Facet Bilge Water Separator CPS B MKIII & EBM14x

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

www.facetinternational.net www.facetusa.com

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

- 2 - Facet Oil Water Separator CPSB MKIII + EBM14x www.facetinternational.net www.facetusa.com

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

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

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

Appendix

Pump

Oil Monitor

Drawings and Bills of Materials

Certificates


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


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


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.


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.


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.


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

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.


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

- 11 - Facet Oil Water Separator CPSB MKIII + EBM14x

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


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


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


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 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.


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


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.


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.


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



MEMBRANEMEMBRANA

BYPASS

BILGE WATER INLET

DE SENTINAS

DESCARGA AL MARWATER OVERBOARD

ENTRADA AGUA

OIL OUTLETSALIDA DE ACEITE


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



MEMBRANEMEMBRANA

BYPASS

BILGE WATER INLET

DE SENTINAS


ENTRADA AGUA


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.


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



MEMBRANEMEMBRANA

BYPASS

BILGE WATER INLET

DE SENTINAS


ENTRADA AGUA


OPERATION MODE

MAN

MODO OPERACION

ON

PUMPBOMBA

AUTO

0



MEMBRANEMEMBRANA

BYPASS

BILGE WATER INLET

DE SENTINAS


ENTRADA AGUA



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


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


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.



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

- 25 - Facet Oil Water Separator CPSB MKIII + EBM14x

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


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



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


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



The level relay does not work correctly


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


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.


PPM Alarm (By Customer requirements)

DESCRIPTION MANUFACTURER CODE FACET

OMD 2005 DECKMA HAMBURG 79510005

SMART BILGE RIVERTRACE 79520010

BILGMON 488 BRNNSTRMS ELEKTRONIK AB 79560000


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


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


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.



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



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



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


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


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

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s irr

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arly

the

conv

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ty is

not

ac

hiev

ed

pres

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is

not

ach

ieve

d

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p do

es n

ot s

tart

pum

p ha

s se

ized

or h

as

stop

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conv

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erat

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oisi

ly

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mes

to

o w

arm

the

stat

or w

ears

ou

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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


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


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

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

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