Rwo DEB 0.1, Installation, Operating And Maintenance Manual

Page 1: ...erating and maintenance manual SKIT S DEB 3rd print version RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 Installation operating and maintenance manual SKIT S DEB acc to IMO Resolut...

Page 2: ...013 by RWO GmbH Bremen Germany All rights reserved The contents of this manual are copyrighted Without a written approval by RWO GmbH the manual must not be partially or in full duplicated circulated...

Page 3: ...3 2 Standard scope of delivery 16 3 3 General function and proper use 17 3 4 Excerpt from the IMO Resolution MEPC 107 49 18 3 5 MARPOL 73 78 Annex I 18 3 6 Regulation 16 5 18 3 7 MEPC 107 49 19 3 8 E...

Page 4: ...uctural measures to prevent sea pollution by oil 32 4 3 Adsorption 32 4 4 Emulsion 32 4 5 Coalescence 32 5 Storage 33 5 1 Transport 33 5 2 Unpacking 33 5 3 Storage 33 5 4 Packaging disposal 34 5 5 Saf...

Page 5: ...64 11 5 1 Mounting the coalescer package for oil separators up to 2 5 m h 65 11 5 2 Mounting the coalescer package for oil separators 5 0 m h and 10 0 m h 65 11 5 3 Mounting the oil separator lid 66 1...

Page 6: ...ates 29 Tab 9 Supply unit consumption list 36 Tab 10 Valve terminal 38 Tab 11 Component overview of control box 42 Tab 12 Component overview installation scheme 44 Tab 13 Process overview 48 Tab 14 Me...

Page 7: ...age 7 Contents RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 Fig 10 Control box 42 Fig 11 Installation scheme 44 Fig 12 Delivery condition 63 Fig 13 Cap 63 Fig 14 Non return flap 64...

Page 8: ...drawings 1 2 Location of the manual A copy of the manual must be kept easily accessible for the operating and supervising staff 1 3 Use of these documents Descriptions are given in the running text En...

Page 9: ...wo veoliawater com Spare parts service 49 421 53705 228 49 421 53705 442 spares rwo veoliawater com Sales 49 421 53705 213 49 421 53705 445 sales rwo veoliawater com Internet www rwo de Postal address...

Page 10: ...ctional condition only The safety devices should be checked regularly to ensure correct function Required personal protection equipment PPE is available and used when required The operation instructio...

Page 11: ...t in most severe or fatal injuries CAUTION CAUTION denotes a potentially dangerous situation Non observance of the instruction can cause injuries IMPORTANT Denotes important information and steps non...

Page 12: ...g maintenance Ensure the intervals and activities for inspection and maintenance are observed as stated in the operating instructions Observe maintenance and repair instructions regarding the single c...

Page 13: ...ter endangering materials such as lubricants and oils hydraulic oil coolants acids and lyes cleaning agents are not to be discharged into the soil or the drain These substances must be collected in su...

Page 14: ...areas WARNING The bilge water oil separator operates with an eccentric spiral pump Do not put your hands into the area of the transmission bell housing stuffing box packing at the rotating shaft Dange...

Page 15: ...i o n 3 1 Component overview Fig 1 Component overview Pos Description 1 Non return valve 2 Power supply 3 Control box 9 Sensor electrode 10 Electric heating 2KW 11 Orifice 12 Safety valve 1 1 bar 14 M...

Page 16: ...1 Vacuum pressure gauge 1 5 bar coalescer input 8 2 Vacuum pressure gauge 1 5 bar coalescer output 17 1 Oil monitor OMD 17 2 Measuring cell 25 3 way ball cock 36 Pressure gauge of pressure reducer 37...

Page 17: ...manually using a switch Fig 10 Control box The first stage is equipped with a drain valve pos 27 and a pressure reducer valve pos 36 Optionally the oil separator system can be equipped with a steam or...

Page 18: ...t in a vaporiser chemical processes by using an adequate coagulation agent membrane ultrafiltration which retains the oil molecules adsorption by means of suitable materials 3 4 Excerpt from the IMO R...

Page 19: ...bilge water always present the 15 ppm Bilge Separator must be capable of separating the oil from the emulsion to produce an effluent with an oil content not exceeding 15 ppm Bilge Alarm 3 8 2 The 15...

Page 20: ...should be provided in a vertical section of the water effluent piping as close as is practicable to the 15 ppm Bilge Separator outlet Re circulating facilities manual 3 way valve should be provided af...

Page 21: ...aning agents under conditions that were as close to normal operation as possible From the vast range of cleaning agents on the market we tested some products out of which the following agents have pro...

Page 22: ...all external connections have to be made by the customer acc to the wiring diagram Pipe connections 3 14 3 Fig 4 Pipe connections Pos Description 4 Oil discharge 5 Flushing water outlet 6 Compressed...

Page 23: ...15 Operating instructions for programmable oil separator control Operation of the oil separator control involves 4 buttons The backlit display has two lines with 20 characters each The operational mod...

Page 24: ...ge indicates flushing in progress Green LED bilge level The green LED indicates that the level in the bilge tank is high and that the oil separator can start operation 10 4 Meaning of the message ligh...

Page 25: ...to the lighting conditions Fig 5 Potentiometer 3 16 Control functions Oil detection and oil discharge 3 16 1 In the upper calming zone of the oil separator the separated oil is collected The RWO level...

Page 26: ...w limit value 1 and limit value 2 The valve for sample water pos 57 is switched to guide the water upstream of the adsorber to the monitor The bypass valve pos 58 is switched to guide the water downst...

Page 27: ...es must be connected instead of the bridges Oil separation starts and the green LED bilge level illuminates when the bilge water level has reached the upper level switch When the bilge water level has...

Page 28: ...ches into standby mode and activates the alarm output Pressure difference switch Option 3 18 5 By factory default the terminals X2 11 and X2 12 NC are bridged The user can connect a pressure differenc...

Page 29: ...performance specifications for type approval of 15ppm bilge alarms Part 3 Specifications for environmental testing for type approval of pollution prevention equipment Part 4 Method for the determinati...

Page 30: ...g stress free and leak tight into the unit Cleaning facilities 3 21 4 Provide a fresh water connection at the unit and some space for doing simple investigations of the technical status of the unit Oi...

Page 31: ...1 3 Design and function RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 3 22 Noise The noise pressure level is below 80 dB A 3 23 Vibrations The unit is made and tested for the accele...

Page 32: ...OM Annex IV Regulation 4 Annex 1 4 3 Adsorption Adsorption from Latin adsorptio adsorbere suck in refers to the enrichment of substances from gases or liquids on the surface of a solid body or more ge...

Page 33: ...lifting use a crane crossbeam and sling only to the available lifting eyes X for the bilge water oil separator and the provided lifting eyes Z for the lid Fig 6 Lifting eyes X and Z 5 2 Unpacking Ope...

Page 34: ...ork free of tension The electric connections have to be carried out acc to the given wiring diagram 5 6 Installation The unit needs a flat surface which is big enough and stable The foundation must be...

Page 35: ...it is to be taken out of operation for a longer time switch off the system and open the covers of the coalescer container and the adsorber s Open the drain valves and clean the containers with freshwa...

Page 36: ...rk check water lines and make sure that they are not under pressure The standard system requires clean water with a pressure of between 1 and max 1 5 bar at the flushing water inlet valve pos 15 for t...

Page 37: ...voltage can destroy electric components All system parts are wired by factory default they are controlled and supplied via the automatic control box Standard systems operate on 3 phase alternating cu...

Page 38: ...0 Valve terminal Plug connections 6 5 1 For the plug in connections the hose lines must meet the following requirements Minimum hardness of 40 Shore D acc to DIN 53505 and or ISO 868 outer diameter ac...

Page 39: ...ided at all costs You can avoid this danger by ensuring that the rotational direction is correct The control system will only start the pump once the oil separator housing is filled with water Note Th...

Page 40: ...nd make sure that they are not under pressure The oil separator system requires clean water with a pressure of between 1 and max 1 5 bar at the flushing water inlet pos 15 chapter 3 14 3 for oil disch...

Page 41: ...d for fittings on the ship s side For operation of the SKIT S DEB no special fittings in the outboards line are required but the outboards outlet should be above the upper edge of the oil separator Re...

Page 42: ...tact with live parts may cause serious injury or death The fixed connection to the operating mains must only be done by trained specialists electrician Fig 10 Control box Pos Description 2S1 Heater 2S...

Page 43: ...he oil separator power The 4 LEDs in the control box door indicate the basic functions The oil sepparator system can be started and the operating modes selected via a main switch and a switch Hand Zer...

Page 44: ...2 Installation scheme suggestion Position list Pos Designation Flange connections 4 Oil discharge valve outlet R thread or DIN 2633 PN16 5 Flush valve outlet R thread or DIN 2633 PN16 21 Sieve basket...

Page 45: ...MD see P ID The adsorber elements remove all types of carbon hydrides from the water The adsorption capacity is mainly limited by the amount of dissolved or emulsified carbon hydrides in the water but...

Page 46: ...s The display of the control system indicates b Sample point exceeds the limit value of 15ppm 5ppm set for alarm 2 and sample point falls below the limit value of 14ppm 4ppm set for alarm 1 Operator w...

Page 47: ...e Oil content less than 14ppm 4ppm limit value 1 by factory default at the sample point downstream of the OWS upstream of adsorber 57 3 way valve in sample line Measurin g upstream of adsorber Voltage...

Page 48: ...gh performance coalescer is flushed with clean water by opening both the flushing water inlet valve pos 15 and the flushing water outlet valve pos 5 The oil separation interval and the flush cycle are...

Page 49: ...s the breaking of a seal The 15ppm Bilge Alarm should be so constructed that the alarm is always activated whenever clean water is used for cleaning or zeroing purposes The Bilge Alarm Monitor OMD com...

Page 50: ...in air will cause repetitive flushing processes This way the oil separator cannot draw any wastewater and thus cannot perform the water oil separation properly Check if bilge water is present 3 Note...

Page 51: ...at the shaft behind the shaft seal WARNING Do not put your hands to the rotating shaft in the area of the transmission bell housing stuffing box packing Danger of severe finger injury Check the pressu...

Page 52: ...l Therefore you should only select this mode if permanent monitoring is ensured Switch on the main switch POWER 1 The control light RED OILDISCHARGE lights up in red oil to the collector tank because...

Page 53: ...e Wastewater present Display of wastewater level If no floating switches must be connected you must bridge the corresponding terminals else automatic operation in the oil separator cannot start STATUS...

Page 54: ...ion display 10 5 2 After 3 seconds of showing the start message the operation mode automatically appears The operation display indicates the status of the control system Under normal conditions the op...

Page 55: ...IL DISCHARGE BETRIEB HAND SPUELEN OPERATION HAND FLUSHING Display only for oil separator with adsorber BETRIEB HAND ENTOELT MIT ADSORBER OPERATION HAND WATER PASS ADSORBER In the position Automatic th...

Page 56: ...ol unit first shows the start message and then switches to the operation mode By means of the menu control you can now call up other displays to query values or to modify parameters The menu control i...

Page 57: ...age selection 10 5 4 In the display language selection select English with the button and German with the button Confirm the selection with Enter and move on to the next main item in the menu structur...

Page 58: ...0 0111 00 The output image displays the state of the 10 output relays 0 indicates that the relay is switched off 1 means that the relay is switched off For better overview the 10 states are divided by...

Page 59: ...the menu and thus to the query if you want to change user settings If you select Yes here you jump back to the beginning of the user settings OEL ERKENNUNG AENDERN NEIN JA OIL IDENT MODIFY NO YES Note...

Page 60: ...ER IDENT VALUE 048 000 100 After entering the last digit and pressing the Enter button the display prompts for confirmation to save the new value OEL ERKENNUNG SPEICHERN NEIN JA OIL IDENT STORE NO YES...

Page 61: ...il separator would then permanently suck air These displays to select changes set values and save values are available for every user setting The only exception is the section Restore defaults WERKSEI...

Page 62: ...e stuffing box gland slightly see operating and maintenance instructions for the eccentric spiral pump section 2 3 If that does not cause the desired success you must replace the stuffing box packing...

Page 63: ...on regulations and the proper use of tools and lifting devices Note The following spare parts and tools should be at hand Coalescer key chapter 13 10 table 26 Lid seals pos 31 chapter 13 tables 18 25...

Page 64: ...d valves pos 4 The valve should remain screwed to the ship s pipeline Disconnect flange or sleeve connection between lid 9 and valves pos 5 The valve should remain screwed to the ship s pipeline Unscr...

Page 65: ...coalescer cross from below out of the oil separator Clean the inside of the oil separator container 20 Mounting the coalescer package for oil separators up to 2 5 m h 11 5 2 Remove circlip from the di...

Page 66: ...ews and tighten by 2 hand Connect valves with pipelines and tighten screws or 3 screw connections In the first two turns tighten the screws of the oil 4 separator lid by half a turn each In all other...

Page 67: ...lift them out Then pull the plug stuff by turning it out of the plug and place it aside for reuse If present take the plugs of the second plug level 4 one by one on the cap turn and pull up until it i...

Page 68: ...ffs and the 8 remaining fastening screw Screw the wing nut onto the third fastening screw 9 Tighten all three wing nuts by hand 10 Close adsorber housing 11 6 4 Place new lid seal onto flange and alig...

Page 69: ...sue 2014 04 10 11 7 Replacing the solenoid valves To dismount the solenoid valve undo the screws and pull out the solenoid valve element towards the front To mount the solenoid valve insert the replac...

Page 70: ...e closed by means of a pre tensioned spring On dismounting the valve drive the spring can eject forcefully and cause injuries CAUTION The oil separator can be heated by a heater electrically or e g by...

Page 71: ...d rotor if necessary Pump shaft blocked Loosen stuffing box Piston valves do not operate Control air failure Check compressed air supply No control voltage present Check automatic system see chapter 5...

Page 72: ...automatic control box between terminal X1 9 10 and X1 11 12 24 V DC must be applied If not replace PCB System does not flush Flushing water outlet pos 5 to the bilge blocked Clear pipeline Piston valv...

Page 73: ...ction replace if necessary Thermo sensor out of tune or defective Set thermo sensor to 45 C or replace it Heater contactor defective Replace contactor No control voltage present Transformer fuse defec...

Page 74: ...09015001 4 1 Pneumatic piston valve complete oil outlet 5936001501 4 4 1 Plug in screw connection 6462121110 4 5 1 Sealing set for piston valve 5924S2150 5 1 Pneumatic piston valve complete flushing w...

Page 75: ...enoid valve 5940033056 58 1 Pneumatic 3 2 way piston valve 5938002001 58 5 1 Sealing set for 3 way piston valve 5925S1200 59 1 Venting valve 5906030081 60 1 Non return flap 5909020002 Tab 17 Spare par...

Page 76: ...er lid seal 8320025002 32 1 Thermometer optional 5921015001 34 1 Coalescer 2704002501 36 1 Pressure reducer valve 5912015001 36 1 Pressure gauge 0 6 bar 5920008092 41 1 Zinc anode 6453020001 43 1 Safe...

Page 77: ...10 bar 5920008094 8 1 1 Vacuum pressure gauge 1 5 bar 5920008090 8 2 1 Vacuum pressure gauge 1 5 bar 5920008090 9 1 Sensor electrode R1 5120302002 10 1 Heater element Important Check the voltage that...

Page 78: ...02020 101 1 set 4 pcs Adsorber element 20 2840005001 104 4 Head plug 5911600002 105 1 Head plate 6200000512 106 1 Wing nut M8 8118008002 107 1 Threaded rod M8 8121008999 1 Pipe fitting R1 4 x 8 mm 646...

Page 79: ...28 1 Funnel 6030020001 29 1 Coalescer container 1 stage 6100100010 30 1 Coalescer lid 6100100011 31 1 Coalescer lid seal 8320100002 32 1 Thermometer optional 5921015001 34 1 Coalescer 2704010001 36 1...

Page 80: ...n screw connection 6462121110 5 5 1 Sealing set for piston valve 5924S2150 7 1 Pressure gauge 0 10 bar 5920008094 8 1 1 Vacuum pressure gauge 1 5 bar 5920008090 8 2 1 Vacuum pressure gauge 1 5 bar 592...

Page 81: ...Venting valve 5906030081 60 1 Non return flap 5909032002 100 1 Base plate 6200001522 101 7 Adsorber element 20 5911602020 101 103 1 set 14 pcs Adsorber element 20 and 10 2840015001 102 7 Connecting n...

Page 82: ...nnection 6462121110 23 5 1 Sealing set for 3 way piston valve 5925S1320 27 1 Drain ball valve R1 coalescer container 5906030401 27 a 1 Drain ball valve R1 2 adsorber 5906030151 28 1 Funnel 6030020001...

Page 83: ...ection 6462121110 4 5 1 Sealing set for piston valve 5924S2200 5 1 Pneumatic piston valve complete flushing water outlet 5936002001 5 4 1 Plug in screw connection 6462121110 5 5 1 Sealing set for pist...

Page 84: ...1 Manual 3 way valve 5905140001 57 1 3 way solenoid valve 5940033056 58 1 Pneumatic 3 2 way piston valve 5925114002 58 5 1 Sealing set for 3 way piston valve 5925S1400 59 1 Venting valve 5906030081 60...

Page 85: ...6462121110 15 5 1 Sealing set for piston valve 5924S2200 23 1 Pneumatic 3 way piston valve complete 5925115002 23 4 1 Plug in screw connection 6462121110 23 5 1 Sealing set for 3 way piston valve 592...

Page 86: ...tional spare parts Pos Piece s Designation Article number 32 1 Thermometer optional 5921015001 50 1 Suction sieve optional DN 20 5922020051 50 1 Suction sieve optional DN 20 5922020051 50 1 Suction si...

Page 87: ...ox Pos Piece s Designation Article number 2S1 1 Heater switch 5131001005 2S3 1 Hand Zero Auto switch 5131001008 1Q1 1 Main switch 5131001001 2K1 1 Contactor for pump 5131005013 2K2 1 Contactor for hea...

Page 88: ...nce manual SKIT S DEB 3rd print version page 88 13 Spare parts RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 3 2 x 2 3 way solenoid valve insert for valve terminal 59406524C1 Tab 27...

Page 89: ...stallation operating and maintenance manual SKIT S DEB 3rd print version page 89 14 Drawings RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 14 D r a wi n g s 14 1 Adsorber second sta...

Page 90: ...e manual SKIT S DEB 3rd print version page 90 14 Drawings RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 14 2 Piston valve pos 4 pos 5 and pos 15 SKIT S DEB 0 1 5 0 m h 14 3 Piston v...

Page 91: ...intenance manual SKIT S DEB 3rd print version page 91 14 Drawings RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 14 4 Sensor electrode pos 9 14 5 3 2 way piston valve pos 23 and pos...

Page 92: ...anual SKIT S DEB 3rd print version page 92 14 Drawings RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 14 6 3 2 way piston valve pos 23 and pos 58 at SKIT S DEB 1 5 10 0 m h 14 1 Coal...

Page 93: ...llation operating and maintenance manual SKIT S DEB 3rd print version page 93 14 Drawings RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 14 2 Coalescer pos 34 SKIT S DEB 5 0 m h 10 0...

Page 94: ...anual mode or automatic mode In manual mode no automatic switch off occurs when the bilge is empty Switch the system s main switch to On a The bilge level LED only illuminates in green when the level...

Page 95: ...The recirculation valve pos 23 guides the water back to the bilge The solenoid valve is currentless The second stage adsorber is filled Close the ventilation tap of the adsorber housing cover During t...

Page 96: ...uring cell contains clean water Alarm monitor OMD alarm 2 is green Off The measuring cell contains clear water Alarm monitor OMD system is green The monitor signals no alarm The recirculation valve po...

Page 97: ...intenance manual SKIT S DEB 3rd print version page 97 15 Annex RWO GmbH Marine Water Technology Bremen Germany Issue 2014 04 10 15 2 Record of the maintenance and repair works Signature Name Performed...