Facet Bilge Water Separator CPS B MKIII & EBM14x

OILDISCHARGE DESCARGADE ACEITE

OPERATION MODE MODOOPERACION

HEATER /CALEFACCION OFF

0

MAN

AUTO

ON

HIGH TEMPERATURE ALTATEMPERA TURA TURA

INLET ENTRADA

WATEROVERBOA RD RD DESCARGAALMAR

BOMBA PUMP

REPLACE MEMBRANE CAMBIAR MEMBRANA MEMBRANE MEMBRANA

ON

BYPASS

RECIRCULATION RECIRCULACION

7309612001 CPSB-2_5B MKIII+EBM14x.doc/Rev MKIII+EBM14x.doc/Rev.0 .0 04/06

www.facetinternational.net www.facetusa.com

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Table of contents

1.

Page

Safety..............................................................................................................................6 1.1. Risks that may be undergone during the operation of the oily water separator...........6 1.2. Labelling of Advice Advice in the Operating Operating Instructions 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 the membrane module ........................ ............................. ........................... 17 6.4. Start Up ............................. ............................ ............................ ............................. ...17 6.5. To Stop .......................... ............................ ............................. ............................ .......18

7.

Operating Principles......................................................................................................19 7.1. Suction and and Separation Separation of the Oil-Water Oil-Water Mixture ............................. ......................... 19 7.2. Automatic Oil Discharge........................... Discharge ........................... ........................... ........................... ...........20 7.3. Passing through the membrane ......................... ............................. .......................... 20 7.4. Recirculation to bilge system.....................................................................................20 7.5. Automatic and Manual Operation Modes

..........21



























8.3. Maintenance Schedule.......................... Schedule .......................... ............................ ............................. ...........26 9.

Trouble Shooting...........................................................................................................27

10.

Spare Part List ........................ ............................. ............................ ............................ .30

Ap pen di x

Pump Oil Monitor

Drawings and Bills of Materials Certificates



























Table Table of Figures

Page Page

Figure 1 Frontal of control panel................................................................................11 Figure Figure 2 Elements Elements ....................... ................................... ....................... ....................... ....................... ....................... ....................... ....................12 .........12 Figure 3 Opening vent and closing drains ......................... ............ .......................... .......................... .......................... ............... 16 Figure Figure 4 Opening Opening water water filling valve ....................... .................................. ....................... ....................... ....................... .................17 .....17 Figure 5 Opening membrane vent.............................................................................18 Figure Figure 6 Disc Discharge harge to the sea ...................... ................................. ....................... ....................... ....................... ....................... ..............19 ...19 Figure 7 Separation water-oil water-oil in the coalescent plates Facet Mpack®......................19 Figure Figure 8 Oil-Discha Oil-Discharge rge ...................... .................................. ....................... ....................... ....................... ....................... ....................... ..............20 ...20 Figure Figure 9 Flow through the membrane membrane ....................... ................................... ....................... ....................... ....................... .............21 ..21 Figure 10 Recirculation to bilge.................................................................................21 Figure Figure 11 Disassemb Disassembly ly of pipes pipes ....................... .................................. ....................... ....................... ....................... .......................22 ...........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



























Index of Tables Page Page

Table 1 Connections Connections .......................................................................................... ............................................................................................................................. ................................... 13 Table 2 dimensions of Connection Connection pipes pipes ......................................................................................... .............................................................................................. ..... 15 Table 2 Maintenance Maintenance Schedule........................................................................................ Schedule............................................................................................................. ..................... 26 Table 3 Trouble Shooting...................................................................................................................... 27 Table 4 Spare Spare Part List.......................................................................................................................... List.......................................................................................................................... 30



























1. S AFETY

These operating instructions contain basic requirements to be observed during the installation, operation and maintenance 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 regarding safety, if it were not properly set up or used, risks could arise and result in damage of: 

The personnel’s 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 t hese instructions: In these operating instructions safety advice whose non-observance could lead to danger for life or limb is labeled with the following text At ten ti on !! !

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. instructions.





























1.4. Security Precautions The following precautions must be taken for the security of the personnel who operate the Separator: 1. Fire prevention measures measures will have to be taken taken if the separated product product requires it. 2. Precaution must be taken taken to keep the area around around the Separator Separator clean to prevent accidents. 3. All product spills must be be dried immediately immediately with with rags, and these removed removed to a safe place. 4. Gloves must be used used when parts are are handled that have been in contact with the fluids handled by the Separator. 5. If some of the handled handled fluids are flammable flammable and volatile, smoking smoking must not be allowed near the Separator and accessory equipment. 6. In these cases suitable suitable fire-fighting fire-fighting equipment equipment must be also installed installed near the Separator before carrying out any type of maintenance. maintenance. 7. Avoid unnecessary unnecessary contact contact of the skin and clothes clothes with the handled handled fluids. fluids. 8. After maintenance or working with with the Separator, Separator, the hands and and parts that have been in contact with the fluids must be thoroughly washed. 9. Immediate medical medical attention must must be lent to cuts in the skin, upset stomach, stomach, etc., due to possible contacts with the product or to the inhalation of gases. At ten ti on!! on !! !

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 Important !!!

SECURITY AND ENVIRONMENTAL PROTECTION ARE THE





























11. The separator must be securely installed on a stable, horizontal surface. following it to tip over would endanger life and limb. At ten ti on !!

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.





























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.





























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 Recommendations 3.2.1. The Inlet line should should be provided with a coarse filter and non non return valve at the suction point 3.2.2. The oil discharge discharge line must not have any valves connected connected to it.





























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 pump driven by an electrical motor, suctions suctions oily water from the bilge. 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 removes oil from water. A level control control system for separated free oil that controls the t he automatic discharge of the separated oil. 4.2.3. Membrane unit containing EBM disposable membrane breaks oil-water emulsions Figure 1 Frontal of con trol panel panel

OIL OUTLET SALIDA DE ACEITE

OPERATION MODE MODO OPERACION 0 AUTO

MAN

BILGE WATER INLET ENTRADA AGUA DE SENTINAS WATER OVERBOARD DESCARGA AL MAR































4.2.4. A control 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 unit when when the the level level in the bilge is adequate 4.2.4.2.

External Contacts for High Oil Content in effluent alarm. HEATER (OPTIONAL) CALEFACCION (OPCIONAL)

OVERBOARD WATER OUTLET DESCARGA AL MAR

CHECK VALVE VALVULA DE RETENCION

NC SOLENOID VALVE VALVULA SOLENOIDE NC

BACK TO BILGE RETORNO A LA SENTINA

CHECK VALVE

MEMBRANE MEMBRANA

OIL DISCHARGE DESCARGA DE ACEITE































4.2.5. Test-cock on the top of the unit and Effluent Effluent sample cock at the the water outlet. 4.2.6. Vacuum and Pressure Gauge 4.2.7. Check Valves Valves on the oil oil discharge line and the the recirculation recirculation line. 4.2.8. Two solenoid valves at the discharge 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 Overboard discharge discharge line. 4.2.10. Solenoid Valve at Oil free Water Inlet line. 4.2.11. Oil Monitor. The equipment includes 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 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































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.































5. INSTALLATION

5.1.

Place the unit in its allocated allocated place and make sure that clearances are available available as indicated on the dimensional drawing.

5.2.

All the pipes pipes that arrive arrive and leave the Separator must must be aligned 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 dimensions of the pipes cannot be smaller than than those indicated indicated in 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. T ABL E 2 DIMENSIONS OF CONNECTION PIPES 3

Capacit Capacit y (m /h) water inlet water outlet

0,5

1.0

2.5

5

DN32 1 ¼” DN32 1 ¼” DN32 1 ¼” DN65 1” BSP

1” BSP

1” BSP

10

2 ½”

1 ¼” BSP

DN65

2 ½”

2” BSP

oil outlet

DN25

1”

DN25

1”

DN25

1”

DN50

2”

DN50

2”

back to bilge

DN25

1”

DN DN25

1”

DN2 DN25

1”

DN32

1 ¼”

DN50

2”

DN25

1”

DN25

1”

Oil-free water supply

5.5.

½” BSP

½” BSP

½” BSP

Connect bilge water inlet to suction 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































6. START UP

After the installation according to Section 5, the 5, the unit is ready for initial filling with oil-free water. First, carry out the following pre-operational checks: 1. Check all bolted bolted connections connections for loose loose bolts and tighten them, ifif necessary. 2. For the pump, pump, oil monitor monitor and the other equipment equipment see relevant relevant instructions 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 the flanged connections connections to make sure that that the gaskets are in place. place. 3. Check that that the bolts of the flanges flanges are tightened. 4. Check bolts and screws of all the accessories to make make sure that they are 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 pipes to verify that they they have not been been flattened or bent. bent. If a pipe is damaged, replace it with a new one. 6. Check racords and and sleeves to verify their their tightness. Do not over-tighten over-tighten the threaded connections as this can give rise to losses or dripping of fluid.

































4. Open the oil-free water filling valve. 5. Close the water filling valve and the cock when when a steady stream of water comes out of the cock. 6. Start the unit with the main main switch in position "1" and Selector 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 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 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 unit by means of the Operation Operation Mode Selector (Auto - 0 - Man) 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.































5. If the separator separator is equipped equipped with electrical electrical heater (only very viscous 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

MEMBRANE VENT VENTEO MEMBRANA































7. OPERATING PRINCIPLES

For purposes of the following explanation please see flow diagram on the drawing list. OIL OUTLET SALIDA DE ACEITE

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.

OPERATION MODE MODO OPERACION 0 MAN

AUTO

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.

BILGE WATER INLET ENTRADA AGUA DE SENTINAS

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

WATER OVERBOARD DESCARGA AL MAR

BOMBA PUMP

REPLACE MEMBRANE CAMBIAR MEMBRANA MEMBRANE MEMBRANA
































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


OPERATION MODE MODO OPERACION 0 AUTO

MAN
































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.


OPERATION MODE MODO OPERACION 0 MAN

AUTO

7.5. Automatic and Manual Operation Modes The system is ready for two operation modes: -

-

Automatic mode: 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


BOMBA PUMP

REPLACE MEMBRANE CAMBIARMEMBRANA MEMBRANE MEMBRANA


































8.

M AINTENANCE 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































8. Loosen and remove the cover bolts or release the swing bolt assembly 9. Remove vessel end end cover cover and inspect the gasket gasket 10. Pull out the trough by the handles in the front side . Figure 13 Removing the trough































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.































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 assembly 1 NUT TUERCA STARLOCK WASHER































14 Reassemble the end caps, gasket gasket washers, flat washers, washers, lock washers washers and hex nuts to centre rods. Be sure to install centre seals seals between the two deep or more element assemblies. 15 Tighten hex nuts nuts with a torque wrench wrench according to drawing drawing after it has has been ascertained that the elements are seated properly on adapters and seals. 16 Discard old cover cover seal to a FIRE-SAFE place. place. Install a new cover seal seal and close cover. Install cover bolts and tighten t ighten bolts evenly and securely to ensure good sealing. 8.3. Maintenance Schedule

































9. TROUBLE SHOOTING































T ABL E 4 TROUBLE SHOOTING































T ABL E 4 TROUBLE SHOOTING





























































PPM Alarm (By Customer requirements)





















































































































































































































































































































































































































































































































































































































































































































DECKMA HAMBURG GmbH

1.0

INTRODUCTION The OMD-2005 Bilge Alarm Unit has been designed specifically for use in conjunction with 15 ppm oil-water separator units and has a specification and performance which exceeds the requirements of the International Maritime Organization specifications for 15ppm Bilge Alarms contained in Resolution MEPC. 107 (49). The unit is supplied with 2 works-adjusted alarms at 15 ppm. Other set points (10 ppm or 5 ppm) are possible and can be adjusted on site at any time by using the buttons at the front panel. If an alarm set point is exceed, the alarms are visible at the front panel and the appropriate relays are switched. In case of malfunction the System LED at the front panel will change from blinking green to permanent red and the appropriate relay will switch the contacts. For the data logging function the unit requires an status input from the separator and a feedback signal from the valve position limit switch. (See Fig. 1, Pos.6) Furthermore a 0(4) - 20 mA (equal to 0 - 30 ppm) signal output is available for driving a recorder or external meter.

2.0

IMPORTANT ANT NO NOTES a) This equipment must must be installed and and operated in strict strict accordance with with the instructions contained contained in this manual. Failure to do so will impair the protection provided. b) Installation and and servicing must be be undertaken by a competent competent and suitable suitable skilled person. c) The equipment must be connected connected to the ground ground according relevant relevant requirements. d) The unit must be isolated isolated from the electrical electrical supply before any maintenance maintenance of the equipment is attempted. e) All National or local codes of practice practice or regulations must must be observed and, where applicable, are deemed to take precedence over any directive or information contained contained in this manual. f) In case of freezing freezing conditions the measuring measuring cell should should be emptied complete. complete.



























DECKMA HAMBURG GmbH

3.0

PRINC INCIPLE OF OF OP OPERATIO ATION N

3.1

Meas ur ur in in g Pr in in ci ci pl pl e

An optical sensor array measure a combination of light scattered and absorbed by oil droplets in the sample stream. The sensor signals are then processed by a microprocessor microprocessor to produce linearised output. If an alarm (works set point 15 ppm) occurs, the two oil alarm relays are activated after the adjusted time delay. The microprocessor continuously monitors the condition of the sensor components and associated electronics to ensure that calibration accuracy is maintained over time and extremes of environmental conditions. 3.2

Feat u r es • • • • • • • • • •

3.3

Robust construction Automatic voltage selection Solid suppression capability Low maintenance Easy installation Constant readiness Low spare part stock holding Watertight Housing Works adjustment Easy settings via menu

A d j u s t m en t

The unit is delivered with a works calibration according the IMO-requirements. The alarm points are set to 15 ppm. The "Zero" point is also works calibrated and can be re-adjusted on site by using the programming mode and clean water. See Section 10.4 “Service-Offset”. A calibration is not permitted. This has to be done according IMO Regulations by the manufacturer or persons authorized by the manufacturer. 3.4

Di sp sp la lay s an d A la lar ms ms

In the unit are two independent oil alarm circuits available. Both can be set separately from 1 to 15 ppm. From the manufacturing both alarms are set to 15 ppm (according IMO). The set points poin ts can be changed c hanged according accor ding to the requirements on site, for example to 10 ppm or 5 ppm. An alarm point setting above 15 ppm is not possible. The adjustment can be done in the programming mode as described in Section 10.4.



























DECKMA HAMBURG GmbH

Both alarm circuits are also related to an alarm LED on the front panel. In case of malfunction the “System” LED will indicate any type of internal fault of the unit. This LED is flashing green in normal conditions and is red in alarm conditions. Also this alarm is related to an relay output. Additional to the alarm LED's each alarm circuit is equipped with a relay with potential free alarm contacts. These contacts can be used for external processing of the signal or for control of further functions. If a malfunction or failure of the power supply occurs, all 3 relays will switch to alarm condition.



























DECKMA HAMBURG GmbH

4.0 4.0

SPECI PECIFI FIC CATION ATION OMDOMD-20 2005 05 Range:

0 – 30 ppm, Trend up to 50 ppm

Accuracy

According IMO IMO MEPC. 107(49)

Linearity

Up to 30 ppm better than ± 2 %

Display

Green Graphic Display

Power Supply: Consumption:

24 V – 240 V AC or DC Automatic Voltage Selection Selection < 15 VA

Alarm Points 1 + 2:

Adjustable between between 1 - 15 ppm (Works adjustment 15 ppm)

Alarm 1 Operating Operating Delay: (for annunciation purpose)

Adjustable between between 1 – 540 sec. (Works adjustment 2 sec)

Alarm 2 Operating Operating Delay: (for control purposes)

Adjustable between between 1 – 10 sec. (Works adjustment 10 sec)

System Fault Alarm:

Red LED

Alarm Contact Contact Rating:

Potential free free 1 pole change change over contacts, 3 A / 240 V

Alarm Indication: Indication:

Red LED's

Output Signal:

0 – 20 mA or 4 – 20 mA for 0-30 ppm reversible, ext. Load < 150 Ω

Sample Water Pressure:

0,1 – 10 bar

Sample Flow:

Approx. 0,1 - 4 l/min depend. to pressure

Ambient Temperature: Temperature:

+ 1 to + 55° C

Sample Water Temperature:

+ 1 to + 65° C

Roll:

Up to 45°

Size (over all):

360 mm W x 240 mm H x 100 mm D

Degree of Protection:

IP 65

Weight:

7,3 kg

Pipe Connections:

R ¼" Female



























DECKMA HAMBURG GmbH

5.0

CONSTRUCTION There are 3 main parts which contained in an OMD-2005: The computer unit is mounted into an epoxy powder painted steel housing to protect the electronics of the display PCB with the data logger and the main board PCB with the terminals for external connections. The measuring cell is built out of an anodized all-aluminium body with inlet and outlet block in stainless steel. This rugged cell contains the optical electronic and correspond with the computer unit via a plugged data cable. The valve assembly contains a special handle to sense the position of the valve. This assembly is connected to the measuring cell by an easy to handle fitting to enable the exchange of the cell for frequently adjustment according the IMO requirements. All components are mounted to a stainless steel mounting plate for easy wall or bulkhead installation. It is also possible to split the computer unit from the measuring cell if the available space is not sufficient. For this version divided mounting plates are available.

OUT 1/4"

OMD-2005

Oil Monitoring Device

ON

Alarm 1

Alarm 2

Sy stst em em

OK DECKMA HAMBUR HAMBURG G www.deckma.com

CLEAN WATER 1/4" DECKMA HAMBURG DH 75450

SAMPLE 1/4"

1

Computer Unit

5

Handle

9

3/2 Way Valve

2

Head Screw

6

Limit Switch

10

Mounting Plate

3

Fitting

7

Spacer

11

Desiccator





























DECKMA HAMBURG GmbH

6.0

INSTALLA ALLAT TION (Refer to Fig. 2 and Fig. 3) See Section 2 for important notes concerning installation.

The OMD-2005 Monitor should be located as close as possible to the oily water separator to minimize response delays. According MEPC.107(49) the layout of the installation should be arranged so that the overall response time (including the response time of the 15 ppm Bilge Alarm) between an effluent discharge from the 15 ppm Bilge Separator exceeding 15 ppm, and the operation of the Automatic Stopping Device preventing overboard discharge, should be as short as possible and in any case not more than 20 s. Mount the OMD-2005 Monitor by means of 6 x M8 screws on to a rigid vertical surface and preferably with the display panel of the monitor at eye level. For service and maintenance sufficient space to all sides should be available. Care must be taken at mounting of the pipes connections to avoid any torsion of the housing and damage of the instrument.

OUT 1/4"

OMD-2005


ON

Alarm 1

OK

Alarm 2

Sy ststem





























DECKMA HAMBURG GmbH

7.0

PIPING (Refer to Fig. 3) Connect the OMD-2005 Monitor to the sample point of the oily-water separator outlet and to a source of oil free water employing 10 mm OD copper or stainless steel pipe. The sample point should be located on a vertical section of the separator outflow piping to minimize the effects of any entrained air. The tapping point should be at a level above the outlet of the monitor to ensure the sample cell is flooded at all times. If connection to a vertical section of the separator outlet piping is impractical, the tapping may be made into the side of the horizontal pipe. Avoid top or bottom entry. For separator discharge pipes up to 75 mm OD a standard "T"-type junction of the welded or screwed type is satisfactory for the tapping point. For the separator discharge pipes of 80 mm OD and above a sample probe should be employed which protrudes into the discharge piping by approx. 25 % of the ID of the pipe.

Automatic Stopping Device

Recirculating Facilities

Overboard discharge

To Bilge

To Bilge

Pressure relief valve (if required) Vacuum breaker Outlet *

OMD-2005


ON

Alarm 1

Alarm 2

System

OK DECKMAHAMBURG www.deckma.com





























DECKMA HAMBURG GmbH

8.0

WIRING (Refer to Fig. 4 + 5) See Section 2 for important notes concerning wiring.

This unit must be connected to the mains supply via a suitable rated and approved fused isolator unless such fusing / isolation is provided by associated equipment. When fitted, the isolator should be close, readily accessible and marked as to function. Electrical connections are made through the metric cable gland openings prepared underneath the instrument.

Fig. 4 Precise wiring details will vary dependent upon the control system to be employed but the most frequently used systems employ alarm relay 1 for alarm only and alarm relay 2 for control purposes. Electrical connections are made to the terminal blocks inside the computer housing. Wires are connected to the terminals by pushing a suitable screwdriver into the clamp holes to release the internal spring loaded clamps. After the wire is inserted to the terminal and the screwdriver is removed, the wire is fixed. If the instrument is operated at high voltages, additional care has to be taken to provide reliable ground connections. Ground (PE) can be connected direct to the terminal or, if this is not sufficient according local rules, to the computer housing





























DECKMA HAMBURG GmbH

Limit Status Switch Separator

2A

Signal Output 0(4)-20 mA

1A

F1 PILOT V L 1

F2 Res.

24-240V IN N PE 2 3

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Logger / Measuring PE PE PE + - PE PE Display Cell F LO LOW ST AT ATU S RES OUTPUT CLEAN PILOT OUT RES ALARM 1 ALARM 2 SYSTEM FAULT L N PE A B PE NO COM NC NO COM NC NO COM NC 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

To Alarmsystem

Contacts shown in Alarm condition conditi on (de-energised)

To Alarmsystem (optional)

Solenoid Valve

1-2 Power Power Supply 4-5 Pilot Voltage Voltage Output Output (Same as Power Power Supply) Supply) 7-8 Spare Voltage Output (Same (Same as Power Power Supply) Supply) 10-12 Potential free Output Output Alarm 1 (Change over contact) 13-15 Potential free Output Output Alarm 2 (Change over contact) 16-18 Potential free Output Output System Fault (Change over contact) 19-20 Input Flow Direction Direction Switch (Deckma Delivery) Delivery) 22-23 Input Status Switch from Separator Separator (Close when running) 25-26 Input Spare Switch 28-29 Signal Output 0(4) to 20 mA 31-32 Optional Output for Autoclean Valve

EXAMPLE Connections Connecti ons may vary with different diff erent separator control boxes

3/2 Way Valve Automatic Stopping Device Power Supply

Air Supply

Fig. 5 Close front door complete after electrical installation. Water inside the instrument may result in corrosion and malfunction.





























DECKMA HAMBURG GmbH

8.1

Ty pi pi ca cal Co nt nt ro ro l Sy st st em em

The installation on site has to make sure that in case of any loss of power supply and/or loss of air supply for the automatic stopping device the overboard discharge valve close the overboard line and open the re-circulating re-circulating line. The system showed in the example, employs alarm relay 2 to control a pneumatic solenoid valve which energises or de-energises a pneumatically operated 3 - way valve as depicted in Fig. 5. The separation process will continue until such time as the pollution level falls below the alarm set point at which time the discharge will be directed overboard. A pump stop stop system is according MEPC.107 MEPC.107 (49) (49) not allowed.

9.0

POWER SUPPLY See Section 2 for important notes.

The unit is designed for a power supply of 24 V to 240 V AC or DC. It has an automatic power selection.

10.0 10.0 COMM COMMIS ISSI SION ONIN ING G See Section 2 for important notes.

On completion of the installation, wiring and piping carry out the following checks: 10.1

El ec ec tr tr ic ic al al

a) Check that the power supply is connected to the terminals 1 + 2 of the terminal block. b) Check the wiring of the automatic stopping device and to the alarm system is according the IMO Requirements. c) Check that the grounding grounding has been been made according to to the relevant































DECKMA HAMBURG GmbH

10.3

Funct unctio iona nall Te Tests sts

a) Run oil free water through through the instrument instrument to purge purge the system. b) Adjust the flow rate through through the unit by using the small small screws in the cell cap (Fig. 1, Pos. 2). Taking out a screw will increase the flow rate. NB : The flow rate should be checked on both, the clean water supply and the separator sample supply. If the clean water supply is obtained from a high pressure source, the flow rate will be higher than from the sample point. The flow rate is not influencing the accuracy of the instrument. The adjustment is only important for the time delay between the sample point and the monitor.

c) Switch on the instrument and make sure, that the Power LED is illuminated and the display is showing the initializing display for about 15 sec. After that time it will change to the standard display, showing the actual measurement. d) During oil free water is running through the monitor check the Zero adjustment according Section 11. The display should be "0" to “2” and the status will show “FW”. If the display varies by greater amounts, it may be that air entrainment is present. If this is the case, the cause must be located and rectified. f) If the Zero Zero need to be be adjusted, this can be done in the programming programming mode as described in section 10.4. (Service – Offset)































DECKMA HAMBURG GmbH

10.4

Progr rogra ammin mming g Mod Mode e

In the programming mode the alarm set points, the time delays, the signal output and the zero can be modified. It is also possible to recall the factory default values at any time. The clock is d r factory set for GMT, Greenwich Mean k w a c o r b a f d w r w a Time, and cannot be changed. r o r o r w A r A r o f o

l e b u D o

r t e E n

w r o A r

n t o t u B " "

o n t o t u B " K " O

o n t o t u B " " +

l e b u D o

n t o t B u l o T o

There are 8 push buttons to control the functions of the display. In general are the upper buttons for the data logger and the lower buttons for changing the display to the different pages of the menu.

OK

Pressing the OK button will give more detailed information about































DECKMA HAMBURG GmbH

To get into the menu press the tool button. Select the required point by using the „+“ or „-„

Select the required point by using the „+“ or „-„ button. Press the „OK“ button.

To change the value, press the “+” or “-“ button. Confirm with “OK”.

Select the required point by using the „+“ or „-„ button. Press the „OK“ button.

To change the value, press the “+” or “-“ button. Confirm with “OK”.

The display will show the actual status of the data logger. To get back to the standard display































DECKMA HAMBURG GmbH

To get into the menu press the tool button. Select the required point by using the „+“ or „-„ button. Press the „OK“ button.

The temperature of the measuring cell and the sample water will be shown

To get into the menu press the tool button. Select the required point by using the „+“ or „-„ button. Press the „OK“ button.

The details of the measuring cell will be shown.

To get into the menu press the

Information about the software































DECKMA HAMBURG GmbH

11.1

Opera perato torr Not Note es

a) When oily water flows flows through the instrument instrument the display display will show the actual value of oil content. b) If the oil concentration exceeds the adjusted threshold (works adjustment 15 ppm), the alarm indicator 1 will be illuminated in intervals during the selected time delay before it change to steady light and the associated alarm relay will operate. Accordingly also the alarm indicator 2 will be illuminated and its associated alarm relay will take the appropriate shut down action.

12.0 12.0 OPER OPERATOR ATOR MAINTE MAINTENANC NANCE E See Section 2 for important notes.

AT WEEKLY INTERVALS: INTERVALS: a) Flush Flush the cell with oil free free water. water. b) Isolate the instrument instrument from both, sample and and oil free water supply. supply. c) Unscrew Unscrew and remove remove the the cell cap. cap. d) Insert a suitable suitable Cell Cleaning brush (Art. (Art. No. 30102) into the cell cell and clean it with upwards and downwards motion through the entire length of the cell several times. e) Remove the the Cell Cleaning brush brush and replace replace the cell cap. cap. f) Reconnect the oil free free water supply and allow this to to flow through through the

































DECKMA HAMBURG GmbH

12.1

Manual nual Ce Cell Cle Clea an Unit Unit Optional item if fitted

This unit facilitates cleaning of the cell without the need of removing the cell cap. Regular use of this device should prevent malfunction of the monitor due simply to fouling of the sample tube and all the inconvenience which this can cause. Operating Operating Instruct ions

a) Ensure that the monitor monitor is switched off and that there there is a clean water supply through the cell. b) Activate the manual manual cell clean unit by pressing pressing the handle several several times. c) Switch the monitor monitor back on and check the the reading is between 0 to to 2 ppm. d) Repeat a) to to c) at least least once a week week or as necessary. necessary. NB: The Manual Cell Clean Unit may also be used during normal operation with sample water, but in this case an alarm occurs because the wiper is passing the































DECKMA HAMBURG GmbH

13.0 13.0 FAULT FIND FINDIN ING G See Section 2 for important notes.

The OMD-2005 will indicate several malfunctions in the status line of the display. Pressing the “OK” button will lead into an information window, similar to the items listed in the table below. Status

Reading

System-Alarmcircuit LED

Alarm Alarmcircuit 1,2

Reason

Servicing

Alarm

OK

0..49

Green / No Blinking

Normal operation

Normal operation

-

OK

EE

Green / No Blinking

Alarm

Sample reading is out of range:

Wait until oil content is within the range,































DECKMA HAMBURG GmbH

Terminals

F1 POWER L 1

F2 PILOT VOLT.

24-240V IN N PE 2 3

Main PCB with Holder

19 20 21 22 23 24 PE PE F LO LO W S TA TA TU TU S PILOT PILOT OUT RES L N PE PE A B 4 5 6 7 8

Computerhousing

25 26 27 28 29 30 31 32 33 Logger / Measuring PE + - PE PE Display Cell RES O UT PU PU T CLEAN ALARM 1 ALARM 2 SYSTEM FAULT PE N O C O M N C NO COM NC NO COM NC 9 10 11 12 13 14 15 16 17 18

Protection Cover Display PCB































DECKMA HAMBURG GmbH

14.0 CALIBR ALIBRAT ATIION 15 ppm Bilge Alarms built according MEPC.107(49) have to be protected against access beyond the checks of instrument drift, repeatability of the instrument reading and zero adjustment. For this reason the instrument is electronically sealed, so that only the manufacturer or his authorized persons, equipped with the related tools, are able to get access for changing the calibration. To provide a simple procedure for check the instrument aboard ship, the OMD2005 is constructed in that way, that the zero check also confirms the instrument drift within the specifications. specifications. 14.1

Calibration libration and and repea repeatability tability check check

a) Switch off the power supply supply and stop any water flow. flow. b) Clean the sample tube tube accurate by using using a suitable cell cleaning brush brush as































DECKMA HAMBURG GmbH

15.0 SPARE ARE PAR PART TS When ordering spares, it is important to supply details of the type of monitor, part number of each spare required, its description and any relevant serial number.

DESCRIPTION

ART-NUMBER

Desiccator

65550

Cell Cleaning Brush

30102

O-Ring Set

75775

Fuse, T 2 A

40107

Fuse, T 1 A

40105

































DECKMA HAMBURG GmbH

16.0 REMARKS ARKS All the modifications modifications and deviations from the standard form, which have to be carried out in the supply, should be attached at this paragraph.





















































































































































































































Drawing

2132770





























































Drawing

4137538











































































































































































































































































































































































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