INSTALLATION MANUAL WAVE 6000 - mdavisgroup.com

NC HYPERBARIC S.A.

CONDADO DE TREVIÑO 6, POLÍGONO INDUSTRIAL VILLALONQUÉJAR

09001 BURGOS. ESPAÑA - SPAIN Tel: +34 947 473874 Fax: +34 947 473531

www.nchyperbaric.com [email protected]

15/02/2011

Y:\Comercial\Ingeniería\Máquinas\Manuales WAVE-6000\02-English_Installation manual HPP equipment WAVE_6000_v13.doc

INSTALLATION

MANUAL

WAVE 6000

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Installation manual.

Index.


INDEX.

1. CIVIL WORKS ........................................................................................................... 3

1.1. Foundations ..................................................................................................... 3

1.2. Hydraulic civil works. ..................................................................................... 5

1.2.1. Drainage. .................................................................................................. 5

1.2.2. Water intake. ........................................................................................... 5

1.3. Electrical civil works........................................................................................ 5

2. CONNECTIONS. ....................................................................................................... 6

2.1. Water connections. ......................................................................................... 6

2.1.1. Water connections for the main tank of the machine. ....................... 6

2.1.2. Water connections for intensifier tanks. .............................................. 7

2.2. Cooling connections ....................................................................................... 8

2.2.1. Open circuit water cooling. .................................................................... 8

2.2.2. Closed circuit water-glycol cooling ....................................................... 8

2.3. Compressed air connection. .......................................................................... 9

2.4. Electrical connections. .................................................................................. 10

2.4.1. Electrical panel power supply. ............................................................. 11

2.4.2. Double intensifier power supply. ........................................................ 12

2.5. Hydraulic oil .................................................................................................. 13

3. OTHER INSTALLATIONS. ...................................................................................... 16

3.1. Teleservice ..................................................................................................... 16

4. LOADING, UNLOADING AND INTERNAL TRANSFER. ....................................... 18

4.1. Loading and unloading. ............................................................................... 18

4.1.1. Transport of the machine in a wooden box: ...................................... 19

4.1.2. Transport of the machine in a container: ........................................... 22

4.1.3. Handling of the vessel: ......................................................................... 23

4.1.4. Transfer via the inside. ......................................................................... 24

5. TOOLING LIST FOR INSTALLATION .................................................................... 25

5.1. Elements to raise and move loads ............................................................... 25

5.2. Assembly tooling .......................................................................................... 26

6. LIST OF SERVICES / CONSUMPTION ................................................................... 27

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Civil Works.


1. CIVIL WORKS

The installation of a high pressure machine starts by fitting out the site which has been set aside for it.

Firstly, it must be ensured that the room where it is to be installed is of sufficient size for the location of the machine and its subsequent handling. Therefore, not only the dimensions of the machine are important, but also the spaces set aside for handling, shipment and the passing of personnel. To avoid further problems during installation, a lay-out of the workshop will be supplied to N.C.Hyperbaric and also a drawing of the accesses the machine will need to go through. The technicians responsible for the installation will review all data to foresee and prevent any problem.

It will also be necessary to respect the spaces set aside for installation and fine tuning by the installation personnel, as well as the spaces required for its subsequent maintenance.

A series of alternatives are offered by Technical Office in terms of the layout of spaces for each individual customer. To this end, a plan will be drafted which may implement such layout in terms of space.

In addition to the location of the machine, it will be necessary to define the civil works which its installation will entail. The civil works will be determined by the type of machine and its requirements with regard to water supply, electrical power supply and surface resistance, etc. All these aspects of civil works are detailed in the following subsections.

1.1. Foundations

The foundations are the element which provides suitable resistance to the surface that bears the weight of the machine. The following table shows the approximate weights of the WAVE 6000 machine models, in which weights of the peripheral devices and intensifiers have been excluded as, at first, they are installed outside the foundation.

WAVE 6000 Weight

W-420 72 Tn

W-300 62 Tn

W-135 45 Tn

W-120 30 Tn

W-55 20 Tn

Table of weights on the foundations

These weights rest on the floor by means of six supporting feet arranged in two rows of three feet each. This configuration makes easier the cleaning of the lower part of the machine.

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Civil works..


In the case of the large WAVE-420, WAVE-300, WAVE-300-T and WAVE-135 models, it is essential to prepare the floor with proper foundations. In the case of the WAVE 6000/55 model, it would not in principle be necessary to prepare a special floor, as a normal industrial floor would bear the weight of the machine. Notwithstanding, it is necessary to study each case on an individual basis.

Example of civil works plan: Foundations.

Close-up of foundations.

The type of foundations suggested for the large WAVE-420, WAVE-300 and WAVE-135 models consists of:

A layer of reinforced concrete of 300 mm (11.8”) in thickness and quality of at least HA25.

Two reinforcing bars which each consist of Ø 12mm (0.47”) of 300x300 (11.9”x11.9”)steel mesh.

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Civil works..


This layer should lay down on compact land.

The dimensions may be seen in the foundations plan which will be handed over to the customer, so that everything may be prepared prior to installation of the machine.

1.2. Hydraulic civil works.

1.2.1. Drainage.

The drainage required for the installation of these machines is mainly of two types:

Drains.

Channels.

The drains will be arranged where the surplus water, the excess water and the water originating from losses need to be drained away. Thus, it will be necessary to fit drains close to tanks, intensifiers and at the entry and exit of the product which needs to be treated, etc.

The drains are part of the drainage system of the room where the machine is installed. They will comprise a pipe with Ø40mm (1.6”) nominal diameter and will convey the water either to the sewage collection circuit or to the nearest channel.

The channels also form part of the drainage system of the machine room. It is therefore necessary for the floor to have a small, suitable (approximately) 1º slope so that the water may flow into it. The area of reinforced concrete foundations shall be left flat and levelled out.

The water collected by the drains and channels must be conveyed to the sewage line. In principle, the room where the machine is installed will be equipped with its own infrastructure as regards the collection and recovery or elimination of water and, therefore, each installation must be fitted out under these circumstances.

The positions of the drains and channels suggested by NC Hyperbaric may be seen in the foundations plan.

1.2.2. Water intake.

The civil works involved in the installation of WAVE 6000 machines must include water connections. The components which must be fed with water are the deposits which, in turn, supply water to the low pressure circuit of the machine and to the intensifiers.

The civil works corresponding to the hydrants must be able to provide the fitter with a suitable hydraulic connection in the position required. This position may be seen in the foundations plan supplied by NC Hyperbaric.

1.3. Electrical civil works.

Another part of the civil works is that corresponding to the electrical energy supplied to the machine and other peripheral equipment (intensifiers, pumps, etc.). To this end, it is necessary for the customer to arrange electrical connections in the required positions.

Once again, the position of these electrical connections is detailed in the foundations plan of the machine.

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Connections.


2. CONNECTIONS.

The type of general connections required for the proper functioning of the machine are detailed in this section.

2.1. Water connections.

Water is the fundamental element in the functioning of the WAVE 6000 machine. Treatment of food products is carried out by pressurizing that water.

The need to have available different water connections was already mentioned in section 1.2. In this section, we are going to deal with the types of connection required, according to use and WAVE 6000 machine model.

2.1.1. Water connections for the main tank of the machine.

The main tank houses the machine’s water supply. This water is that which is inserted in the vessel where the product is treated. Liquid decantation is carried out thanks to a hydraulic pump fitted in the low pressure unit of the machine itself.

This tank will be equipped with a mains water-filling connection. The circuit has a 1” female end for its connection; therefore, a 1” male end must be used for connecting the mains to the tank. The filling system of this tank is carried out from the upper part and is equipped with an electrovalve that regulates the opening of the passing of water.

There are outlets on the upper part of the tank, one for draining and the other for cleaning. These must be put in contact with the main drains, which is why they both have 1½ ’’ ends.

If the tap water has the required quallity for the intensifiers, this same connection will be used to supply water to the intensifiers tank.

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Connections.


2.1.2. Water connections for intensifier tanks.

In principle, the water supply of the intensifiers comes from an accumulator tank, from which a hydraulic pump decants the water required with sufficient flow and pressure.

The filling system of this tank is similar to the previous one; therefore, a water feed will be required using a 1” male end. Likewise, the tank has two outlets, one for draining and the other for cleaning, which are connected using 1½ ’’ ends.

It is essential that the water pumped by the intensifiers needs some type of prior treatment (such as decalcification). The recommended water properties are as follows:

Chloride in the form of Cl (mg/l) < 30

Free chlorine (mg(l) < 1

Iron in the form of Fe (mg/l) < 0.1

pH value 6.5 – 8.5

Total dissolved solid (mg/l) 200>TDS> 5

Total hardness in the form of CaCO3 (mg/l) 1 - 25

Min/Max input temperature (ºC) 5 - 30

Electrical conductivity at 25º C S 50 - 300

Table of water properties.

It will also be absolutely necessary for the water not to have been subjected to any osmosis or deionisation process.

It will be asumed thay the tap water meets all the requirements. Therefore, the machine will have just one water connection that will internally fork to feed the main tank and the intensifiers tank, and in some cases the cooling of the intensifiers.

If the customer says that the water does not meet all the requirements of the intensifiers and needs to be treated, the machine will have 2 connections. The main tank will be fed with tap water and the intensifiers with treated water. The connection will be the same kind as the one for the main tank.

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Connections.


2.2. Cooling connections

Intensifiers heat the oil while working. For that reason this oil needs to be cooled. Besides, some customers need that the process water remains between some certain values. In both cases this installation will be a responsibility of the customer.

2.2.1. Open circuit water cooling.

When only the hydraulic oil of intensifiers needs to be cooled, the solution can be the use of tap water in open circuit. After cooling, the water is thrown away to the drainage. If this is the required solution, the connection for the main tank will be used. An internal fork will be used to supply the requirede flow. The real water consumption will depend on the room temperature, the number and type of cycles, the tap water temperature…

The water requirements of this connection are:

Pressure > 3 bar (44 psi).

Water temperature lower than 20ºC (68ºF).

See 6. List of services / consumption.

The following chart can be used as an approximate data for the cooling installation of each double intensifier:

Cooling power (kW) [HP]

Temperature of the inlet water (ºC) [ºF]

Water flow (l/min) [gal/min)

OPTION 1 26 kW [35HP] 15 ºC [59 ºF] 43 l/min [11 gallons/h]

OPTION 2 26 kW [35HP] 10 ºC [50ºF] 24 l/min [6 gallons/h]

OPTION 3 26 kW [35HP] 5 ºC [41ºF] 17 l/min [4 gallons/h]

2.2.2. Closed circuit water-glycol cooling

Pumping a water-glycol mixture in a closed circuit can be another possibility to cool the oil of the intensifiers. This fluid could come from the cooling installation of the plant, or the customer could install a chiller for this purpose.

This solution needs to be used when also the temperature of the process water wants to be controlled.

Depending on the model, the machine has different elements:

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Connections.


Wave 6000-55, Wave 6000-135 and Wave-300.

The main tank of these machines is equipped with cooling coil, an electrovalve, and a temperature probe. The rest of elements and their installation will be responsibility of the customer. The inlet and the outlet of the cooling coil have two male connections of ½”.

Wave 6000-420.

This model has a more complete system. It is equipped with a plate heat exchanger, a motor-pump, a filter, a temperature probe and the electro-valves required to control the flow of the coolant. It will be used to cool the oil of the intensifiers and also to keep the temperature of the main tank under control. The inlet and the outlet of this circuit have two male connections of 1”. It is recommended using water with propilen glycol (concentration of 25%), with an inlet temperature between -4ºC and -2ºC (25ºF and 28ºF) and an aproximate flow of 3.000 l/min (792 US liq.gal/min).

2.3. Compressed air connection.

All WAVE 6000 models require a compressed connection in order for some of their components to function. Specifically:

To drive the stop cylinder from the entry of the product.

For driving the pneumatic valves.

An air connection of P > 6 bar connection of Ø 8 mm must be made available for all of them in the electrical cabinet, where all pneumatical control in placed.

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Connections.


2.4. Electrical connections.

WAVE 6000 machines require a series of tapping points in order for them to function. The differences between the large models (WAVE-300 T, WAVE-300 and WAVE-135) and the small model (WAVE 6000/55) are once again evidenced as regards their electrical power supply, as the small model is monobloc and includes the intensifier. Power consumed by the machine and by each intensifier may be seen in the following table:

Model Panel Power - kW (HP) Double Intensifier Power - kW (HP)

Wave 6000 / 55 51 Kw (69 HP) --

Wave 6000 / 120 99 Kw (135 HP) --

Wave 6000 / 135 10 kW (14 HP) 93 kW = 2x45 kW + 3 kW

(126 HP = 2x61 HP + 4 HP) Wave 6000 / 300 10 kW (14 HP)

Wave 6000 / 420 13 kW (18 HP)

The total power supply of the machine logically depends on the No. of intensifiers:

Model Number of Intensifiers Total Power - kW (HP)

Wave 6000 / 55 1 51 kW (69 HP)

Wave 6000 / 120 2 99 kW (135 HP)

Wave 6000 / 135 Wave 6000 / 300

2 103 kW (140 HP)

4 196 kW (266 HP)

6 289 kW (393 HP)

Wave 6000 / 420 8 385 kW (523 HP)

These charts show the nominal power of the electrical motors. In certain moments of the cycle, these motors can work with peaks over the nominal power. The motors of the intensifiers have a nominal power of 45 kW, with a sequential Y-Δ (wye-delta) start of two 3 phase, 45kw, type F motors. Bear it in mind to size the main circuit breaker. The design of this installation should be made according to this value and the aplicable regulations.

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Connections.


2.4.1. Electrical panel power supply.

The WAVE-135, WAVE-300 and WAVE-420 models require a power supply of less than 13 kW (18 HP) in the electrical cabinet (double for the Tandem machine). The connection required consists of a three-phase line without neutral and with grounding. In the following figure is shown the terminal board corresponding to a WAVE-300 in which the connection is made to the electrical panel of the machine (the connection will correspond to the 4 terminals on the left: grounding and three phases respectively).

Terminal connection to power supply of machine

WAVE-300.

The power supply required for the WAVE 6000/55 and WAVE 6000/120 models is substantially greater, 51 kW (69 HP). Power is once again supplied by means of a three-phase line without neutral and with grounding.

The WAVE 6000/55 model has the peculiarity of being a piece of monobloc equipment and the intensifier is therefore incorporated into the machine itself. This intensifier needs to be driven by a hydraulic unit which is responsible for increasing the connection power of the electrical panel in relation to other models.

Terminal connection to power supply of machine WAVE 6000/55.

The terminal boards of the WAVE-420, WAVE-300 and WAVE-135 waves enable section cables of up to 16 mm2 (0.025inch2) to be fitted and, in the case of the WAVE 6000/55 and WAVE 6000/120, this section is 35 mm2 (0.04inch2). Nevertheless, the choice of specific cable section will be the customer’s responsibility, as there exist differences in each country in terms of regulations of this type of installation and also in voltage and frequency.

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Connections.


2.4.2. Double intensifier power

supply.

Only the WAVE-135, WAVE-300, WAVE-420 models require peripheral intensifier equipment. As has already been mentioned, the WAVE 6000/55 and WAVE 6000/120 model is equipped with an intensifier incorporated into the machine.

The intensifiers are separate pieces of equipment responsible for generating high pressures in the product treatment vessel. The electrical power supply required by each double intensifier is supplied by means of a three-phase line without neutral and with grounding with a power of 2 x 45 + 3 = 93 kW (2 x 61 HP + 4 HP = 126 HP)

Double intensifier.

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Connections.


2.5. Hydraulic oil

The customer should have the hydraulic oil shown in the following table, to fill the tanks of the machine and intensifiers during the installation.

Wave-55 Wave-120 Wave-135, Wave-300 or Wave-420 300 litres (79 gallons)

500 litres (132 gallons)

500 litros per double intensifier (132 gallons)

The use of premium quality mineral-oil based hydraulic oils such as HLP oils (additives for high pressure) pursuant to the DIN 51 524 standard, chapter 2 is recommended. These are high-performance anti-wear hydraulic fluids with an excellent viscosity-temperature ratio and high filtering quality which are suitable for all types of pumps. Normally, additives are included to enhance the anti-foam, anti-combustion and anti-corrosive properties.

Viscosity/Temperature

The normal service viscosity required for hydraulic operation of the Wave HPP machine is 46 mm^2/s (cSt) pursuant to the ASTM-D 445 standard, bearing in mind that the fluid temperature affects the viscosity (viscosity index). Anything higher than 320 mm^2/s is not recommended to avoid problems during cold start. The chart below serves as a guide to choose the best product (approximate values).

Minimum ambient temperature

Kinematic viscosity at 0ºC

Kinematic viscosity at

Kinematic viscosity at

Viscosity index

>10ºC 500 42-50 6.8-8 120

<10ºC 320 42-50 10.5-13 182**

*Maximum operation temperature of the system is 60ºC

**Normally, NAS7 is difficult to achieve in high viscosities (please consult

Hyperbaric/Desmasa)

Degree of Cleanliness

The purity of the hydraulic fluid of the system is extremely important. For that reason, the system has been provided with a highly effective filtering system (auxiliary bypass system + additional pressure filtering for proportional valves). In order to optimise the life span of the filters and to avoid problems after start-up, it is recommended that the chosen fluid meets the following cleanliness parameters:

ISO 4406 cleanliness code: 17/15/13

Particle count summary:

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Connections.


Size Particle count per ml

ISO 4406 Code. NAS1638 (approx) (SAE AS4059)

>4 µm (c) 640-1300 17 7

>6 µm (c) 160-320 15 7

>14 µm (c) 40-80 13 7

*The ISO code refers to a particle count greater than 4.6 and 14 µm (c) in one ml of

sample fluid.

Compatibility with hydraulic seals

The material used on hydraulic seals of the system of the machine, such as NBR, EPDM or VITÓN are compatible with any type of HLP anti-wear hydraulic oil. It is recommended to check this parameter in the technical documentation of the product prior to acceptance.

Food option

The client can decide on using a product compatible with the food industry depending on the type of process and internal specifications. However, the food option should not be detrimental to the above-mentioned parameters. Due to this new interest of present-day industry, there is a new generation of synthetic food oils based on polyalphaolefin, which are highly recommended as hydraulic oils. Moreover, these oils exceed requirements of the DIN 51 524 standard part 2 for HLP oils.

These are transparent liquid lubricants, which are biologically inert and certified to NSF H1 as they are manufactured fully compliant with the FDA requirements (a US Agency for Food and Drug Control) for applications in which an incidental contact with a food product is possible.

Its properties are excellent:

- Rust proof

- Excellent behaviour in extreme temperatures

- Trouble-free cold start-up because of its natural high viscosity index

- Entirely miscible with mineral oils

- The transformation from a mineral oil to a synthetic food does not take place over several stages, there are no undesired reactions, and material and seals of the mechanisms are not affected.

- Up to 2% of water may be absorbed without it affecting the properties.

The use of mineral white oil is not permitted on the hydraulic system of the machine.

Recommended brands

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Connections.


o Room temperature >10ºC

-Renolin HM 225 (HLP 46) by FUCHS (http://www.fuchs-oil.de/home_en.html)

-Tellus 46 (HLP 46) by SHELL (http://www.shell.com/)

-Hydraulic Oil AW 46 (HLP 46) by TEXACO (http://www.texaco.com/)

-Hydrex AW 46 (HLP 46) by PETRO-CANADA (http://www.petro-canada.ca)

o Room temperature <10ºC

-Renolin B 520 (HLP 46) by FUCHS (http://www.fuchs-oil.de/home_en.html)

-Tellus T 46 (HLP 46) by SHELL (http://www.shell.com/)

-Mobil DTE 25 (HLP 46) by ESSO (www.mobil.com)

-Rando HDZ 46 (HLP) by TEXACO (http://www.texaco.com/)

o Food option

-Geralyn SF 46 by FUCHS

Any alternative employed by the final customer shall be studied and assessed by the manufacturer of the unit. A copy of the technical documentation of the oil to be analysed must be included.

http://www.fuchs-oil.de/home_en.html

http://www.shell.com/

http://www.texaco.com/

http://www.petro-canada.ca/

http://www.fuchs-oil.de/home_en.html

http://www.shell.com/

http://www.mobil.com/

http://www.texaco.com/

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Other installations.


3. OTHER INSTALLATIONS.

There exist other possibilities available to the customer as regards the auxiliary installations of the WAVE 6000.

3.1. Teleservice

The teleservice enables a specialist technician to assist a customer remotely thanks to an Internet connection.

The teleservice installation is very useful for assisting in all types of problem. It is of special interest during the first months of life of the machine, during its period of maturing, as this is when the machine requires the most adjustment.

Therefore, in the case of customer approval, it would be essential for the fitter of the WAVE 6000 to have an IP connection prior to installation which must be prepared by the customer itself. The position of this connection will be implemented in the plan issued by Technical Office.

The NC Hyperbaric machine has a router installed so that the ethernet network used for connecting the different devices of the machine and the customer’s network are separated completely. The customer’s network will only be used for getting internet access for the machine. This router will automatically establish a VPN connection to a server located at NC Hyperbaric’s premises which will allow technicians access the machine remotely.

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Other installations.


The internet connection may be done using the customer’s internet access or either using a separate DSL connection. In any case, the customer must install a shielded ethernet cable with the IP address, subnet mask, default gateway and DNS configuration for that router.

A proper connection will ensure an effective after-sales service. The connection must be ready when the technicians from NC Hyperbaric arrive for the installation of the machine.

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Loading, unloading and internal transfer.


4. LOADING, UNLOADING AND INTERNAL TRANSFER.

4.1. Loading and unloading.

Depending on the weight and volume of each machine, it is dismantled in a series of parts in order to be dispatched. In the following table may be seen one of these parts with the weights of the main elements. Logically, the total weight of the machine depends on the “N” number of intensifiers. The handling and shipment procedures for the most awkward parts are then specified afterwards:

Model PART 1 PART 2 PART 3 PART 4 TOTAL

Wave 6000 / 55

The whole machine 19.5 Tn

--- --- Feeders 0.5 Tn

20 Tn

Wave 6000 / 120

Yoke + Beds + Plugs + Wedges 20 Tn

Vessel + Cradles 9 Tn

--- Feeders 1 Tn

30 Tn

Wave 6000 / 135


Vessel + Cradles 8.5 Tn

Double Intensif. N = (1 ÷ 2) N x 2.5 Tn

Feeders Enclosure. 1 Tn

48 ÷ 50 Tn

Wave 6000 / 300



Double Intensif. N = (2 ÷ 4) N x 2.5 Tn


70 ÷ 75 Tn

Wave 6000 / 420



Double Intensif. 4 x 2.5 Tn


82 Tn

i-Wave 6000 / 420



Double Intensif. 4 x 2.5 Tn

Feeders Enclosure + Platform 7 Tn

87 Tn

Machine weights

These weights refer to the machine once it is outside the packaging. For handling prior to taking out the machine, the weight of the packaging itself must be taken into account, both in the case of its being shipped in wooden packaging and in a container:

Modelo Wooden packaging 40-feet container: 4 Tn 20-feet container: 2.5 Tn

Wave 6000 / 55 --- Parts 1+4 ---

Wave 6000 / 120 --- Part 1 Parts 2+4

Wave 6000 / 135 Part 1: 3 Tn --- Parts 2+3+4

Wave 6000 / 300 Part 1: 4.5 Tn Parts 2+3+4 ---

Wave 6000 / 420 Part 1: 4.5 Tn Part 2

--- Parts 3+4

i-Wave 6000 / 420 Part 1: 4.5 Tn

Part 2

--- Part 3

Part 4

Packaging weights.

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As regards loading or unloading, below is described how this must be properly done. Handling of feeders, intensifiers, enclosure and other accessories do not entail any complications. In any case it is advisable that staff from N.C. Hyperbaric takes part

in this handling.

4.1.1. Transport of the machine in a wooden box:

Not handling the wooden box in a proper way, can be a risk for the people and also for the own machine. Therefore, these operations will be carried out very carefully, following the instructions:

The lifting of the wooden box must be made slipping a chain through the steel profiles under the box (the wooden box shows red paintings to avoid any mistake) and holding the chains from 2 lifting beams. As shown in the following picture, the load will be well balanced:

These lifting beams will be held from a crane with enough capacity according to the chart of weights. As a result of trying to lift this load in any other way, the box could fall or break, being a risk for people and materials.

The wooden box has some eyebolts to avoid the movement of the load during truck or ship transport:

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Using these eyebolts to lift the load would involve breaking the box and damaging the machine.

When the truck with the box arrives to the door of the plant, the roof of the wooden box and also the walls will be unassembled. To do that, there is no need to unload the box from the truck. All the parts that come with the machine will be unloaded.

The 4 nuts that fix the floor of the wooden box to the machine will be removed and finally the machine will be lifted with the crane. In some cases is not easy to remove these 4 nuts. In these cases, the machine and the floor will be lifted. Then, some wooden blocks will be placed on the ground, and the machine will be lowered up to a point where the floor of the wooden box rests firmly on the blocks. Of course, the machine will remain held from the crane. In this position the 4 bolts can be removed easily. The floor of the wooden box will rest on the blocks and the machine will be lifted alone.

The machine will be lifted using 4 slings of the same length. They will be place around the 4 big upper nuts of the machine and some bars will be used to avoid the sling to slip out of the nuts, as shown in the following picture.

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In Wave 6000/55 model, the lifting beams are supplied with the machine to avoid any damage on the protections. For the rest of models it will not be necessary. A wooden block can be placed to avoid that the slings cause any damage on the upper elements of the machine.

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4.1.2. Transport of the machine in a container:

When the machine in shipped in a container (Wave 6000/55, Wave 6000/120) the procedure will be similar to the previous case. With the container on the platform of the truck, the roof will be removed. All the parts that come with the machine will be unloaded using the crane. Finally, the machine will be unloaded following the same procedure previously described:

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4.1.3. Handling of the vessel:

Vessels of machines Wave-135 Wave-300, Wave-420 will be shipped apart from the rest of the machine, because the whole weight would be too much. To unload from the container the procedure will be as shown in the following picture:

It is important that the slings go around the vessel but not the longitudinal tubes to avoid their bending (as shown in the picture).

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4.1.4. Transfer via the inside.

Transfer of the WAVE 6000 via the inside of a customer’s installations is carried out by means of some skates capable of bearing the weight of the machines (consult table of weights in section 4.1). It is important placing some wooden blocks between the skates and the yoke so as not to let the weight of the machine rest on the stainless steel skin of the yoke, because it could get damaged.

Movement of the machine on skates.

The skates must be arranged in the correct position after lifting the machine from the floor using hydraulic jacks.

To pull the machine so as to roll the skates, a fork lift with enough power will be needed. If the floor can be damaged, it is advisable to place some steel plates on the floor to make a path. Skates will roll on this path.

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Tooling list for installation.


5. TOOLING LIST FOR INSTALLATION

Some tooling will be required to install the machine in the customer’s house. The customer will ensure they are available during installation.

5.1. Elements to raise and move loads

Crane suitable for the loads specified in a previous point. The distance between load and crane will be given to the supplier to calculate the necessary size of the crane. This crane will be equipped with slings, wooden blocks, etc.

Suitable skates for the load specified in a previous point, will be used to move the machine inside the workshop.

For loading and unloading the machine from the skates inside the facility they will be necessary two bottle shaped hydraulic jacks. Depending on the machine size, these jacks need to be bigger or smaller.

They also be used some wooden plugs in order to make the hydraulic jacks fit the correct size.

To pull the machine a powerful forklift (of at least 2 Tn) will be needed. The required power will depend on the size of the machine to install, and also on the slope of the floor.

To avoid any damage on the floor of the workshop, it is convenient to lay some steel plates to make a path for the skates to roll on. These plates should be at least 2 mm (1/16”) thick. 50 mm (2”) wider than the width of the skates and at least 20 m (65 feet) of total length in parts of about 1.5 m (5 feet).

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Tooling list for installation.


5.2. Assembly tooling

The standard required tools to assembly the machine can be seen in the following picture. They will be supplied by the customer for assembling the machine and will be also useful for future maintenance operations.

N.C. Hyperbaric will also supply with the spares of the machine, some specific tooling for the maintenance of the equipment.

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List of Services / Consumption.


6. LIST OF SERVICES / CONSUMPTION

Type

Specification Consumption Height above the

floor

W- 55 W-120 W-135 W- 300

W- 420 W- 55 W-120 W- 135 W- 300 W-420

1 Electrical Energy Box of Machine

51 Kw

(69HP)

99 Kw

135(HP)

10 Kw

(14HP)

13 Kw

(18HP) 2 kW-h / cycle 4.5 kW-h / cycle 5 kW-h / cycle 11 kW-h / cycle 15 kW-h / cycle

---

2 Electric Energy Box of each Double Intensifier (I)

--- 93 kW (126HP) ---

3 Internet connection

4 Compressed air Connection Ø 8 mm; P > 6 bar (87psi) Average Consumption: 20 l/h; Max: 100 l/h ---

5 Water for the main tank Connection F 1”; P > 3 bar (44psi) Average Consumption: 0 l/h; Max: 1,000 l/h 2.1 m (7’)

6 Water for the intensifiers (II) Conexión F 1”; P > 3 bar (44psi) A.C: 78 l/h

Max: 1,000 l/h A.C: 156 l/h

Max: 1,000 l/h A.C: 182 l/h

Max: 1,000 l/h A.C: 369 l/h

Max: 1,000 l/h A.C: 517 l/h

Max: 1,000 l/h ---

7 Cooling fluid for the main tank (III)

Conexión F 1/2” P > 3 bar (44psi)

Con. F 1”; P > 3 bar (44psi)

(V) 2.2 m (7’)

8 Cooling fluid for the intensifiers (IV)

P > 3 bar (44 psi); Temp.<20ºC (68ºF) (VI) ---

9 Drainage for the main tank Ø 50 mm 66 l/h (17gal./ h) 144 l/h (38 gal./ h) 165 l/h (44 gal./ h) 360 l/h (95 gal./ h) 504 l/h (133gal./ h) 0

(I) One intake for each “N” double intensifier fitted. (II) Treatment time: 3 min at 6,000 bar (87.000 psi), each machine with its standard configuration. (III) Optional if the temperature of the water process needs to be controlled. Tap water or glicol can be used, depending on the target temperature, and inlet cooling temperature. (IV) Tap water or glicol can be used. This cooling fluid can be installed directly on each double intensifier (pipe Ø16 mm), can be taken from the main tank supply (if tap water is used), or can be taken from the main tank cooling. (V) Consumption depends on the diferent temperatures (target temperature, inlet temperature, room temperature…). (VI) Consumption depends on the diferent temperatures. If tap water is used, in the following chart, some aproximative values for each double intensifier can be found:

Double intensifier cooling

Heat Load (Kw) Inlet water temp.

Water Flow Rate (l/min)

26 (35HP) 15 ºC (59 ºF) 43 l/min (11 gallons/h)

26 (35HP) 10 ºC (50ºF) 24 l/min (6 gallons/h)

26 (35HP) 5 ºC (41ºF) 17 l/min (4 gallons/h)

Documents

INSTALLATION MANUAL WAVE 6000 - mdavisgroup.com