
Apply antiseize graphite petroleum on the output pivot of the
drive (ANT) and slide on the rotating unit (RTE). Insert plug-in
shaft pin (309) horizontally.
Splash ring position (310) Outer edge of splash ring (310) has
to occlude with outer edge of plug-in shaft (309).
310 309307 SEA
7.4.3 Rotating Pump Parts - Re-assembly
Prepare main components: Prepare rotor (600) and plug-in shaft
(307) as described in document OM.PJT.__ item 2 to 2.2. Joint (G)
re-assembly as described in document OM.PJT.__ item 3.
600 307
7.4.4 Suction Casing (500), Casing Gasket (501) - Re-assembly
Lay protective cover (SH) over rotor (600). Assemble casing gasket
(501) and suction casing (500).
501500 600 7.4.5 Stator (601) - Assembly / Re-assembly Easier
assembly: Assembly of the stator can be much facilitated by
moistening the stator (601) and rotor (600) with an antiseize agent
(soft or liquid soap) prior to assembly. The antiseize agent is
evenly distributed on the inner surface of the stator and on the
rotor. By this, the friction between rotor and stator is
considerably reduced. Lock drive (ANT) shaft against rotation. Turn
stator (601) to the right and slip it onto rotor (600) at the same
time.
7.4.6 Pressure Flange (700) - Assembly
CAUTION Tighten bolts equally.
-
Operating Instructions Progressive Cavity Pump Pin Joint
Assembly
Dokument document Ausgabe issue Blatt sheet
OM.PJT.08e A / 04.04.03 1 (2)
1. Dismantling of Joint 1.1 Holding Band (406) and Universal
Joint Sleeve (405) Cut through loop (SCL) of the holding band (406)
with a metal saw. Wear protective goggles when squeezing out the
two halves of the holding band loop (SCL).
Remove holding bands (406,407). Pull back universal joint sleeve
(405) together with retaining sleeve (401) in rotor (600) direction
and fix it by using a special maintenance tool (W15/see document
OM.SPT.01)
1.2 Separation of Joint Eject coupling rod pin (402). Pull rotor
(600) out of joint top.
2. Prepare main components for Re-assembly 2.1 Rotor (600) -
Preparation for Joint Assembly First remove any burr, flaws or
similar defects from the rotor, then clean it. Clean rotor and
check top drilling regarding wear.
CAUTION If the top drilling shows wear, a new rotor will have to
be used.
Correct top drilling 2.2 Plug-in Shaft (307) - Preparation for
Joint Assembly Remove any burr, flaws or similar defects from the
plug-in shaft (307), then clean it. 3. Joint - Re-assembly Moisten
surface of rotor top (600) and inner surface
of universal joint sleeve with joint grease (see index for
special grease).
Pull back universal joint sleeve (405) over rotor (600) top and
fix it by using a special maintenance tool (W15/see Point 9)
Slip on Retaining sleeve (401) on plug-in shaft (307). Fill
joint top with joint grease (098), see index for
special grease.
Put top of the Rotor (600) into plug-in shaft (307)
and mount coupling rod pin (402).
-
Operating Instructions Progressive Cavity Pump Pin Joint
Assembly
Dokument document Ausgabe issue Blatt sheet
OM.PJT.08e A / 04.04.03 2 (2)
Pull back retaining sleeve (401).
Pull back universal joint sleeve (405) over retaining
sleeve (401).
De-aerate interior of joint with tool/screw driver
(WS)
Holding band re-assembly
Mount holding bands (406, 407) using tool (W3/see document
OM.SPT.01) as described in document OM.HBD.01
-
Operating InstructionsProgressive Cavity PumpHolding Band
Re-assembly
Dokumentdocument
Blattsheet
Ausgabeissue
OM.HBD.01e
1 (2)A / 23.02.95
Holding Band (HBD) - Assembly
Tools required for the re-assembly, see documentOM.STP.01, Point
9.
Prepare holding band
Only prefabricated double-band holding bandsshould be used. The
diameter () and in particularthe breadth (b) of the holding band is
matched to theuniversal joint sleeve.
Test holding band
The bent holding band (HBD) must fit against theholding band
loop (SCL), if necessary applypressure with the tool/pliers
(WZ).
Assembly of holding band
Insert holding band in tool (W3/ see Point 9). Holdfree end of
holding band with control lever (EX),turn crank (KU) until the
holding band is strainedand fitting against the holding band loop
(SCL).Carefully contract holding band until it fits insidethe
circular groove of the universal joint sleeve.
Correct holding band tension (HBD)
CorrectHolding band(HBD) hasslightly con-tracted outerform of
univers-al joint sleeveand is stuck inposition.
IncorrectHolding band(HBD) is tooslack and liableto slip.
IncorrectHolding band(HBD) is too tight.Universal jointsleeve
will bedamaged/shearedoff.
Folding back the holding band (HBD)
Slowly swivel mounting tool upward by 60, at thesame time
slackening the crank (KU) byapproximately one half revolution.
Swivel cuttinglever (SH) forward until the pressure plate
fitsagainst the holding band loop (SCL).
Shearing off holding band (HBD) made of materialAISI 304 and
AISI 316
A blow with the palm of the hand against thecutting lever (SH)
causes the end of the holdingband behind the loop (SCL) to be
folded back andsheared off. If the holding band on the sheared
offside is slightly raised as a result, it must bestraightened
carefully.
CAUTIONNever tap or hammer against the loop of theholding band
(SCL), otherwise damage to theuniversal joint sleeve may occur.
Shearing off holding band (HBD) made of HastelloyC
The high strength of this material makes it impossible to shear
off the holding band (HBD) with the cutting lever (SH). Once the
end of the holding band is folded back, cut off the holding band
(HBD), file off projecting edges and remove burr.
-
Operating InstructionsProgressive Cavity PumpHolding Band
Re-assembly
Dokumentdocument
Blattsheet
Ausgabeissue
OM.HBD.01e
2 (2)A / 23.02.95
Check after mounting of holding band
The holding band must run all the way round thegroove of the
universal joint sleeve.The holding band (HBD) must be bent back
andsheared off at the holding band loop (SCL) in such away that the
holding band (HBD) is unable to slipback through the holding band
loop (SCL). If this hasnot been accomplished, then the holding
band(HBD) must be replaced by a new one.
-
8.Breakdown, reasons, remedies
Breakdown
pum
p ha
s no
suc
tion
pum
p co
nvey
s irr
egul
arly
the
conv
eyin
g ca
paci
ty is
not
ac
hiev
ed
pres
sure
is
not
ach
ieve
d
pum
p do
es n
ot s
tart
pum
p ha
s se
ized
or h
as
stop
ped
conv
eyin
g
pum
p op
erat
es n
oisi
ly
mo
tor
beco
mes
to
o w
arm
the
stat
or w
ears
ou
t ear
ly
shaf
t sea
ling
leak
s
1 2 3 4 5 6 7 8 9 10 Reasons / Remedies
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
t
u
v
w
x
y
seepex progressive cavity pumps will operate trouble-free if
they are used in accordance with our data sheet (see item 9) and
our operating and maintenance instructions:
Check rotational direction of the pump per data sheet and
nameplate. In case of wrong direction, change wiring of motor.
Suction pipe or shaft sealing leak. Eliminate the leakage.
Suction head too high (item 6.5.3.1). Check suction head with
vacuum gauge. Increase the suction pipe diameter and fit larger
filters. Open the suction valve
Viscosity of the liquid too high. Check and accommodate per data
sheet.Wrong pump speed.Correct pump speed per data sheet.
Avoid inclusions of air in the conveying liquid.
Pressure head too high (point 6.5.3.2). Check pressure head with
manometer. Reduce the pressure head by increasing the pressure pipe
diameter or by shortening the pressure pipe.Pump runs partially or
completely dry (point 6.5.2). Check flow in the suction chamber.
Install dry running protection TSE.Check coupling, possibly pump
shaft is misaligned to drive. Check whether coupling gear is worn.
Realign coupling. The coupling gear has perhaps to be
replaced.Speed too low. Increase the speed when high suction
performances are required and when the liquid is very thin.Speed
too high. Reduce the speed when pumping products with high
viscosities - danger of cavitation.Check the axial play in the
coupling rod linkage. Check that the bush has been installed
correctly see document OM.PJT.__e item 2.2Check for foreign
substances in the pump. Dismantle the pump, remove foreign
substances and replace worn parts.
Stator or rotor worn. Dismantle the pump and replace defective
parts.
Joint parts worn. Replace worn parts and fill with special pin
joint grease .
Suction pipework partially or completely blocked. Clean suction
pipework.
Temperature of the pumping liquid too high. Excessive expansion
of the stator. Check temperature and install rotor with diameter
smaller than specified.Gland packing too strongly tightened or
worn. Ease or tighten stuffing box. Replace defective packing
rings.Solid contents and/or size of solids too large. Reduce pump
speed and install perhaps a screen with suitable meshes. Increase
fluid share.When the pump is non operational the solids settle out
and become hard. Clear and flush the pump immediately.The liquid
becomes hard when temperature falls below a certain limit. Heat the
pump.Stator swollen and unsuitable for the pumped liquid. Select a
suitable stator material. Use perhaps rotor with diameter smaller
than specified.The bearing in the drive casing of the pump or in
the drive engine is defective. Replace bearing.Mechanical seal
defective. Check seal faces and O-rings. If necessary replace
corresponding defective parts.
Adhesion between rotor and stator excessive (as delivered).
Lubricate (soft soap, genuine soap) between stator and rotor. Then
turn the pump by means of the tool W2 .
OM.REC.01e
1 (1)
A / 05.01.95
Operating and Maintenance InstructionsProgressive Cavity
Pump
Dokumentdocument
Blattsheet
Ausgabeissue
-
Stckliste Baureihe BW Schnittzeichnung-Nr.: 106-001A2
Dokument document Ausgabe issue Blatt sheet
SL.106.001 A / 24.02.03 1 (1)
d e f Stckliste Baureihe BW Parts list range BW Liste des pices
srie BW Baugren sizes tailles Schnittzeichnung Nr. sectional
drawing No. plan no. Benennung denomination dsignation
Stck. Pos. Stck. / Pos. Qty. / item Qt. / Poste 1 200 Laterne
lantern lanterne 2 202 Halbrundkerbngel round head grooved pin
rivet 1 203 Typenschild type plate plaque signalitique 4 210
6kt-Schraube hexagon bolt vis 4 212 Federring spring washer
rondelle frein 4 213 6kt-Mutter hexagon nut crou 1 307 Steckwelle
plug-in shaft arbre broche 1 309 Steckwellenbolzen plug-in shaft
pin cheville pour arbre broche 1 310 Spritzring splash ring bague
de projection 1 330 Gleitringdichtung mechanical seal garniture
mcanique 1 333 Gleitringdichtungsgehuse mechanical seal casing
carter de la garniture mcanique 1 372 Sttzring support ring bague
d'appui 2 401 Gelenkhlse retaining sleeve douille d'articulation 2
402 Kuppelstangenbolzen coupling rod pin axe d'articulation 1 405
Manschette universal joint sleeve manchette 1 406 Halteband holding
band collier de serrage 1 407 Halteband holding band collier de
serrage 1 500 Druckgehuse pressure casing carter de refoulement 1
501 Gehusedichtung casing gasket tanchit du carter de refoulement1
502 Verschlussschraube screwed plug bouchon de vidange 1 503
Dichtring sealing ring joint d'tanchit 4 506 Stiftschraube stud
bolt boulon filet 4 507 Federring spring washer rondelle frein 4
509 6kt-Mutter hexagon nut crou 1 600 Rotor rotor rotor 1 601
Stator stator stator 4 602 6kt-Schraube hexagon bolt vis 4 604
6kt-Mutter hexagon nut crou 4 606 Scheibe washer rondelle 1 700
Druckstutzen pressure branch bride de refoulement 098
seepex Gelenkfett Typ und Fllmenge siehe Angaben im
Inhaltsverzeichnis der zur Pumpe gehrenden Betriebsanleitung
seepex joint grease for type and filling quantity refer to index
of operating instruction belonging to pump
seepex graisse darticulations voir sommaire pour type et
quantit
Verschleissteile und Dichtungen: siehe Dokument OM.WPS.__d
Wear parts and sealings refer to document OM.WPS.__e
Pices dusure et tanchits voir document OM.WPS.__f
Werkzeuge: Fr Demontage und Wiedermontage erforderlich siehe
Dokument OM.SPT.01
Tools: required for disassembly and reassembly, refer to
document OM.SPT.01
Outils: Requis pour le dmontage et le rmontage, voir document
OM.SPT.01
-
Operating InstructionSingle-Acting Mechanical Seal
Dokumentdocument
Blattsheet
Ausgabeissue
OM.SEA.02e
1 (2)A / 10.02.95
1.General
Please take the appertaining drawing fromrespective pump data
sheet.
The mechanical seal is suitable for the operatingconditions
indicated in the pump data sheet.Modifications are only admissible
after the customerhas consulted with seepex. Additionally,
attentionmust be paid to the manufacturers operatingmanual.
2.Safety
Any mode of operation impairing the operating safetyof the
mechanical seal has to be avoided.
The operator is advised to consider the possibleeffects on the
environment which could be caused bya defective mechanical seal and
what additionalmeasures must be taken to protect the environmentand
the public.
The pump must be mounted and operated in sucha way that
operation with a defective mechanical sealwill not result in injury
or harm to the public and thatany leakage can be safely and
properly dealt with.
Mechanical seals are often used to seal hazardousmaterial
(chemicals, drugs, etc.). It is essential thatrules pertaining to
the handling of hazardous materialsare adhered to.
Modifications effected by the customer himself andchanges
influencing the safety of the mechanical sealare not allowed.
3.Emissions
A mechanical seal is a dynamic seal and leakage
isunavoidable.
ATTENTIONComponents that may contact leakage must beresistant to
corrosion or be protected accordingly.
Mechanical seal leakage must be drained in a safeand proper
manner.
4.Flushing or circulation of single-acting mechanicalseals
Single-acting mechanical seals contacting the con-veying liquid
require no additional flushing or acirculation pipe because
sufficient flushing and heatexchange occurs around the seal due to
the conveyingliquid.
However, in particular cases, a direct flushing pipe canbe
installed into the flushing connection on themechanical seal
housing.
5.Commissioning
Regardless of the pump's operating status, the con-veying medium
to be sealed must always be in liquidform at the mechanical seal.
This particularly appliesto the pump's commissioning and its
placing out ofservice.
6.Maintenance
When operating the pump according to the instruc-tions, no
maintenance is required.
7.Disassembly / Reassembly
7.1Disassembly
- Remove flushing connections at shaft seal housing(SAE).
- Lift / displace splash ring (310) and eject plug-inshaft pin
(309) horizontally.
- Withdraw rotating unit (RTE) together with shaft sealparallel
from output shaft of drive and avoidchocking.
- Clean plug-in shaft (307) and remove burrs etc.,which may
damage sealing elements. Moisten plug-in shaft (307) with slip
additive (diluted fluid soap).
- Loosen axial safety device of mechanical seal (330or 372) and
withdraw mechanical seal (330) fromplug-in shaft (307).
- Remove mechanical seal housing (333) from lantern(200).
- Press counter-ring of mechanical seal with o-ring outof
mechanical seal housing (333).
-
Operating InstructionSingle-Acting Mechanical Seal
Dokumentdocument
Blattsheet
Ausgabeissue
OM.SEA.02e
2 (2)A / 10.02.95
7.2Reassembly
ATTENTIONMechanical seals are precision parts of high
quality.Therefore, the installation must be effected with
care.Gentle handling and extreme neatness are essential.
- Clean mechanical seal housing (333)- Evenly press counter-ring
with o-ring into mecha-
nical seal housing (333). To facilitate assembly, theo-ring
should be moistened with a lubricant (dilutedfluid soap).
ATTENTION- Oil or grease must not be used to facilitate
assembly.- Install mechanical seal housing (333) to lantern
(200) and onsure correct position of flushingconnections.
- Remove plug-in shaft (307), burrs and roughnessand clean the
unit.
- Check / adjust set dimension of mechanical seal onplug-in
shaft (307). Moisten plug-in shaft (307) andelastomer parts of
mechanical seal with lubricant(diluted fluid soap).
- Slip mechanical seal onto plug-in shaft (307) as faras set
ring.
- Lubricate drive shaft (ANT) with antiseize
graphitepetroleum.
- Moisten splash ring (310) and plug-in shaft (307)with pin
joint grease, (for type, please see index) andslip splash ring
(310) onto output shaft of drive. Noteinstallating position of
splash ring and refer todescription on splash ring.
- Move rotating unit (RTE) through mechanical sealhousing (333)
and splash ring (310) and slip splashring (310) onto output shaft
of drive (ANT). Push inplug-in shaft pin (309) in horizontal
position.
- Position of splash ring:Collar of splash ring shall be fitted
in a distance ofabout 0.5 mm to lantern (200).
-
Operating Instructions Progressive Cavity Pump Wearing Parts and
Gaskets
Dokument document Ausgabe issue Blatt sheet
OM.WPS.85e A / 04.04.03 1 (1)
Wearing parts and gaskets Sizes: 1 bis 3 Range: BW To avoid the
expenses incurred by lengthy stop periods of the pump, seepex
recommend the acquisition of a set of wearing parts and a set of
gaskets. The table below shows the contents of these sets.
smal
l set
of
wea
ring
part
s
big
set o
f
wea
ring
part
s
set o
f gas
kets
Item number acc. to sectional drawing of pump and parts list
Part designation Number
Rotor 1 600
Stator 1 1 601
Universal joint sleeve 1 405
Coupling rod pin 1 402
Holding band, small 1) 1 407
Holding band, big 1) 1 406
Flushing ring 1 310
Casing gasket 1 501
Sealing ring 1 503
Mechanical seal 1 330
Plug-in shaft 1) - 307
Special joint grease 098 1 cart. 300 gr (c. 315cm) grease
quantity per pin joint, see tech. specifications 1. Kart.
Tool Essential for assembly, see document OM.SPT.01 1) see tools
document OM.SPT.01
-
Allgemeine normierte Werkzeuge
Standardized tools
Werkzeug Nr. tool No.
W1 W2 W5 W6 W9 W11 W13zur Montage von:
Packung Stator Gelenk Lager allgemein Mutter fr
Teflonmanschette
Stator
tool for mounting of:
packing stator joint bearing general nut for teflon universal
joint sleeve
stator
Benennung: Packungszieher Ketten-Rohrzange + Ersatzkette
Durchschlag Bolzen Montierhebel Bandschlssel Bandschlssel
denomination: packing lever chain pipe wrench +replacement
chain
drift pin mounting lever strap wrench strap wrench
Baugre
size0015-24 Siehe W 13003-12/-24 PKZ XX 000 see W 13 WKZ SBD
140006-12/-24 0000 0 X35M0012-12/-24
025-12
025-24 DHS 00 02005-12 0000 0 000001-6L
05-24 PKZ XX 000 KRZ XX Z55 1-6 0000 0 X0FQ0 0250 0 000001-12
KEZ XX Z552-6L 0250 0 00000 DHS 00 050 BLZ 00 0201-24 0000 0 00000
0008 0 000002-6
2-12
5-6L
2-24
5-6 DHS 00 050 BLZ 00 0205-12 0000 0 00000 0010 0
0000010-6L/15-6LT PKZ XX 0005-24 0000 0 XOHV0 2 Stck10-6 DHS 00 100
BLZ 00 020 2 pieces10-12 0000 0 00000 0010 0 00000 MHL XX SA 610
WKZ SBD 14017-6L/30-6LT
26-6L/40-6LT KRZ XX Z550300 6 00000
10-24 KEZ XX Z5517-6 0300 6 00000 DHS 00 120 BLZ 00 02517-12
0000 0 00000 0012 0 0000035-6L/55-6LT
52-6L/75-6LT
17-24
52-12
35-6 DHS 00 160 BLZ 00 03035-12 PKZ XX 000 KRZ XX Z55 0200 0
00000 0012 0 0000070-6L/110-6LT 0000 0 XA01A 0300 8 0000035-24 KEZ
XX Z5570-6 0300 8 00000 DHS 00 200 BLZ 00 03570-12 0200 0 00000
0012 0 00000130-6L
200-6L
70-18
70-24 DHS 00 240 BLZ 00 040130-6 KRZ XX Z55 0250 0 00000 0015 0
00000130-12 0301 2 00000202-6L KEZ XX Z55130-24 0301 2 00000 BLZ 00
040240-12 0015 0 00000350-6L
Die Preise sind dem Preisblatt AL.SPTde zu entnehmen / prices
are listed on price sheet AL.SPTde
1) Gilt nur fr Pumpen in Edelstahl Ausfhrung / only valid for
pumps in special steel design
1)
OM.SPT.01
1 (2)
B / 13.08.96
Exzenterschneckenpumpe - WerkzeugeProgessive Cavity Pumps -
Tools
Dokumentdocument
Blattsheet
Ausgabeissue
-
Empfohlene seepex Werkzeuge SpezialwerkzeugeAufgrund der
Ausfhrung fr bestimmte Montagen empfohlen, durch allgemeine
normierte Werkzeuge fr bestimmte Montagen bedingt ersetzbar.
unbedingt erforderlichRecommended seepex tools Special toolsDue to
the design recommended for certain repairs, these tools partially
replace the standardized tools. definitely needed for
certain repairsWerkzeug Nr. tool No. W4 W7 W8 W10 W12 W14 W15
W3zur Montage von:
Gelenk Lager Schmiernippel Steckwelle Teflon-manschette
Kuppelstangen-buchsen
Manschette Halteband
tool for mounting of:
joint bearing lubrication nipple
plug-in-shaft teflon universal joint sleeve
coupling rod bushing
universal joint sleeve
holding band
Benennung: Montagedorn Montagehlse Einschlag-hlse Demontage
Werkzeug
Montage-werkzeug
Prewerkzeug Montage-platte Montagewerkzeug
denomination: assembly mandrel
mounting sleeve drive-in sleeve dismantling tool mounting tool
pressing tool mounting plate mounting tool
Baugre
size0015-24 MTD L2 060003-12/-24 M120 0 XXXXX MTP A7
703006-12/-24 2) M120 0 002XX012-12/-24025-12025-24 MTD L2 060 MTH
M8 060 AZV B2 262 MTP A7 70305-12 M500 0 XXXXX M500 0 XXXXX M500 0
XXXXX M500 0 002XX1-6L05-241-61-122-6L MTD L2 060 MTH M8 060 AZV B2
262 MMT M8 060 PWZ C6 0601-24 0020 0 XXXXX 0020 0 XXXXX 0020 0
XXXXX 0020 0 XXXXX 0020 0 XXXXX2-62-125-6L2-245-6 MTD L2 060 MTH M8
060 AZV B2 262 MMT M8 060 PWZ C6 0605-12 0050 0 XXXXX 0050 0 XXXXX
0050 0 XXXXX 0050 0 XXXXX 0050 0 XXXXX10-6L/15-6LT5-2410-6 MTD L2
060 MTH M8 060 AZV B2 262 MMT M8 060 PWZ C6 06010-12 0100 0 XXXXX
0100 0 XXXXX 0100 0 XXXXX 0100 0 XXXXX 0100 0 XXXXX17-6L/30-6LT MHB
WH A0026-6L/40-6LT MTD L2 060 MTH M8 060 ESH N0 000 AZV B2 262 MMT
M8 060 PWZ C6 060 1WHV 0 01000
0140 0 XXXXX 0140 0 XXXXX 0000 0 XXXXX 0140 0 XF5XX 0140 0 XXXXX
1400 0 XXXXX10-2417-6 MTD L2 060 MTH M8 060 AZV B2 262 MMT M8 060
PWZ C6 06017-12 0170 0 XXXXX 0170 0 XXXXX 0170 0 XG0XX 0170 0 XXXXX
0170 0 XXXXX35-6L/55-6LT52-6L/75-6LT17-2452-12 MTD L2 060 MTH M8
060 MMT M8 060 PWZ C6 06035-6 0350 0 XXXXX 0350 0 XXXXX 0350 0
XXXXX 0350 0 XXXXX35-1270-6L/110-6LT35-2470-6 MTD L2 060 MTH M8 060
PWZ C6 06070-12 0700 0 XXXXX 0700 0 XXXXX 0700 0
XXXXX130-6L200-6L70-1870-24 MTD L2 060 MTH M8 060 PWZ C6 060130-6
1300 0 XXXXX 1300 0 XXXXX 1300 0 XXXXX130-12202-6L130-24 PWZ C6
060240-12 2400 0 XXXXX350-6LDie Preise sind dem Preisblatt AL.SPTde
zu entnehmen / prices are listed on price sheet AL.SPTde2) entfllt
ab Pumpen-Herstellungsdatum 01.04.93 / can be omitted as from
01.04.93 (pump manufacturing date)
OM.SPT.01
2 (2)
B / 13.08.96
Exzenterschneckenpumpe - WerkzeugeProgessive Cavity Pumps -
Tools
Dokumentdocument
Blattsheet
Ausgabeissue
-
www.facetinternational.net www.facetusa.com
www.facetinternational.net www.facetusa.com
-
INSTRUCTION MANUAL
15ppm Bilge Alarm
Type OMD-2005
DECKMA HAMBURG GmbH
-
DECKMA HAMBURG GmbH
Issue: 12.07.05 Instruction Manual OMD-2005 Page 2 of 24
IMPORTANT NOTICE
Replacement components for 15ppm Bilge Alarms.
General
All monitors in our range are inspected and tested to the
related I.M.O. requirements atour factories prior to delivery.In
normal use the units should operate correctly and without fault
over a long period oftime requiring only small amounts of
maintenance to be carried out as outlined in theinstruction
manuals.
Service Exchange Units
In the event of a monitor malfunction due to electrical or
electronic component failure itis our recommendation that a service
exchange unit be ordered.The defective instrument should be
returned to our works within 30 days of supplyingthe service
exchange unit, then only the repair charge is payable. Otherwise
the wholecost of a service exchange unit becomes payable.This
procedure is by far the easiest and most cost effective way of
ensuring the monitoron board conforms to I.M.O. resolution MEPC.107
(49).
Remark:
According the MEPC.107(49) 4.2.11 the unit has to be checked at
IOPP Certificaterenewal survey by the manufacturer or persons
authorized by the manufacturer.Alternatively the unit may be
replaced by a calibrated 15 ppm Bilge Alarm. The OMD-2005 is
designed in that way, that only the measuring cell needs to be
changed, as thisunit carry the calibration onboard. The Calibration
Certificate with the date of the lastcalibration check should be
retained onboard for inspection purposes.
If for some reasons the computer unit needs to be changed, it
has to make sure, thatthe memory card wi