jowa 3sep ows

JOWA 3SEP OWS OILY WATER SEPARATOR

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JOWA OILY WATER SEPARATOR

JOWA 3SEP OWS

1.0m3/h

OPERATING INSTRUCTIONS AND

TECHNICAL MANUAL

Jim

Typewritten Text

Jim

Typewritten Text

rev: 2, proj: STD


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Table of Contents 1.0 Introduction............................................................................................ 4

1.1 General ............................................................................................................. 4 1.2 System overview , normal flow and oil release through the OWS ................. 5 (See flow diagram) ....................................................................................................... 5 1.3 Guarantee and service...................................................................................... 6 1.4 Note on recycling. ............................................................................................ 6

2.0 Technical specification ......................................................................... 7 Technical data for JOWA 3Sep OWS 1,0m3/h............................................................ 7

3.0 Installation.............................................................................................. 8 3.1 Delivery ............................................................................................................ 8 3.2 Placement of the skid........................................................................................ 8 3.3 Pipe connections............................................................................................... 8 3.4 Separator pump................................................................................................. 9 3.5 Electric connections.......................................................................................... 9 3.6 Air supply pipes and connections................................................................... 10 3.7 Filter media JOWA F - 200 C ........................................................................ 10 3.8 Quantity of filter media .................................................................................. 10

3.8.1 Filling the tanks T2, T3 with filter media............................................... 11 3.9 Initial start-up checklist .................................................................................. 11

4.0 System Function.................................................................................. 12 4.1 Manual shut-off valve positions ..................................................................... 12

4.2 High level start switch/ Low Level stop switch ......................................... 12 4.3 Low Level switch only. ............................................................................. 12 4.4 Dry running protection ............................................................................... 12 4.5 Prime water................................................................................................. 12

4.4.0 Optional features on the 3SEP OWS.............................................................. 13 4.4.1 Bilge clean mode (optional) ................................................................... 13 4.4.2 Transfer mode (optional) ........................................................................ 13 4.4.3 Level switches in 2 bilge tanks (optional).............................................. 13 4.4.4 3SEP OWS with JOWA Emulsion Breaking Unit EBU (Optional) ...... 14

5.0 Operation.............................................................................................. 15 5.1 General ........................................................................................................... 15 5.2 Start/Stop the 3SEP OWS .............................................................................. 15

5.2.1 Start/Stop OWS manual mode................................................................ 15 5.2.2 Start/Stop OWS auto mode..................................................................... 15 5.2.3 Start/stop transfer mode (optional)......................................................... 16 5.2.4 Start/stop transfer manual Mode ............................................................ 16 5.2.5 Start/stop transfer auto mode.................................................................. 16 5.2.6 Start/Stop bilge clean mode (optional) ................................................... 16

5.3 The PLC User Interface.................................................................................. 17 5.3.1 OWS manual and auto operation.......................................................... 18 5.3.2 OWS remote operation (activated in service menu)............................... 19 5.3.3 Timers and settings................................................................................. 20 5.3.4 Transfer, manual or auto operation. (option).......................................... 21 5.3.5 Information displays. .............................................................................. 22 5.3.6 Alarms .................................................................................................... 22 5.3.7 Service mode .......................................................................................... 24


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5.4 The oil content meter...................................................................................... 25 5.5 The pneumatic solenoid control valves .......................................................... 25 5.6 Oil sensor CT03.............................................................................................. 25

6.0 Maintenance......................................................................................... 26 6.1 Back flushing procedure for filter tanks T2, T3. ........................................... 26 6.2 Changing JOWA F - 200 C filter media in filter tanks T2, T3. ..................... 27

6.2.1 Removing the filter media ...................................................................... 27 6.2.2 Filling the tanks T2, T3 with filter media............................................... 27

6.3 Checking the anode protection ....................................................................... 28 6.3.1 Position of anodes in the tanks. ............................................................. 28

6.4 Regular maintenance timetable ...................................................................... 29 6.4.1 Before start ............................................................................................. 29 6.4.2 After every operation.............................................................................. 29 6.4.3 Every month ........................................................................................... 29 6.4.4 Every six months .................................................................................... 29 6.4.5 Every 12 months..................................................................................... 29

7.0 Trouble Shooting................................................................................. 30 7.1 General ........................................................................................................... 30 7.2 Operation errors.............................................................................................. 30

8.0 Flow Diagram (P & I)............................................................................ 31 9.0 Mechanical Drawings .......................................................................... 32 10.0 Electrical Drawings and Pneumatic Drawings .................................. 33 11.0 Pump Operating Manual ........................................................................ 34 12.0 Spare/ Consumables Parts List .......................................................... 35 13.0 Approval Certificates........................................................................... 36


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1.0 Introduction The 3SEP OWS is an oily bilge water separation system designed to separate free/emulsified oil from the bilge water and check that the oil residues in the treated water do not exceed 15ppm before discharge overboard. The 3SEP OWS complies with IMO Resolution MEPC 107(49). According to MARPOL 73/78 all vessels above 400 DWT require an approved bilge water separator and alarm. The treated water released by the 3SEP OWS contains not more than 15-ppm oil in water. The system has been designed to meet the requirements prescribed by IMO MEPC 107 (49). For bilges with heavily emulsified oil in the bilge water a 3SEP OWS coupled to a JOWA EBU (Emulsion Breaking Unit) offers the best solution and ensures treated water under 5ppm. The 3SEP OWS is supplied standard with the necessary inlet for connecting a JOWA EBU. For additional information about the EBU system contact JOWA.

1.1 General

To obtain all the advantages from operating a 3SEP OWS ensure that all users have adequate education for the equipment, ensure that the installation is correct and ensure that the 3SEP OWS is maintained and operated in accordance with the instructions in this manual. The correct function of the equipment cannot be guaranteed if the user fails to follow these instructions. We reserve the right to make changes to the 3SEP OWS without previous notice. Before installation and start-up read this manual carefully. Supplier and manufacturer: JOWA AB Tulebovägen 104 S-428 34 Kållered , Göteborg Sweden Phone: +46-31 726 54 00 Fax: +46-31 795 45 40 Internet:: www.jowa.se


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1.2 System overview , normal flow and oil release through the OWS

(See flow diagram)

The 3SEP OWS is designed for a continuous flow with automatic operation, the system does not require any chemicals. The following text gives an overview of the 3SEP OWS separation process and the 3SEP OWS general arrangement. In the first stage, tank T1, oil release is controlled by an oil sensor, CT03. The sensitivity of the oil sensor CT03 is operator adjustable in order to minimise the amount of treatable water released from T1 to the sludge tank. To adjust the sensitivity of the oil sensor CT03 see chapter 5.3 and 5.6. In the second stage emulsified oil is removed in the two filter tanks and the ppm value is monitored continuously by an oil content meter before the treated water is discharged overboard. The pneumatically controlled valves V02 and V03 release the free oil at the top of T2 and T3 to the concentrated sludge tank. Oil is released from V02 every five minutes, for a time period of 20 seconds (adjustable). Oil is released from V03 every hour for a fixed period of 5 seconds. When the JOWA 3SEP OWS is started an automatic oil release from V02, and V03 occurs for a fixed period of 3 seconds. This ensures that the pure oil that has gathered at the tops of the tanks while the unit has been in stand by mode is now released. When a 15 ppm alarm occurs, the 3SEP OWS will automatically close the overboard line V04 and open re-circulate valve V05. When the contamination falls below 15 ppm the valve for re-circulate valve V05 close and valve for overboard line V04 will open automatic. The recirculation cycle occurs for 5 minutes and is adjustable (See Chapter 5.3.3). If the treated water remains above 15ppm at the resumption of normal flow after the recirculation cycle, the 3SEP OWS will stop and an alarm will occur. The 3SEP OWS can be back flushed and restarted. See Chapter 6.1 for back flushing instructions. The system is designed as a compact skid assembly with all connection points collected, for easy “Plug n’ Play” installation. When the unit reaches the customer the only remaining thing to do is to connect water inlets/outlets, the electrical power supply and air connection, facilitating quick and easy installation onboard. Before leaving our workshop each unit has to pass a quality-test, where all functions are tested and checked. All equipment has the highest quality; the tanks are made of acid proof stainless steel, AISI 316L. Our pumps are supplied by internationally recognised brands. Spare parts are easily available from one of our offices or representatives worldwide.


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1.3 Guarantee and service. The JOWA 3SEP OWS is covered by a guarantee period. Guarantee claims can be made according to JOWA’s Guarantee claim procedure. The JOWA 3SEP OWS contains components with no user serviceable parts which are sealed. Breaking the seals placed on these components automatically voids the warranty. Contact JOWA for assistance. Service should only be carried out by an authorised JOWA service engineer.

1.4 Note on recycling.

In the design and manufacture of the JOWA 3SEP OWS all Efforts have been made to use components that can be recycled. This product or the parts of it must be disposed of in an environmentally sound manner. Use the local public or private waste collection service


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2.0 Technical specification This chapter contains a quick reference table with the main technical specifications for the 3SEP OWS.

Technical data for JOWA 3Sep OWS 1,0m3/h Type: 3Sep OWS-1m3/h Capacity: 1,0 m³/h Influent: Bilge water Effluent oil content. < 15 ppm acc. IMO MEPC 107(49) Ambient temperature: 5 - 55°C Operation Pressure: Normal 0,5 – 2 Bar, Safety Valve: 4 bar Volume (total): 225 L Weight (total): excl. Filter mtrl & pump

225 kg (dry) 450 kg (wet)

Total power consumption: 2 kW (standard) Air supply: 4 – 6 Bar dry clean instrument air

Common alarm. 15 ppm alarm.

Long time run alarm. (option) Alarm outputs:

Transfer alarm (option) Tank material: AISI 316L Gaskets: Nitrile Tank volumes: 3 x 75 L Filter media: JOWA F200 Filter media quantity: 50 kg Type Approval: Type approval by U.S.C.G Number 162.050/9057/0

DNV,CCS,RMRS,KR Bilge Pump

Type: Mono Screw Pump Flow rate: 1 m³/h Weight: 21 kg Suction: Max. 4,5 m lift capacity Voltage: 230 – 480 VAC, other available on request. Frequency: 50 - 60 Hz

Power consumption: 0,55 - 0,66 kW 1,51 - 2,77 A

R.P.M. 885 - 1060 Protection class: IP55 Thermal insulation class: F

Prime water & dry running protection as standard.


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3.0 Installation This chapter contains step-by-step information detailing how the 3SEP OWS is installed. At the end of the chapter is a quick reference check list to aid in start-up after installation or service.

3.1 Delivery

The 3SEP OWS is delivered complete with all valves, pipes, necessary fittings and an oil content meter mounted on a single skid ready for installation onboard. The unit has passed a work-shop tested before delivery.

3.2 Placement of the skid

The 3SEP OWS skid should be placed on a plane surface and welded or bolted using the pre drilled holes in the skid. When installing the unit it is important to leave a minimum of 500mm working space in front of the unit (see mechanical drawings).

3.3 Pipe connections

All connection points are collected together for easy “Plug n’ Play” installation:

Piping connections: Oily bilge water

inlet: 1” – DN25

Oil release outlet (to

sludge tank): 1” – DN25

Back flush water inlet: 1” – DN25

Water outlet (overboard) 1” – DN25

Drain and Re-circulate water

(to bilge) 1” – DN25

Outlet to JOWA EBU (Optional)

1” – DN25


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3.4 Separator pump The pump is delivered as a separate unit. To be installed as close to the bilge water tank as possible and not more than 4,5 meters suction height to avoid suction problems. Use piping with the same dimension as the pump is designed for. Refer to the flow diagram chapter and the recommended installation drawing. Use pipe connections according to specification below. 1” ( DN 25 )

3.5 Electric connections

The electrical equipment of the separator is ready for installation when delivered. The power supply should be three phase 380-480 VAC 50/60Hz. Other power supplies on request. See the electrical drawings for further information. The mains supply should have a 10A fuse. Cable for pump, mains supply and 3 pole circuit breaker are not included in the delivery. Voltage: 3 phase 380-400-415-440-460-480 VAC 50/60 Hz. Other power supplies on request.


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3.6 Air supply pipes and connections Air supply is connected to the pneumatic solenoid control valves. The solenoid block is located just below the control cabinet. The counter connector is supplied for attaching of 8 mm Cu-pipe. The pressure should be 4-6 bar dry instrument air.

Fig 3.6.1 Air inlet to solenoids.

3.7 Filter media JOWA F - 200 C

The filter media, JOWA F – 200 C, for the filter tanks T2 and T3 is delivered fully prepared in sacks of 25 kilos each. The Separator is always empty by delivery. Filter media for the first filling is included in the delivery. NOTE! For guaranteed function we recommend the JOWA F - 200 C filter media.

3.8 Quantity of filter media Model Tank size quantity (2 Tanks) 1.0m3/h 75l 50kilo


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3.8.1 Filling the tanks T2, T3 with filter media NOTE! Before filling check that the internal strainers are carefully fastened. Fill the tanks T2 and T3 through the upper hatches to 60-70 % of the tank volume, approximately 10-15 centimetres below the upper strainers. When the tanks are filled with filter media mount the upper hatches and back flush each filter one by one until clean fresh water is coming through the sample valves V18 and V19 (See Chapter 6.1 for detailed back flushing instructions). We recommend back flushing with fresh water at a pressure of no more than 4 bar. Maintain low water pressure and speed during back flushing to avoid losing filter media from V30. Throttle V15 and V16 to about 30%open to control water speed and pressure during back flushing.

3.9 Initial start-up checklist

Use the following start-up checklist after installation or service. Fill tank T2 and T3 with filter media Make sure the bilge pump is filled with water before start, to prevent

running dry. Check that the manual valve positions on the 3SEP OWS are correct for

normal operation (See System function chapter 4) Open all valves between the bilge water tank and the separator. Open all valves on the separator discharge line.

Back flush filter tanks 2 and 3 for a short while.(See Maintenance Chapter 6).

Turn the power on at switch S1. Check rotation of the pump Now the separator is ready for normal operation.


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4.0 System Function. This chapter provides a detailed description of the unique functions of the 3SEP OWS. The material provided in this chapter gives the operator the possibility to gain an good understanding into how and why the 3SEP OWS performs its functions. It is intended that the information in this chapter may be used to help the operator optimise the 3SEP OWS performance to his or her specific bilge requirements.

4.1 Manual shut-off valve positions

The following tables indicate which of the manually controlled valves are open and closed during normal operation of the 3SEP OWS.

4.2 High level start switch/ Low Level stop switch

Automatically starts the 3SEP OWS when the bilge water level is high and stop the OWS when bilge water level is low, using level switches located in the bilge tank. (the OWS need to be in AUTO mode)

4.3 Low Level switch only.

In some installations there are only a low level switch installed in the bilge tank. To control the OWS by this switch please connect it to the terminals for low level switch and make a jumper on terminals for high level switch. The OWS will now start when the low level switch is high and stop when the low level switch is low. (the OWS need to be in AUTO mode)

4.4 Dry running protection

Protects the 3SEP OWS pump from running dry. (see electrical drawings)

4.5 Prime water

Automatically primes the 3SEP OWS pump. (see electrical drawings)

Opened V10 V12

Closed V11 (If no EBU) V13 V14 V15 V16 V17 V18 V19 V30

Partly Closed FR01 Adjust so there is sample to the bilge alarm, se the flow diagram.


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4.4.0 Optional features on the 3SEP OWS. The following are optional features for the 3SEP OWS:

4.4.1 Bilge clean mode (optional) In bilge clean mode the flow from the bilge only passes through the first stage tank T1 and then returns to the bilge tanks. The bilge water is pumped into the top of T1 thru valve V10 where most of the free oil is gathered on the coalescence surfaces. When the oil senor CT03 detects oil it is released through the pneumatically controlled valve V01 and is delivered to the concentrated sludge tank. The flow then passes through V13 and returns to the bilge.

4.4.2 Transfer mode (optional)

Some vessels have more than one bilge tank. Transfer mode uses the OWS bilge pump to transfer water between these different bilge tanks without flow passing through the 3SEP.

4.4.3 Level switches in 2 bilge tanks (optional)

It is possible to control level switches in more than 1 bilge tank. If this option is at the OWS, a switch for tank selection is mounted. With this switch it is possible to run the OWS in Auto from 2 tanks. Standard delivery is 1 tank.


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4.4.4 3SEP OWS with JOWA Emulsion Breaking Unit EBU (Optional)

A JOWA EBU system may be coupled to the 3SEP OWS as an extra pree-treatment stage. The JOWA EBU & 3SEP OWS package can achieve treated water with in 5ppm. It is strongly recommended that the operator consider a 3SEP OWS coupled with JOWA EBU if the bilge water contains high levels of emulsified oil. The JOWA EBU is a chemical treatment of the emulsified oil in water. The chemical is a flocculent that helps the small particles of oil coalesce together and thus separate by gravity. The 3SEP OWS skid is ready supplied with the connection for a JOWA EBU (See Flow Diagram).

Fig 4.4 JOWA EBU schematic.


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5.0 Operation This chapter gives the operator detailed information on how the major control components of the 3SEP OWS are operated and adjusted.

5.1 General

General operation of the 3SEP OWS is facilitated by the PLC user interface and the switches located on the door of the main control box. All of the electric and pneumatic control equipment is located on the control cabinet stand at the side of the 3SEP OWS skid frame. • All electric equipment is connected to the main control box and the 3SEP

OWS is operated from here. The main power switch, S1, for the 3SEP OWS is located on the side of the main control box.

• The electronic parts for the oil content meter are located inside the oil content meter control box.

• The pneumatic solenoids for the pneumatic control valves are located on the side of the 3SEP OWS skid frame control stand

5.2 Start/Stop the 3SEP OWS

After the actions in section 3.9 ‘Initial Start-up Checklist’ have been completed the unit can be started and run in normal operation.

5.2.1 Start/Stop OWS manual mode

To start, please turn switch S2 to position OWS MAN. To stop, switch S2 to position 0. It is possible to start the OWS by a remote signal in manual mode. Se chapter for remote operation.

5.2.2 Start/Stop OWS auto mode

To start, please Turn switch S2 to position OWS Auto In this mode the OWS is controlled by the high/low level switches located in the bilge tank. To stop, switch S2 to position 0.


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5.2.3 Start/stop transfer mode (optional) Transfer mode can be operated in both auto and manual mode. In Auto mode the pump is controlled by the level switches in the tank and in manual mode the operator need to start and stop the system. However, the operator must exercise caution and see that the manual ball valves between the bilge tanks are in the correct position for transfer mode function correctly. It is possible to start the transfer by a remote signal in manual mode. Se chapter for remote operation.

5.2.4 Start/stop transfer manual Mode

To start, turn switch S2 to position TRANS MAN. To stop, switch S2 to position 0. It is possible to start the transfer by a remote signal in manual mode. Se chapter for remote operation.

5.2.5 Start/stop transfer auto mode

To start, turn switch S2 to position TRANS AUTO. In this mode the OWS is started by the high/low level switches located in the tank. To stop the transfer, switch S2 to position 0.

5.2.6 Start/Stop bilge clean mode (optional)

To start, turn switch S5 to position 2 for bilge clean mode. To stop, switch S5 to position 0.


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5.3 The PLC User Interface

The PLC user interface facilitates the running and understanding of the 3SEP OWS. Through the user interface and display on the main control cabinet door you receive all messages concerning the 3SEP OWS such as operational status, alarms, and pre-set times.

Fig 5.3 PLC Interface The user moves up and down through the menu display tree using the up/down and left/right keys. Information such as timers is input using the number keys. The input value is confirmed by pressing the enter key.

Left/ Right Keys

Up/ Down Keys

Enter Key

Display Window


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5.3.1 OWS manual and auto operation

OWS Man/Auto Select Man/Auto Mode

Electric Power has been connected or Electric Power has been shut down and returned. Stand by Waiting for mode select. Mode selected Waiting for start signal OWS running OWS Stopped

OWS AUTO OWS MAN

LS2

LS1

Reset AlarmS3

S2 S2

High

Low

S2 0


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5.3.2 OWS remote operation (activated in service menu)

OWS man mode

Select Local or Remote Start Electric Power has been connected or Electric Power has been shut down and returned. Stand by Waiting for mode select. Man mode selected Select Local or Remote start. Waiting on remote start OWS running When remote is activated in service mode it is also possible to run the transfer (manual only) in remote mode.

OWS Man

Reset AlarmS3

S2

A1 1

S2 0

RPB

A1

Start/Stop

2

S2 0


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5.3.3 Timers and settings

To select and adjust settings, press key “Down/6”

Step in Menu with up/down/left/right arrows. When a figure in display flashes, this value can bee adjusted. After new value has been inserted, press Enter button. If no value should be adjusted, please press enter and down arrow to go to the next setting To go back from the right setting menu, Please press left arrow.


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5.3.4 Transfer, manual or auto operation. (option)

Transfer bilge water between two bilge tanks.

Transfer Man/Auto Select Man/Auto Mode

Electric Power has been connected or Electric Power has been shut down and returned. Stand by Waiting for mode select. Mode selected Waiting for start signal Pump Running Pump Stopped

TRANS AUTO TRANS MAN

LS2/LS1

LS1

Reset Alarm S3

S2 S2

High

Low/High

S2 0


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5.3.5 Information displays.

Is displayed when V01/Tank 1 makes oil release

When OWS Pump is stopped, OWS makes a drop of system pressure to avoid unnecessary flow in sample line.

Outlet flow from T3 trough V04 is changed to V05 when high ppm. This display is not active when the recirculation time is set to 0.

5.3.6 Alarms

The different alarm conditions are listed in this section. A Failure message indicates the problem. When the failure is corrected the alarm can be reset by pressing the red reset button.


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ALARM TEXT.

Alarm trigged every time power has been shut down. Reset Alarm to start OWS in “Stand By Mode”

Alarm trigged when pump motor has been over heated check that OWS pump is running without disturbing.

Alarm trigged when flow to OWS pump is missing. Check pipe and valves in suction pipe.

Alarm trigged when still high ppm after recirculation time is run out. Status is high ppm alarm.

Alarm trigged after set “long run time” is reached

Alarm trigged when over heating protection relay is activated. Check if heater is on when no water in tank.

V01 has been open longer than set time. Check if there is Water, Oil or Air in tank T1 ~PV:002 = Air in tank T1 ~PV:040 = Oil in tank T1

Circulation Pump has been running longer than set time. Check flow, level in tank, stop in pipe, valves on pipe.

Transfer Pump is restarted cause of repeated high level in tank. Check for leaks in tank and check level switches.


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5.3.7 Service mode

Activate / Deactivate Options

To open Service Mode

To activate function, stop OWS when Alarm, press button 1. To deactivate function, Stop OWS when Alarm, press button 0. To switch display, press up or down arrow. To activate Remote Start in Man Mode, press button 1. To deactivate Remote Start in Man Mode, press button 2. To return to Maine Menu, press Enter, or wait time delayed return.

Push/hold button 1 for 6 sec

After 6 sec, Push Enter to open service mode


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5.4 The oil content meter The oil content meter is located on the control cabinet stand on the 3SEP OWS skid. The oil content meter door displays the oil content in PPM in the water being discharged from the 3SEP OWS. The alarm limit for the oil content is adjustable between 0 - 15 PPM. The oil content in the water is measured by the sensor unit at the oil meter. Technical and Operation manual for the Oil Content meter will be delivered separate..

5.5 The pneumatic solenoid control valves

The pneumatic solenoid control valves control the valves V01 to V05. Each pneumatic solenoid control valve is marked with the valve position number. The air pressure to the solenoid control valves must be 4-6 BAR dry instrument air to get a proper function and performance of the valves.

5.6 Oil sensor CT03

The oil sensor, CT03, measures the capacitance between the sensor rod and the pipe wall. The index of the oil sensor varies from 2 to 100, where 2 is air and 100 is clean water (oil has a value of 2-20). The factory set point value is 80. The set point of CT03 may be adjusted by the operator to suit the amount of free oil in the bilge water. For example a lower set point value on CT03 may suit a bilge with high amounts of free oil. Lowering the set point value has the advantage of decreasing the amount of water released to the concentrated sludge tank. However lowering the value may also shorten the lifespan of the JOWA F – 200 C filter media, as it must absorb more oil. Conversely, raising the value will result in more water being released to the concentrated sludge tank but a longer filter media lifespan. The sensor rod has to be cleaned regularly to ensure its correct function, See chapter 6 for cleaning instructions.


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6.0 Maintenance This chapter provides detailed instructions for common maintenance operations on the 3SEP OWS. A regular maintenance timetable is also included. The timetable is designed to aid the operator in scheduling minor periodic maintenance tasks thus avoiding unnecessary breakdowns.

6.1 Back flushing procedure for filter tanks T2, T3. • After JOWA F - 200 C is installed at start-up • The oil content meter gives an alarm indicating an oil content exceeding 15

ppm for a period of extended time. • After changing the JOWA F - 200 C filter media as part of regular service, • After every operation of the OWS. Proceed as follows: 1. Switch off the unit, close the valve V10 (and V11 if 3SEP OWS is connected

to a JOWA EBU). 2. Make sure that the pressurised fresh water is available at the valve V12 3. Start the back flushing of filter tank T2 by opening the valve V12 carefully. 4. Open the 3-way valve V30 so the handle is pointing against T2. Open V15

Do not fully open V15, open it slowly, and only 30% This avoids flushing away the JOWA F - 200 C filter media trough the valve V30. It also avoids damage to the pneumatic and non-return valves from flushing the JOWA F - 200 C filter media into them.

5. Be sure that V30 is allowing the flow to pass thru T2. You may check this by observing the outlet pressure at V18

6. Check the water quality through the valve V18. 7. Back flush until the water is clean. 8. Close the valves V15 ,V18 and V30 9. Start the back flushing of filter tank T3 by opening the 3-way valve V30 so

the handle is pointing against T3. Open V16, Do not fully open V16, open it slowly, and only 30%

10. Be sure that V30 is allowing the flow to pass thru T3. You may check this by observing the outlet pressure at V19.

11. Check the water quality through the valve V19. 12. Back flush until the water is clean. 13. Close the valves V12, V16, V19 and V30. 14. Open valve V10 (and V11 if 3SEP OWS is connected to a JOWA EBU).

Back flushing is complete.


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6.2 Changing JOWA F - 200 C filter media in filter tanks T2, T3. The filter media must be changed when back flushing is not cleaning the filters sufficient to get the reading in the oil meter below 15ppm. This section describes the procedure for changing the filter media.

6.2.1 Removing the filter media

NOTE! When removing filter media, make sure that you do not damage internal filter tank strainers. The strainers are located in the top and bottom of T2 and T3, see mechanical drawings. • Stop the 3SEP OWS at the main control box, close V10 (and V11 if 3SEP

OWS is connected to a JOWA EBU). • Open the filter tanks bottom valves V15, V16 and V14 to drain the water from

the filter tanks. • Open the sample valves V18 and V19 to let air into the top of the tanks. • Remove the upper hatches and wait until the water flow at the bottom has

stopped. • Open the lower hatches and empty the tanks of filter media. Clean the tanks carefully inside and check that the internal strainers are undamaged and free of carbon and oil. Check the zinc anodes and change them if more than 70 % of the zinc has corroded.

6.2.2 Filling the tanks T2, T3 with filter media

NOTE! Before filling check that the internal strainers are carefully fastened and undamaged. Should the strainers be damaged replace them. See Spare/Consumables Parts List. Fill the tanks T2 and T3 through the upper hatches to 60-70 % of the tank volume, approximately 10 centimetres below the upper strainers. When the tanks are filled with filter media mount the upper hatches and back flush each filter one by one until clean fresh water is coming through the sample valves V18 and V19 (See the previous section of this chapter for detailed back flushing instructions). NOTE! For guaranteed function we recommend the JOWA F - 200 C filter media.


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6.3 Checking the anode protection The first stage tank, T1 and the filter tanks T2, T3 are made of acid proof stainless steel AISI 316L. The tanks, pipes and fittings are protected against corrosion by fixed zinc anodes. The zinc anodes should be checked every 30 days. They should be changed if more than 70% of their mass is corroded

6.3.1 Position of anodes in the tanks.

Tank T1: The zinc anode is located at the front of the tank in the lower socket. Tanks T2, T3: The zinc anode is located inside lower hatch The location of the anodes are marked with labels. Drain the tanks before checking the anodes.


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6.4 Regular maintenance timetable

6.4.1 Before start

• Check that the pneumatic solenoids and valves are functioning properly

• Check for leaks of both air and oil/water

6.4.2 After every operation

• Back flush the filter tanks T2 and T3 according to the instructions in 6.1.

• Clean the oil content meter measuring according to the manufacturers instructions. Refer to the manual

6.4.3 Every month

• Check the Oil sensor CT03. Clean the rod of the oil sensor thoroughly by unscrewing and removing CT03 from T1.

• Check the zinc anodes..

6.4.4 Every six months

• Check the Stator at the pump P01.

6.4.5 Every 12 months

• Clean tank T1 on the inside. Remove the oil release flange and pipe and clean the tank thoroughly using high pressure hot water to remove the oil.


30

7.0 Trouble Shooting This chapter provides the operator with a comprehensive trouble-shooting guide.

7.1 General

Every error in the operation is indicated as an alarm and presented at the operators display of the PLC. 7.2 Operation errors

Error Remedy/Action

The oil content meter indicates over 15 PPM1. Back flush the filter tanks T2 and T3. 2. Replace the JOWA F - 200 C filter media if necessary

The pump, P01, does not give a flow.

1. Check the Stator and replace it if necessary. 2. Check that the electric motor is receiving the right voltage. 3. Check the rotation of the pump. 4. Check the pipes are not clogged

Pressure too high at the pressure gauge P1 and the safety valve V50 opens

1. Check that the manual valves in the flow direction are opened. 2. Check that air is connected. 3. Run the pneumatic valves manually by turning the small screws on the solenoid control valves. 4. Check the connectors for the valves for air leaks. 5. Back flush the filter tanks T2 and T3.

The pneumatic valves do not open.

1. Check the air connection (4-6bar) 2. . Run the pneumatic valves manually by turning the small screws on the solenoid control valves. 3. Check the connectors for the valves for air leaks. 4. Check the plastic hoses.

V01 does not close CT03 reading incorrectly

1. Check for leakage on the suction side of the bilge pump, air is entering the pipes. 2. Check water inside the tank by open check valve V17 3. Check the settings for the oil sensor.


31

8.0 Flow Diagram (P & I)


32

9.0 Mechanical Drawings

A

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

CHECK

REV

APPR.

DRAWN

FILE NAME SIZE

ID NO

MODEL ID SCALE

JOWA ABTULEBOVÄGEN 104Göteborg-SWEDEN

Teleph. +46 31 795 00 40

24-0010-01-01 3Sep 1m3.iam A3Greg Shannon

#9 090303 DW

24-0010-01 1:15

24-0010-01

2004-09-17

GA, MAJOR DIMENSIONS

JOWA 3SEP OWS 1 m3/hMARPOL IMO MEPC 107(49) -01

A950

1165

DRY MASS: 260 kgWORKING PRESSURE: 2 BARMAINTENANCE AREA: 500mm PERIMETER IN FRONT OF UNIT COMPLIES WITH MARPOL IMO MEPC 107(49)

10 377

760

1784

821

40

80

n14(4x)

16028

541053

566078

5

869

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

CHECK

REV

APPR.

DRAWN

FILE NAME SIZE

ID NO

MODEL ID SCALE


Teleph. +46 31 795 00 40


#9 090303 DW

24-0010-01 1:10

24-0010-01

2004-09-17

ISO GA, CONNECTION POINTS

JOWA 3SEP OWS 1m3/hMARPOL IMO MEPC 107(49) -02

B: OIL RELEASE OUTLET,TO SLUDGE TANK MALE THREAD DN 25

E: WATER OUTLET, <15ppm FOR OVERBOARDDICHARGE MALE THREAD DN 25

FILTER TANKS

OIL REMOVAL TANK

F: BACKFLUSH WATER, RECIRCULATED WATER >15 PPM AND DRAIN OUTLETTO BILGE TANKMALE THREAD DN 25

D: WATER INLETFOR BACKFLUSHMALE THREAD DN25

TANK T1ANODE

FILTER TANKANODES

A:OILY WATER INLETFROM BILGEMALE THREAD DN 25

C:OPTIONAL WATEROUTLET TO JOWA EBUFURTHER PROCESSEDTO ACHIEVE <5ppmMALE THREAD DN 25

INSTRUMENT AIRCOMPRESSIONCOUPLING DN8

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

CHECK

REV

APPR.

DRAWN

FILE NAME SIZE

ID NO

MODEL ID SCALE


Teleph. +46 31 795 00 40


#9 090303 DW

24-0010-01 1:10

24-0010-01

2004-09-17

ISO GA, PARTS LIST

JOWA 3SEP OWS 1m3/hMARPOL IMO MEPC 107(49) -03

99100-000110.3 kgS235Lift ear M16314886-0000-01-018.5 kg JOWA Sea Guard11422303-202240.4 kgBRASSSafety valve DN 20-22mm 4 Bar113 0.5 kgBRASSFlow restrictor DN25112 0.3 kgBRASSNon return valve DN2521150-0075-0115.5 kgAISI316LFilter Tank 75L21024001-002014.8 kg Control Cabinet1950075 - 220020.1 kgPlasticF75 Strainer 0,5mm L=210mm2850075 - 210020.1 kgPlasticF75 Strainer 1,0mm L=210mm2750100 - 210020.1 kgPlastic3Sep Drain Strainer 0,5mm2622311-036001.1 kg Oil Sensor CLM-36N1510109-000020.1 kg Pressure gauge, 0-10 Bar1422304-002561.5 kgBRASSPneumatic solenoid valve N.C.5324-0010-0143.4 kgAISI316LGravity 3SEP tank 75l1224-0010-01149.6 kgS2353Sep Frame 1,0m3/h11

ID NUMBERMASSMTRLDESCRIPTIONQTITE

4

3

3

2

1

3

3

5

NOTES:1. INTERNAL PIPE SPEC: 28 x 1.2 MTRL: COPPER2. INTERNAL PLUMBING CONNECTIONS IN BRASS AND COPPER PRESS FITTING SYSTEM WITH OIL RESISTANT SEALS3. ALL TANKS ANODE PROTECTED4. SKID FRAME CONSTRUCTED IN S235 STEEL 5. FILTER MATERIAL JOWA F-200, 50kg TOTAL (2x25kg)

7

68

9

10

10

11

12

13

14

GRAVITY SEPARATOR TANKOIL RELEASE SAMPLE POINT.


33

10.0 Electrical Drawings and Pneumatic Drawings

id23528468 pdfMachine by Broadgun Software - a great PDF writer! - a great PDF creator! - http://www.pdfmachine.com http://www.broadgun.com


34

11.0 Pump Operating Manual

Index

IndexIssued - December 2000

SECTION 1 INSTALLATION

START-UP PROCEDURE

ASSEMBLY AND DISMANTLING ADVICE

SECTION 2 FAULT FINDING

SECTION 3 DRAWING REFERENCE NUMBERS

SECTION 4 DISMANTLING AND ASSEMBLY DIAGRAMS

EXPLODED VIEWS

SECTION 5 MONO PRODUCTS

Declaration

Manufacturer’s Declaration

Mono Manufacturer’s Declaration as required by theEEC Machine Directive 98/37/EC, Annex ll B:

The Mono machines delivered in accordance with ourdesign are intended to be fitted in one machine orassembled together with other machines to form onemachine/plant.

The machinery must not be put into service until themachinery into which it is to be incorporated has beendeclared in conformity with the provisions of theDirective.

Particular attention must be paid to the safetyrequirements specified in EN 809 (Pumps and PumpEquipment for Fluids) as well as the information inthese operating instructions.

Signed: G D ThomasChief Engineer

Declaration of Conformity

Mono machines that do not possess any safetyaccessories do not fulfil the requirements of the EECMachine Directive 98/37/EC.

For this reason, no Declaration of Conformity asrequired by the EEC Machine Directive 98/37/ECAnnex ll A can be issued before appropriate safetydevices have been installed/mounted on the machineand/or plant with due regard to the information given inthese operating instructions.

The following harmonised standards are particularlyapplicable:EN 809, EN292T1, EN292T2

Applicable national standards and specifications mustbe taken into consideration.

Following assessment of the conformity of themachine/plant with the EEC Machine Directive,customers may on their own initiative place on the fullmachine/plant the EEC symbol ‘CE’ as defined inIdentification Directive 93/68/EEC.

Installation, Operation & Maintenance Instructions

Section 1, Page 1Issued - December 2001

INSTALLATION

1.1 INSTALLATION AND SAFETYRECOMMENDATIONS

In common with other items of process plant a pumpmust be installed correctly to ensure satisfactory andsafe operation. The pump must also be maintainedto a suitable standard. Following theserecommendations will ensure that the safety ofpersonnel and satisfactory operation of the pump isachieved.

1.2.1. GENERAL

When handling harmful or objectionable materials,adequate ventilation must be provided in order todisperse dangerous concentrations of vapours. It isrecommended that wherever possible, Mono pumpsshould be installed with provision for adequatelighting, thus ensuring that effective maintenancecan be carried out in satisfactory conditions. Withcertain product materials, a hosing down facility withadequate draining will simplify maintenance andprolong the life of pump components.

1.2.2. SYSTEM DESIGN & INSTALLATION

At the system design stage, consideration must begiven to provision of filler plugs, and the installationof non-return and/or isolating valves. The pumpsmust also be protected by suitable devices againstover pressure and dry running.

i. HORIZONTAL MOUNTING

All ranges excluding P Range Mono pumps arenormally installed in a horizontal position withbaseplates mounted on a flat surface, grouted inand bolted, thus ensuring firm fixing and a reductionin noise and vibration.

The unit should be checked after bolting down toensure that the alignment of the pump to its primemover is correct.

ii. VERTICAL MOUNTING

P Range Pumps Only

The P range pumps are intended for verticalinstallation. Care must be taken when lifting thepump into the vertical position. Normally ‘P’ rangepumps will be designed with a sole plate that will bebolted to the customers framework.

If the pump is to be mounted in any way other thandescribed above, confirmation of the installationmust be agreed with Mono Pumps Limited. All thepipework should be independently supported.

1.3.1 HANDLING

During installation and maintenance, attention mustbe paid to the safe handling of all items. Where apump or its components weigh in excess of 20 kg(45lb) it is recommended that suitable lifting tackleshould be used to ensure that personal injury ordamage to components does not occur.

For safe handling of both bareshaft pumps andpump units (pump/ gearbox/motor etc.) slings shouldbe used. The position of the slings will depend uponthe specific pump/unit construction and should becarried out by personnel with the relevantexperience to ensure that the pump is not damagedand injury to personnel does not occur.

If eyebolts do exist then these should only be usedfor lifting the individual components for which theyare supplied.

1.3.2 STORAGE

SHORT TERM STORAGE

Where a pump has to be stored for 6 months orless then the following steps are advised:-

1. Store pump inside wherever possible or if this is notfeasible then provide protective covering. Do notallow moisture to collect around the pump.

2. Remove the drain plug, if fitted. Any inspectionplates fitted should also be removed to ensure thatthe suction housing can drain and dry completely.

3. Loosen the packed gland and inject sufficient greaseinto the stuffing box. Tighten the gland nut handtight. If a water flush system is to be used do notgrease, a small amount of light oil is recommendedfor these.

4. See Manufacturers Instructions formotor/gearbox/drive instructions for storageprocedures.



LONG TERM STORAGE

If the pump is to be kept in storage for more than sixmonths then in addition to the above the followingprocedures should be carried out regularly (every 2 -3 weeks if possible):

1. If practicable rotate the pump at least three quartersof one revolution to avoid the rotor setting in thestator.

2. Note, however, that the pump is not to be rotated formore than two revolutions each time becausedamage could be caused to the rotor/ statorelements.

IMMEDIATELY PRIOR TO INSTALLATION ANDSTARTING

Before installing the pump please ensure that allplugs and inspection plates are replaced andthat excess grease/oil is removed from thestuffing box.

1.4 ELECTRICAL

Electrical connection should only be made usingequipment suitable for both rating and environment.Where any doubts exist regarding the suitability ofequipment, Mono Pumps Limited, should beconsulted before proceeding. Normally the Monopump should be installed with starting equipmentarranged to give direct on line starting.

Earthing points will be provided on electric drives (ifsupplied) and it is essential that these are correctlyconnected. When the motor is being wired andchecked for rotation, the start/stop sequence mustbe instantaneous to prevent dry running (see 2) orpressurising upstream equipment. (Check directionarrow on pump nameplate). The electricalinstallation should include appropriate isolatingequipment to ensure that the pump unit is safe towork on.

1.5 PRESSURE RELIEF VALVES AND NON-RETURNVALVES

1. It is recommended that a suitable safety device isinstalled on the discharge side of the pump toprevent over-pressurisation of the system.

2. It is also recommended that a non-return valve isinstalled on the discharge side of the pump toprevent reverse flow through the system.

When both are installed it is advised that the reliefvalve is positioned closer to the pump than the non-return valve.

IMPORTANT

The pump must never run against a closed inletor outlet valve, as this could result inmechanical failure.

1.6 GENERAL SAFETY

GREAT CARE MUST BE TAKEN TO PROTECTALL ELECTRICAL EQUIPMENT FROMSPLASHING WHEN HOSING DOWN. WHEREMONO PUMPS LIMITED HAVE SUPPLIED ABARESHAFT PUMP THE ONUS IS ON THE USERTO FIT ADEQUATE GUARDS IN COMPLIANCEWITH THE REQUIREMENTS OF THE RELEVANTREGULATIONS.

All nuts and bolts, securing flanges and basemounting fixtures must be checked for tightnessbefore operation. To eliminate vibration, the pumpmust be correctly aligned with the drive unit, and allguards must be securely fixed in position. Whencommissioning the plant, all joints in the systemmust be checked thoroughly for leakage.

If, when starting, the pump does not appear tooperate correctly (see 2), the plant must be shutdown immediately and the cause of the malfunctionestablished before operations are recommenced. Itis recommended that depending upon plant systemoperation, either a combined vacuum and pressuregauge, or a vacuum gauge only be fitted to thepump inlet port, and a pressure gauge fitted to theoutlet port, these will then continuously monitor thepump operating conditions.

1.7 DUTY CONDITIONS

Pumps should only be installed on duties for whichMono Pumps Limited have specified the materials ofconstruction, flow rates, pressure, temperature, speed etc. Where dangerous materials are to be

pumped, consideration must be given to the safedischarge from relief valves, gland drains etc.

IF THE DUTY SHOULD BE CHANGED, MONOPUMPS LIMITED SHOULD BE CONTACTED ANDTHEIR RECOMMENDATIONS SOUGHT IN THEINTEREST OF APPLICATION, SAFETY OFPLANT, EFFICIENCY AND PUMP LIFE.



2. START-UP PROCEDURE

Pumps must be filled with liquid before starting. Theinitial filling is not for priming purposes, but toprovide the necessary lubrication of the stator untilthe pump primes itself. When the pump is stopped,sufficient liquid will normally be trapped in therotor/stator assembly to provide lubrication upon re-starting.

If, however, the pump has been left standing for anappreciable time, moved to a new location, or hasbeen dismantled and re-assembled, it must berefilled with liquid and given a few turns beforestarting. The pump is normally somewhat stiff toturn by hand owing to the close rotor/stator fit.However, this stiffness disappears when the pump isrunning normally against pressure.

2.1 DRY RUNNING

NEVER RUN THE PUMP IN A DRY CONDITIONEVEN FOR A FEW REVOLUTIONS OR THESTATOR WILL BE DAMAGED IMMEDIATELY.CONTINUAL DRY RUNNING COULD PRODUCESOME HARMFUL OR DAMAGING EFFECTS.

2.2 ROTATION PUMP ROTATION DETAILS

PUMP RANGE BI-DIRECTIONAL COMMENT

E Yes Monobloc B Yes Merlin Industrial Yes S, SL Yes LF Yes W No **Merlin Widethroat No **MM ML No *MS No **G No *CB/SB No *Placer No **Grout Injection No **P No *CP0011 No **CP0025,CP0800,CP1600 No *

* Clockwise when viewed from drive end.

** Anti-clockwise when viewed from drive end.

DIRECTIONS OF ROTATION

BEFORE THE DIRECTION OF ROTATION ISCHANGED, MONO PUMPS LIMITED MUST BECONSULTED SO THAT THE SUITABILITY OFTHE PUMP CAN BE CONFIRMED WHENOPERATING ON THE NEW DUTY.

2.3.1. GLAND PACKING

Where a pump is supplied fitted with gland packing(manufactured from a non-asbestos material), thegland will require adjustment during the initialrunning in period. Under normal working conditionsa slight drip from the gland under pressure does notharm and assists in lubricating the packing. A glanddrip is, however, undesirable when handlingcorrosive, degreasing, or abrasive materials. Underthese conditions the gland must be tightened theminimum amount whilst the pump is running toensure satisfactory sealing when under pressure, orto stop entry of air when under suction conditions.

Provision of a gland drain should be considered,especially for the leakage of hazardous products.

CARE IS REQUIRED WHEN ADJUSTING THEGLAND WHILST PUMP IS RUNNING.

2.3.2 MECHANICAL SEALS - ALL PUMPS

When a mechanical seal is fitted to the pump it maybe necessary to provide a barrier fluid to some partof the seal. This should be provided in line with theseal manufacturers instructions.

2.4. GUARDS

In the interests of safety, and in accordance with theU.K. Health and Safety at Work Act 1974, all guardsmust be replaced after necessary adjustments havebeen made to the pump.

2.5 WARNING/CONTROL DEVICE

Prior to operating the pump, if any warning or controldevices are fitted these must be set in accordancewith their specific instructions.

2.6 PUMP OPERATING TEMPERATURE

The range of temperatures the pump surfaces willdevelop is dependent upon factors such as producttemperature and ambient temperature of theinstallation. There may be instances where theexternal pump surface can exceed 50oC.

In these instances, personnel must be made awareof this and suitable warnings/guarding used.



2.7 NOISE LEVELS

1. The noise sound pressure level will not exceed85dB at one metre distance from the pump.

2. This is based on a typical installation and does notnecessarily include noise from other sources or anycontribution from building reverberation.

3. For pumps identified below, the noise levels varybetween 85 and 95dB but will not exceed 95dB atone metre distance from the pump.

Pump Sizes (based on E Range PumpingElement)

Single Stage Size 12 and aboveTwo Stage Size 9 and aboveFour Stage Size 7 and aboveSix Stage Size 7 and aboveEight Stage Size 6 and above

2.8 LUBRICATION

Pumps fitted with bearings should be inspectedperiodically to see if grease replenishment isnecessary, and if so, grease should be added untilthe chambers at the ends of the bearing spacer areapproximately one third full.

Periodic bearing inspection is necessary to maintainoptimum bearing performance. The most expedienttime to inspect is during periods of regularscheduled equipment downtime - for routinemaintenance or for any other reason.

Under tropical or other arduous conditions, however,a more frequent examination may be necessary. Itis therefore advisable to establish a correctmaintenance schedule or periodic inspection.

BP LC2 / Mobilgrease XHP 222 or their equivalentmust be used for replenishment.

2.9 PUMP UNITS

Where a pump unit is dismantled and re-assembled,consideration must be given to ensure that whereappropriate the following steps are covered.

1. Correct alignment of pump/gearbox2. Use of appropriate couplings & bushes3. Use of appropriate belts & pulleys correctly

tensioned.

2.10 CLEANING PRIOR TO OPERATION

i. Non Food Use

During the commissioning of a new pump orrecommissioning of an overhauled pump, it isadvisable to clean the pump prior to the initialoperation of the pump in the process.

ii. Food Use

When a pump has been supplied for a foodapplication, it is important to ensure that the pump isclean prior to initial operation of the pump.

Therefore, it is important that a clean-in-placetreatment is executed on the pump at the followingtimes:-

1. When the pump is first commissioned for use.

2. When any spare components are fitted into thewetted area of the pump.

A recommended CIP procedure is as follows:

This procedure should not be used on the CPPump Range. Please consult our applicationengineers for a suitable procedure.

Caustic WashLQ94 ex Lever Diversey or equivalent2% concentration

Acid WashP3 Horolith 617 ex HenkelEcolab or equivalent 1% concentration

Procedure

1. Caustic wash @ 75°C for 20 mins2. Water rinse @ 80°C for 20 mins3. Acid wash @ 50°C for 20 mins4. Water rinse @ 80°C for 20 mins

• CIP flow rates (hence pumpspeeds) should be maximised to achieve highestlevel of cleanability.

Pumps fitted with CIP by pass ports will permithigher flow rates without the need to increase pumpspeed.



• The use of ‘neat active’ causticand acid chemicals is notrecommended. Proprietary cleaningagents should be used in line with manufacturersinstructions.

• All seals and gaskets should bereplaced with new if disturbedduring maintenance.

• Pump internals should be regularly inspected toensure hygienic integrity is maintained, especiallywith respect to elastomeric components and seals,and replaced if necessary.

The four stages constitute one cycle and werecommend that this cycle is used to clean the pumpbefore use on food.

Once the pump has been commissioned, thecleaning process will depend upon the application.The user must therefore ensure that their cleaningprocedures are suitable for the duty for which thepump has been purchased.

2.11 WIDETHROAT PUMPS

Specific pumps may have auger feed screws, withor without a bridge breaker system to feed thepumping element. If the pump installation requiresthat these cannot be enclosed, care must be takento ensure personnel cannot gain access whilst thepump is operating. If this is not possible anemergency stop device must be fitted nearby.

2.12 EXPLOSIVE PRODUCTS/ HAZARDOUSATMOSPHERES

In certain instances the product being pumped maywell be of a hazardous nature.

In these installations consideration must be given toprovide suitable protection and appropriate warningsto safeguard personnel and plant.

2.13 ACCESS PORTS

Where access ports are fitted then the followingsteps must be followed prior to removal:

1. Pump must be shut down and the electrical supplyisolated.

2. Protective clothing should be worn, especially if thepumped product is obnoxious.

3. Remove access plate with care utilising wherepossible drip trays to collect product leakage.

Access ports are included to assist in removingblockages and to allow a visual check on thecomponents within the suction chamber.

It is not to be considered as an additional method indismantling the pump.

Re-assembly of the plate should be completed usingnew gaskets prior to the pump being switched on.

2.14 ADJUSTABLE STATORS

If adjustable stators are fitted then the followingsteps must be followed for adjusting the clampingdevices.

The adjustable stator assembly is designed to givean even compression around the statorcircumference. It is designed to be used whenpump performance reduces through wear to anunacceptable level, to restore the required flow rate.

The stator compression is increased using thefollowing steps:-

1. Release the six locking screws half a turn.

2. Tighten the eight clamp screws until adjustmentallowed by releasing the lock screws has been takenup.

3. Repeat steps 1 and 2 until the pump performancehas been restored to its former level.

NOTE

It is imperative that when adjusting the stator thatonly sufficient pressure is placed on the stator toenable the capacity of the pump to be reinstated.

Over tightening of the stator could easily result indamage to the driver by overload and so extremecare must be taken when carrying out theseadjustments. It is therefore advisable to make theadjustment while the pump is running and powerreadings can be monitored.

REMOVAL OF ADJUSTABLE STATOR

The procedure for removal of an adjustable stator isthe same as that of a standard one, except it isnecessary to remove the clamp plates before thestator can be twisted off the rotor.



This can be done by undoing the clamp screws;then releasing the clamp plate by using the lockingscrews as jacking screws to remove the clampplates.

Re-assembly will be done using the reverseprocedure.

2.15 MAINTENANCE OF WEARING COMPONENTS

2.15.1 ROTOR AND STATOR

The wear rate on these components is dependenton many factors, such as product abrasivity, speed,pressure etc.

When pump performance has reduced to anunacceptable level one or possibly both items willneed replacing.

2.15.2 DRIVE SHAFT - PACKED GLAND

The wear rate of the gland area is dependent onmany factors such as product abrasivity and speed.Regular gland maintenance will maximise the life ofthe shaft. Replacement of both the gland packingand shaft will be necessary when shaft sealingbecomes difficult to achieve.

2.15.3 COUPLING ROD JOINTS

Regular maintenance and lubrication will maximiselife of the joints.

Replacement of one or both joint assemblies andpossibly the coupling rod may be necessary whenwear is apparent.

It is essential to replace all the joint items withgenuine Mono parts to ensure maximum life.

2.15.4 FLEXISHAFT DRIVE PUMPS

With this design there are no wearing items toreplace in the drive train, however, if during routineinspection the shaft is visibly damaged / distortedor the protective coating is damaged, then this itemshould be replaced to avoid unexpectedbreakdowns.

3.0 ASSEMBLY AND DISMANTLING

Section 4 contains the steps to dismantle andre-assemble the pump. All fastenings must betightened securely and when identified theappropriate torque figures should be used.

3.1 USE OF ITEMS NOT APPROVED ORMANUFACTURED BY MONO PUMPS LIMITED

The pump and its components have been designedto ensure that the pump will operate safely within theguidelines covered by the legislation.

As a consequence Mono Pumps Limited have declared the machine safe to use for the dutyspecified as defined by the Declaration ofIncorporation or Conformity that is issued with thisInstruction Manual.

The use of replacement items that are not approvedby or manufactured by Mono Pumps Limited mayaffect the safe operation of the pump and it maytherefore become a safety hazard to both operatorsand other equipment. In these instances theDeclaration provided will therefore become invalid.The guarantee referenced in the Terms andConditions of Sale will also be invalidated ifreplacement items are used that are not approved ormanufactured by Mono Pumps Limited.

DISPOSAL OF WORN COMPONENTS

When replacing wearing parts, please ensuredisposal of used parts is carried out in compliancewith local environmental legislation. Particular careshould be taken when disposing of lubricants.

Diagnostic Chart


SYMPTOMS POSSIBLE CAUSES1. NO DISCHARGE

2. LOSS OF CAPACITY

3. IRREGULAR DISCHARGE

4. PRIMING LOST AFTER START

5. PUMP STALLS AT START UP

6. PUMP OVERHEATS

7. MOTOR OVERHEATS

8. EXCESSIVE POWER ABSORBED BY PUMP

9. NOISE AND VIBRATION

10. PUMP ELEMENT WEAR

11. EXCESSIVE GLAND OR SEAL WEAR

12. GLAND LEAKAGE

13. SEIZURE

1. 2. 3. 7. 26. 28. 29.

3. 4. 5. 6. 7. 8. 9. 10. 22. 13. 16. 17. 21. 22. 23. 29

3. 4. 5. 6. 7. 8. 13. 15. 29.

3. 4. 5. 6. 7. 8. 13. 15

8. 11. 24.

8. 9. 11. 12. 18. 20

8. 11. 12. 15. 18. 20.

8. 11. 12. 15. 18. 20

3. 4. 5. 6. 7. 8. 9. 11. 13. 15. 18. 19. 20. 22. 23. 27. 31

9. 11.

12. 14. 25. 30.

13. 14.

9. 11. 12. 20.LIST OF CAUSES REMEDIAL ACTIONS

1. INCORRECT DIRECTION OF ROTATION

2. PUMP UNPRIMED

3. INSUFFICIENT N.P.S.H. AVAILABLE

4. PRODUCT VAPORISING IN SUPPLY LINE

5. AIR ENTERING SUPPLY LINE

6. INSUFFICIENT HEAD ABOVE SUPPLY VESSEL OUTLET

7. FOOTVALVE/STRAINER OBSTRUCTED OR BLOCKED

8. PRODUCT VISCOSITY ABOVE RATED FIGURE

9. PRODUCT TEMP. ABOVE RATED FIGURE

10. PRODUCT VISCOSITY BELOW RATED FIGURE

11. DELIVERY PRESSURE ABOVE RATED FIGURE

12. GLAND OVERTIGHT

13. GLAND UNDERTIGHT

14. GLAND FLUSHING INADEQUATE

15. PUMP SPEED ABOVE RATED FIGURE

16. PUMP SPEED BELOW RATED FIGURE

17. BELT DRIVE SLIPPING

18. COUPLING MISALIGNED

19. INSECURE PUMP/DRIVE MOUNTING

20. SHAFT BEARING WEAR/FAILURE

21. WORN PUMP ELEMENT

22. RELIEF VALVE CHATTER

23. R.V. INCORRECTLY SET

24. LOW VOLTAGE

25. PRODUCT ENTERING PACKING AREA

26. DRIVE TRAIN BREAKAGE

27. NEGATIVE OR VERY LOW DELIVERY HEAD

28. DISCHARGE BLOCKED/VALVE CLOSED

29. STATOR TURNING

30. STUFFING BOX “EATS” PACKING

31. VEE BELTS

1. REVERSE MOTOR

2. BLEED SYSTEM OF AIR/GAS

3. INCREASE SUCTION HEAD OR REDUCE SPEED/TEMP.

4. INCREASE N.P.S.H. AVAILABLE (SEE 3 ABOVE)

5. CHECK PIPE JOINTS/GLAND ADJUSTMENT

6. RAISE VESSEL/INCREASE PIPE SIZE

7. CLEAN OUT SUCTION LINE/VALVES

8. DECREASE PUMP SPEED/INCREASE TEMP.

9. COOL THE PRODUCT

10. INCREASE PUMP SPEED/REDUCE TEMP.

11. CHECK FOR BLOCKAGES IN DELIVERY LINE

12. ADJUST GLAND SEE O&M INSTRUCTIONS

13. ADJUST GLAND SEE O&M INSTRUCTIONS

14. CHECK FLUID FLOWS FREELY INTO GLAND

15. DECREASE PUMP SPEED

16. INCREASE PUMP SPEED

17. RE-TENSION BELTS

18. CHECK AND ADJUST ALIGNMENT

19. CHECK AND TIGHTEN ALL PUMP MOUNTINGS

20. REPLACE BEARINGS

21. FIT NEW PARTS

22. CHECK CONDITION OF VALVE/RENEW

23. RE-ADJUST SPRING COMPRESSION

24. CHECK VOLTAGE/WIRING SIZES

25. CHECK PACKING CONDITION AND TYPE

26. CHECK AND REPLACE BROKEN COMPONENTS

27. CLOSE DELIVERY VALVE SLIGHTLY

28. REVERSE PUMP/RELIEVE PRESSURE/CLEAR BLOCKAGES

29. REPLACE WORN PARTS/TIGHTEN UP STATOR BOLTS

30. CHECK FOR WORN SHAFT AND REPLACE

31. CHECK AND ADJUST TENSION OR REPLACE

Dismantling & Assembly Diagrams

Section 4, Page 1a Issued - December 2000

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Section 4, Page 2 Issued - December 2000

1

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11

Bareshaft

Exploded Views


24A

22A

A11

2161

F

25A

26A

21A

P10

0232

S

A11

2201

F

S11

0870

P

01A

K11

3242

F

N11

3102

FW

1132

52F

06A

R10

1082

F

65A

32A

A11

1101

F

6650

1050

W11

5050

F

GF,

GG

, GH

MO

DEL

S M

ON

OB

LOC

VER

SIO

N W

ITH

MEC

HA

NIC

AL

SEA

L

Dwg.ref. DescriptionQty Per Unit

25A ROTOR 122A STATOR 126A COUPLING 132A SHAFT-STD GF,GG,GH23 MK3 165A SEAL HOUSING-STD M/SEAL 11050 MECHANICAL SEAL 16650 COLLAR M/SEAL M & MK3 G RANGE 121A BARREL 124A END COVER 101A BODY-STD C.I. 106A NP E RANGE DOG PACK SIZE=100 1*) THROWER GUARD PVC 2W113252F SNGL.COIL SPRING WASHER M8. 4N1131102F STEEL HEX.NUT M8 4K113242F STL.HEX.HD.BOLT M8 X 30 4R101082F RIVERT 3,2X15 2A111101F H.T.STL.SOC.CAP SCREW M5 X 10 2W115050F ST. STEEL BRIGHT WASHER BRB12 1S110870P TORL SEAL RING 0845-30 BK NITR 1A112201F H.T.STL.SOC.CAP SCREW M6 X 20 4A112161F H.T.STL.SOC.CAP SCREW M6 X 16 4P100232S MAL.IRON.TAPER PLUG 1/4 BSP 1

*) Not shown on actual exploded view

OWS 1 ( pump code at 60 Hz = CGG233R1)

Performance Curve for - CGG243R1/H923

LiquidViscosityCapacityPressureSpeed Solids

Bilge water5.00 cP0.90 m3/hr2.00 bar1137 RPM2.5/1 mm (soft/hard)

Min Pwr Req.Absorbed PowerStart TorqueRunning TorqueNPSHR

0.37 kW0.25 kW2.5 Nm2.1 Nm01.60 m

RPM

RPM

m3/hr

0.25

0.5

0.75

1.0

1.25

ABRASION

VISCOSITY(STOKES)

Light Nil

.0121050

200 400 600 800 1000 1200 1400 1600 1800

kW

0.10

0.20

0.30

200 400 600 800 1000 1200 1400 1600 1800


35

12.0 Spare/ Consumables Parts List

JOWA 3SEP OWS Spares Rev H

Spare part list and recommendedconsumables for JOWA 3SEP OWS 1.0m3/h

Article No DescriptionRecommended quantity for:1.year

COMSUMABLES:17004-12407 Jowa F-200C Filter material 5020013-70800 Zinc Anode Filter Tanks 220013-02500 Zinc Anode Gravity Tank 1 1

Note: please order 2 x 20013-70800 and 1 x 20013-02500 per separator

SPAREPARTS:50075-21002 Filterscreen top 1.0mm 250075-22002 Filterscreen bottom 0.5mm 250100-21002 Filterscreen Drain 0.5mm 2

Note: please order 2 x 50075-21002 , 2 x 50075-22002 and 2 x 50100-21002 per separator

22311-03600 Oil Sensor Stick CLM-36N10109-00002 Pressure gauge 0-10 BAR P110107-08436 Pressure Gauge Valve DN899200-16509 Fuse 0,5 A, 10X38 (10 pack)27060-20102 Main Switch KG2027060-42001 Power On CG4 A178727060-42102 1-0-2 Switch CG4 A21099100-34001 Reset Push Button 20600-00110 OPLC M91-2-R120600-00111 Epander PLC EX90-D18-R08

Note: When ordering artno:20600-00110 please provide the serialno. of the separator.

42000-00230 Relay PT37073020700-75552 Transformer 380-480/2X11099100-00188 Transformer 230VAC/24V DC

OIL CONTENT METER86000-00001 JOWA SeaGuard Bilge Alarm

PUMP22415-00010 Pump Mono 1.0 m3 Cgg23001-00012 Stator Mono Cgg23002-19572 Rotor Mono Cgg23002-19573 Coupling22415-00001 Mechanical Seal

VALVES22304-00256 Pneumatic valves DN2522304-06212 Solenoid valve 1/8 ( 5 in one set)22304-06213 Coil ( 5 in one set)22303-20224 Safety valve DN20 4 BAR


36

13.0 Approval Certificates

Coast Guard Approval Number: 162.050/9057/0 Expires: 25 January 2013

OIL POLLUTION PREVENTION EQUIPMENT The following device has been tested in accordance with

IMO Resolution MEPC.107(49)

JOWA AB Tulebo 865

S-428 34 Kallered Gotheburg SWEDEN

JOWA 3SEP Series OWS; 15 ppm Separator Equipment manufactured by JOWA AB to specification/assembly drawing no. 24-0005-01-01 dated 9/19/2007; 24-0010-01-01 dated 9/17/2004; 24-0025-01-01 dated 7/6/2004 and 24-0050-01-01 dated 6/30/2004. Coalescer manufactured by JOWA AB part no. JOWA F-200C. Maximum throughput of system is: 3SEP OWS 0.5 M3/Hr - 0.5 M3/Hr ( 2.2 GPM) 3SEP OWS 1.0 M3/Hr - 1.0 M3/Hr ( 4.4 GPM) 3SEP OWS 2.5 M3/Hr - 2.5 M3/Hr (11.0 GPM) 3SEP OWS 5.0 M3/Hr - 5.0 M3/Hr (22.0 GPM) A copy of this Certificate should be carried aboard a vessel fitted with this equipment at all times. IMO Certificates of Type Approval do not expire and are valid for equipment manufactured at any time during the period of validity of this Certificate. Test data and results attached in the appendix. This certificate documents compliance with 46 CFR 162.050.

*** END ***

THIS IS TO CERTIFY THAT the above named manufacturer has submitted to the undersigned satisfactory evidence that the item specified herein complies with the applicable laws and regulations as outlined on the reverse side of this Certificate, and approval is hereby given. This approval shall be in effect until the expiration date hereon unless sooner canceled or suspended by proper authority.

GIVEN UNDER MY HAND THIS 25th DAY OF JANUARY 2008, AT WASHINGTON D.C. C. K. MARCY Chief, Machinery Branch U.S. Coast Guard Marine Safety Center

TERMS: The approval of the item described on the face of the Certificate has been based upon the submittal of satisfactory evidence that the item complies with the applicable provisions of the navigation and shipping laws and the applicable regulations in Title 33 and/or Title 46 of the Code of Federal Regulations. The approval is subject to any conditions noted on this Certificate and in the applicable laws and regulations governing the use of the item on vessels subject to Coast Guard inspection or on other vessels and boats.

Consideration will be given to an extension of this approval provided application is made 3 months prior to the

expiration date of this Certificate.

The approval holder is responsible for making sure that the required inspections or tests of materials or devices covered by this approval are carried out during production as prescribed in the applicable regulations.

The approval of the item covered by this certificate is valid only so long as the item is manufactured in conformance

with the details of the approved drawings, specifications, or other data referred to. No modification in the approved design, construction, or materials is to be adopted until the modification has been presented for consideration by the Commandant and confirmation received that the proposed alteration is acceptable.

NOTICE: Where a manufacturer of safety-at-sea equipment is offering for sale to the maritime industry, directly or indirectly,

equipment represented to be approved, which fails to conform with either the design details or material specifications, or both, as approved by the Coast Guard, immediate action may be taken to invoke the various penalties and sanctions provided by law including prosecution under 46 U.S.C. 3318, which provides:

"A person that knowingly manufactures, sells, offers for sale, or possesses with intent to sell, any equipment subject to

this part (Part B. of Subtitle II of Title 46 U.S.C.). and the equipment is so defective as to be insufficient to accomplish the purpose for which it is intended, shall be fined not more than $10,000, imprisoned for not more than 5 years or both."

jowa 3sep ows

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