Installation Drawings_2058-9601-020.pdf

Installation Drawings Rev.1

Customer: US Coast Guard

Hull / Project: WMEC-901 - 913

WS-Ordernumber: 1451.546.584

Model: BilgeMaster-E 500 cleandesign engineering for a better world

Contents

1. Installation Instructions, Graphical Symbols

2. Bilge Water

Installation Guidelines Designation Bilgewater Treatment Systems Type BilgeMaster-D Units / BilgeMaster-D cleandesign Units / BilgeMaster-E cleandesign Units No. 2011-9601-000 | Edition 0113

GEA Mechanical Equipment engineering for a better world

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ORIGINAL INSTRUCTION MANUAL

Content subject to change!

The authors are always grateful for comments and sugges-tions for improving the documentation. These can be addressed to:

GEA Mechanical Equipment

GEA Westfalia Separator Group GmbH

Werner-Habig-Straße 1, 59302 Oelde, Germany Tel.: +49 2522 77-0, Fax: +49 2522 77-2488 www.gea.com

GEA Westfalia Separator Group

2011-9601-000 / 0113 3

1 General 5

1.1 Target groups

1.2 Other applicable documents

1.3 Structure and meaning of the safety precautions

1.4 Service

1.5 Liability

2 Safety 11

2.1 Intended use

2.2 Reasonably foreseeable misuse

2.3 Qualification of the personnel

2.4 Responsibility of the plant operator

2.5 Hazards from products and operating materials

2.6 Modifications to the system

2.7 Requirements for spare parts and operating materials

3 Transport and storage 15

3.1 Safety information

3.1.1 Hazards from ambient temperatures

3.1.2 Using load suspension devices safely

3.1.3 Using lifting eye bolts or lifting eye nuts as load handling devices

3.2 Transport

3.3 Storage

3.4 Storing and handling electrical equipment

3.5 Preserving the system

3.5.1 Storing and preserving the pump/pump unit

4 Assembly and installation 25

4.1 Installation of the system

4.2 Space requirement

4.2.1 Operating area of standard BilgeMaster BM-D

4.2.2 Operating area of standard BilgeMaster BM-E

4.3 Space requirement for removal of filter elements (optional)

4.4 Space requirement for separators

4.4.1 Separators with belt drive

4.5 Transporting the bowl parts

4.5.1 Bowl dimensions and weights

4.5.2 Note regarding required hoisting equipment for separators

4.6 Ventilating the separator room

4.7 Foundation work and vibrations

4.7.1 Vibration values for separators

4.8 Securing the foundation plate

4.8.1 Securing the foundation plate on board

4.8.2 Securing the foundation plate onshore

4.8.3 Welding the foundation plate to the steel structure

4.9 Installing supply lines

4.9.1 Heating medium

4.9.2 Compressed air

4.10 Operating water

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4.10.1 Operating water quality

4.10.2 Supply pressure and temperature of operating water

4.10.3 Operating water flow rate

4.11 Product lines

4.11.1 Pipe cross-sections

4.11.2 Functional description of centripetal pump (gripper)

4.11.3 Information on pressure monitoring

4.11.4 Maximum suction head of the pump

4.12 Electrical installation

4.12.1 Control cabinet

4.12.2 Installing and securing the control cabinet

4.12.3 Electrical connection

4.12.4 Connecting external voltages

4.12.5 Electrical connection for shipboard operation

4.12.6 Electrical connection for onshore operation

4.12.7 Electromagnetically-compatible installation

4.12.8 Electrical design

4.12.9 Equipotential bonding of the pumps

4.12.10 Equipotential bonding of the electric heater

4.12.11 Equipotential bonding of the foundation plate

4.12.12 Installing and operating controllers

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1 General

1.1 Target groups

1.2 Other applicable documents

1.3 Structure and meaning of the safety precautions

1.4 Service

1.5 Liability

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Preface

These installation guidelines

• are part of the overall documentation for the BilgeMaster systems.

• Describe the specifications for the design, manufacture and implementation of BilgeMaster systems

• Contain basic information for installing BilgeMaster systems.

• Contain general guidelines for BilgeMaster systems.

These content of these guidelines reflects the acceptable minimum for the de-sign and construction of frames, piping and the electrical installation.

The system must be installed in accordance with the order-specific documents:

• Installation diagram and equipment list

• Dimension drawing (information on space requirement for operation and maintenance, minimum clearance from walls/pillars or other machines)

Technical information for the BilgeMaster system is subject to change!

1.1 Target groups

The target groups of this documentation are all individuals who transport, set up, and install the system.

What work may be carried out by what target group depends on the qualification of the personnel and on the type of work.

Operator

The operator is employed by the customer and has been briefed in the following operations:

• Starting and shutting down the machine.

• Monitoring the machine and process (e.g., by reading indicators).

• Performing simple re-lubrication and cleaning work.

• Recognizing malfunctions and emergency shutdown.

When given specific instructions, the operator is able to make simple changes in the process control, e.g.:

• Adjusting temperatures, pressures and throughputs.

• Dosing additives.

Skilled worker

The skilled worker is normally employed by the customer and has been briefed in the following areas:

• Performing simple assembly work.

• Performing routine maintenance work or inspection.

• Recognizing malfunctions and emergency shutdown.

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The skilled worker has basic technical knowledge. The basic knowledge corre-sponds to a technical apprenticeship (mechanical or electrical).

The skilled worker is selected and deployed by the employer (plant operator).

GEA Westfalia Separator undertakes only the introduction to specific technical features that belong directly to the scope of supply and points out possible risks.

This briefing is no substitute for a professional apprenticeship.

Trained specialist

The trained specialist normally belongs to the service team of GEA Westfalia Separator.

In exceptional cases, skilled workers employed by the customer can obtain a corresponding qualification by attending training courses held by GEA Westfalia Separator.

1.2 Other applicable documents

The following documents apply in addition to this documentation:

• Instruction manual for the centrifuge

• Centrifuge datasheet in accordance with DIN EN 12547

• P&ID (Piping & Instrumentation Diagram).

• Documents for the control of the system , e.g., startup and shutdown instructions and setting values.

• Instruction manuals for components of other manufacturers, such as motors, pumps and valves.

Further information

If further information is required on the topics in this documentation, it can be requested from the following sources:

– Direct from Westfalia Separator in Oelde.

– From your local GEA and Westfalia Separator representative.

– Per Internet under: www.westfalia-separator.com

– Per e-mail under: Info@gea-westfalia.de http://www.westfalia-separator.com/

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1.3 Structure and meaning of the safety precautions

Signal word

Type and source of risk.

Possible consequences of disregarding the warnings.

– Measures for danger prevention.

The signal word indicates a dangerous situation and its potential.

DANGER

Indicates an imminently dangerous situation which, if not prevented, will result in serious injury or death.

WARNING

Indicates a potentially dangerous situation which, if not prevented, could result in serious injury or death.

CAUTION!

Indicates a potential situation which, if not prevented, could cause slight or moderate injury.

NOTE

Indicates a situation which, if not prevented, represents a risk for ma-chine, material and environment.

Important supplementary information.

1.4 Service

Westfalia Separator provides comprehensive service for the following areas:

– Assembly.

– Commissioning.

– Regular maintenance.

– Repairs.

– Checking the operational status.

– Inspection in a dismantled status.

– Decommissioning for a long standstill period.

– Storage and preservation in the case of a long standstill period.

– Re-commissioning.

– Decommissioning and disposal.

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– Training.

Ask about the original service from Westfalia Separator.

1.5 Liability

Reasons for the immediate passing of liability to the plant operator independent of existing warranty and guarantee periods.

– Improper installation by inadequately trained persons.

– Improper handling in deviation from the intended use.

– Non-observance of the user instructions.

Warranty and liability conditions in the Conditions of Sale and Delivery of West-falia Separator are not extended by the above.

Westfalia Separator shall accept no liability for damage caused by un-qualified or unauthorized personnel.

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Note Notes

Notizen Anotaciones

Notizen Notes Note

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2 Safety

2.1 Intended use

2.2 Reasonably foreseeable misuse

2.3 Qualification of the personnel

2.4 Responsibility of the plant operator

2.5 Hazards from products and operating materials

2.6 Modifications to the system

2.7 Requirements for spare parts and operating materials

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2.1 Intended use

The BilgeMaster bilgewater treatment system is used to ...

The system is intended exclusively for commercial operation. It is technically designed according to the mode of operation contractually agreed with the manufacturer.

It is suitable for the following applications:

• Deoiling of bilgewater on ships in accordance with MARPOL Annex I

• Deoiling of drainage water onshore and offshore

• Deoiling of process water and surface water in refineries

For information on process conditions, operating conditions and environmental conditions, see:

• System nameplate

• Data sheet

• The following requirements must be met to ensure that the system is operated safely at all times:

• Use only genuine spare parts and genuine operating materials.

• Comply with limits.

• Do not change or expand the system.

• Use the system only for its intended purpose.

2.2 Reasonably foreseeable misuse

The instruction manual contains instructions for the intended use. Any operation of the system that does not fall under the intended use constitutes unintended use and is considered to be misuse.

Reasonably foreseeable misuses include:

– Use of unsuitable spare parts

– Use of impermissible operating materials

– Exceeding of defined limits

– Modifying or expanding the system

– Changing the process conditions, operating conditions and environmental conditions without the consent of the manufacturer

Any misuse of the system may cause bodily injury and property damage.

• Use the system only as intended.

2.3 Qualification of the personnel

Special expertise is required for working on and with the system. The qualifica-tion of the personnel with this expertise is an important requirement for the op-erational reliability. The requirements for the qualification are described in the individual chapters of the instruction manual. They depend on the tasks as-signed.

Faulty operation, installation errors and handling errors can result in danger to life and limb as well as severe damage to property.

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The plant operator must implement measures for the qualification of its person-nel:

– Assign only reliable individuals to work on the system.

– Allow only authorized individuals to work on the system.

– Give special training and briefings to the personnel for the tasks assigned.

– Clearly define responsibilities.

– Make sure that the assigned individuals have read and understood the safety information before beginning work.

– Make sure that the assigned individuals have read and understood all sec-tions of the instruction manual required for their work before beginning work.

– Give special briefings to persons who cannot read, and monitor their work.

– Persons still undergoing training may only be deployed under supervision.

2.4 Responsibility of the plant operator

The operation of a system is subject to rules and regulations for occupational health and safety.

The order of the rules and regulations listed below is not a reflection of their pri-ority. The list lays no claim to completeness:

– Regulations relating to safety and health (accident prevention regulations) based on Article 118a of the treaty establishing the EEC, e.g., RL 89/655/EEC and follow-up versions or corresponding national regula-tions issued by the country of operation.

– Regular inspection of safety devices.

– Compliance with regulations governing health protection and safety of em-ployees in hazardous areas, e.g., RL 1999/92/EC or corresponding national regulations issued by the country of operation.

– Compliance with ATEX RL 94/9/EC, EMC RL 89/336/EC, Low-Voltage Di-rective RL 73/23/EC or corresponding national regulations issued by the country of operation when working within the responsibility of the manufac-turer.

– Compliance with the Machinery Directive 2006/42/EC or corresponding na-tional regulations issued by the country of operation when working within the responsibility as manufacturer.

– Compliance with the German Equipment and Product Safety Act or corre-sponding national regulations issued by the country of operation when working within the responsibility as manufacturer.

The plant operator is responsible for complying with rules and regulations and the safety-conscious and hazard-conscious work of the assigned persons. The-se include the following measures:

– Ensuring that the statutory and other binding regulations on safety, accident prevention and occupational safety are known and complied with.

– Assigning only qualified and authorized personnel with technical under-standing and fundamental technical knowledge and skills to work on the centrifuge.

– Clearly defining and communicating responsibilities for tasks.

– Operating the system only in perfectly functional condition in line with the intended use. For the intended use, refer to the section Intended use.

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– Checking all safety devices for proper functioning before each commission-ing.

– Having the system checked regularly by qualified persons for its operational reliability. Having the system checked at least once a year in operational status and at least every 3 years in dismantled condition.

2.5 Hazards from products and operating materials

Hazardous materials are all materials that, on physical contact, represent a hazard for the persons operating in the environment of the system.

Systems that have been purpose-built for operation with hazardous materials are marked with safety stickers.

Hazards resulting from the following product characteristics and operating mate-rials are known from product observation:

– Hot products

– Cold products

– Hazardous, chemically critical products

– Hazardous, biologically critical products

– Cleaning agents

2.6 Modifications to the system

Modifications to the system are not permitted. They represent an unintended use and endanger the operational reliability of the system. This may cause bodily injury and property damage.

– When modifications to the system are necessary, e.g., due to new opera-tional sequences, contact GEA Westfalia Separator.

– Clarify the planning and the measures for the modifications to the system with GEA Westfalia Separator.

2.7 Requirements for spare parts and operating materials

Spare parts, wear parts, and operating materials can cause bodily injury and property damage if they do not meet the requirements.

Genuine spare parts and operating materials from GEA Westfalia Separator meet all requirements for operational reliability of the system.

– Use only genuine spare parts.

– Use only genuine operating materials.

– Use the order-specific spare parts catalog supplied.

– See the chapter "Spare parts" for ordering spare parts and operating mate-rials.

– Comply with limits.

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3 Transport and storage

3.1 Safety information

3.1.1 Hazards from ambient temperatures

3.1.2 Using load suspension devices safely

3.1.3 Using lifting eye bolts or lifting eye nuts as load handling devices

3.2 Transport

3.3 Storage

3.4 Storing and handling electrical equipment

3.5 Preserving the system

3.5.1 Storing and preserving the pump/pump unit

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3.1 Safety information

Pay special attention to the basic safety information contained in the overall documentation for the BilgeMaster system!

3.1.1 Hazards from ambient temperatures

The system has lines and tanks that are filled with water. The system can be damaged as a result of frost or high temperatures.

• To avoid damage, take measures to prevent the effects of frost during transport and storage.

• Do not install or store the system next to objects with strong heat radiation.

3.1.2 Using load suspension devices safely

The working load limit of the slings depends on the method of use. They may only be used for their intended purpose.

Unintended use may cause the slings to tear or break. There is a danger to life and limb of persons and damage to property.

For the reduction of the working load limit in individual cases, see the manufac-turer's specifications.

GEA Westfalia Separator recommends the use of round slings made of synthet-ic fibres.

Observe the following points when using load suspension devices:

– Inspect the slings for damage before each use.

– Do not use damaged or incomplete load suspension devices or slings.

– Use slings only in the way approved by the manufacturer.

– Never load the slings beyond their maximum working load limit (WLL). The

WLL specification is located on the sling label.

– Conduct periodic training for the slingers and the individuals who are as-signed to perform transport work.

– Use only the load fastening points specified in the documentation.

– Use only suitable ground conveyors and hoisting equipment with adequate lifting capacity.

– Pack and secure the load before transport in accordance with the Cargo

Transport Unit transport guidelines.

– Observe all regional regulations and laws governing transport and transport securing.

Load suspension devices for transport of system

Lifting tools for transporting the system to the installation site must be provided by the plant operator.

For removal or installation of heavy components, suitable hoisting equipment, e.g., a crane, must be provided by the plant operator.

Load suspension devices for repair of system

Load-carrying equipment and slings that are required for removal, installation or repair of the system components are located with the supplied special tools, e.g., for the centrifuge.

2011-9601-000 / 0113 17

In line with their intended use, they must not be used for other lifting work.

Slings include, for example, the chain suspension gear, and the load-carrying equipment includes the lifting eye nuts and eyebolts.

Use slings safely; observe the following points for this:

• Use only slings with a nameplate.

The nameplate on the sling shows the following data:

– CE mark

– Manufacturer

– Year of manufacture

– Part number

– Intended use

– Maximum load

– Dead weight

Fig. 1 Example of a nameplate

– Only use slings as prescribed in this instruction manual.

– Observe the permitted loading limit.

– Check the sling for visible damage before each use.

– Use only slings that are in perfect condition.

– Do not carry out repairs to slings.

– Send damaged slings to the manufacturer.

– Always screw in threaded rods as far as they will go.

– Tighten all nuts fully.

– Tighten all screws fully.

– Do not walk under suspended loads.

– Inspect slings regularly; see maintenance schedule of the “Plant Manual” or the “Maintenance and spare parts list” brochure in the overall documenta-tion for the system.

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3.1.3 Using lifting eye bolts or lifting eye nuts as load handling devices Incorrect use of lifting eye bolts or lifting eye nuts during transport can lead to serious accidents, e.g. due to overload.

Warning

Deformed lifting eye bolts or lifting eye nuts due to overload!

Danger to life and limb through falling loads when lifting eye bolts or lift-ing eye nuts break.

Observe the following points to avoid accidents:

• the pertinent standards and guidelines of the national associations in the country of origin on the operation of load handling devices in lifting mode

• Only trained specialists are authorized to mount lifting eye bolts or lifting eye nuts.

• Mount lifting eye bolts or lifting eye nuts only as illustrated.

• Screw in lifting eye bolts or lifting eye nuts completely.

• Attach load handling devices as vertically as possible, e.g. chains.

– Pull max. 45° diagonally.

– Modes of assembly other than those shown are not admissible, e.g. lateral pull.

Fig. 2

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3.2 Transport

The representation below is of a seaworthy transport package from GEA West-falia Separator.

Fig. 3 Example of a seaworthy package

. • Transport the transport package with the aid of a crane.

Fig. 4

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• Attach ropes around the transport package and hang them into the load hook of the crane.

Attention!

• Wind one piece of rope twice around the hook to prevent the ropes from slipping.

Fig. 5

DANGER

Danger of accidents and injuries from use of unsuitable, under-sized, or damaged hoisting equipment.

• Avoid accidents and injuries by using hoisting equipment that is suitable for the load for transport and installation.

Attention

Danger of damage to the system caused by improper transport.

• For safety reasons, the unpacked BilgeMaster system may only be lifted us-ing a cross-beam.

• Do not transport the unpacked sys-tem with a floor conveyor vehicle, e.g., fork-lift truck.

Fig. 6

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• Always use a cross-beam to transport the unpacked system.

• When using a rope during transport, ensure that the ropes do not dam-age the pipes, control cabinet, heat-er, etc.

• The rope must be properly attached to the cross-beam.

• Ensure that the fastening of the ropes does not cause the transfer of impermissible compression or ten-sion forces to machine parts.

Fig. 7

3.3 Storage

• The system may only be stored in the original GEA Westfalia Separator transport packaging.

• A storage duration longer than 12 months is only possible after consultation with the manufacturer.

• A closed, dry room must be provided for the storage location.

• The storage temperature should not fall below 5°C (41 F) or exceed 50 °C (122 °F).

The following requirements must be observed for the storage and transport packaging.

Handle delicate goods to be transported with care!

Protect the goods to be transported from moisture!

Protect the goods to be transported from heat!

3.4 Storing and handling electrical equipment

The following points must be observed when installing, storing and handling electrical equipment.

– If the installation site is not complete or brickwork will still be performed, do not remove the original packing or protective foil.

– It must be ensured that stored electrical equipment is not exposed to tem-peratures above +55 °C (131 °F) or below +2 °C (35.6 °F) or to corrosive atmosphere and that no fouling or condensation occurs.

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– Window coverings and displays on control cabinets should be covered with a barrier to protect them during assembly and for the time period up to commissioning of the control cabinet.

– Monitors as desktop models that are not suitable for operator control and monitoring in the immediate vicinity of the machine may only be installed in dry rooms, air-conditioned where appropriate, e.g. control rooms. This also applies to controllers and control stations in IP54 degree of protection.

– Dust and corrosive atmospheres are not permissible.

– Control cabinet heating – if present – must be connected to the external voltage and switched on ahead of time, i.e., before the system is commis-sioned.

– Do not remove base plates for cable entry into free-standing cabinets and consoles.

– If dust has penetrated, the control cabinet must be blown out with dry air before commissioning.

– Remove desiccant bags only after switching on the controller. The desic-cant is effective for about one year.

– The ambient temperature must not exceed +45 °C (113 °F) and the relative humidity must be less than 70%.

NOTE:

Improper storage and handling releases the supplier from the warranty.

3.5 Preserving the system

If the system will be at a standstill for an extended time period, it must be pre-served.

Preserving the separator

Required material:

– Anti-corrosion oil, e.g., SHELL Ensis Fluid E

– Grease, e.g., lubricating grease WS part number 0015–0119–010

– Dry rags

– Collecting vessel for lubricating oil

The following preservation work must be performed:

• Clean the bowl and bowl support.

• Drain the lubricating oil.

• Fill the oil pan with anti-corrosion oil up to the middle of the sight glass.

• Start up the separator and let it run until all the drive parts are wetted with an-ti-corrosion oil.

• Remove the bowl.

• Manually apply anti-corrosion oil to the upper spindle end and cover with a protective hood.

• Remove the sealing rings.

• Remove the drive belt.

• Store the sealing rings and drive belt in a cool and dry location.

• Use suitable packing to protect the sealing rings and drive belt from dust and light and to thereby prevent them from becoming brittle.

2011-9601-000 / 0113 23

• Write the storage date of the sealing rings and drive belt on the packing mate-rials.

• Close the shut-off elements for water and check for leak-tightness. If shut-off elements are found to leak, disconnect the water supply lines in order to pre-vent damage from dripping water.

• Close the operating water supply at the mains to prevent inrush of water caused by inadvertent opening of the operating water supply.

• Dry-clean and apply grease to bare machine parts.

Preserve STU

Preserve HU

Preserve FPU

Preserve COMU

Prepare and store control parts as follows:

• Store control unit and accessories in a dry location.

• Storage temperature: +5 to +50 °C (41 to 122 °F)

• Store control unit and accessories in a vibration-free location.

• Use suitable packing to protect the control unit and accessories from dust and high heat.

IMPORTANT! Store system in a vibration-free location in order to prevent dam-age to the units during storage caused by vibration of the units at standstill.

3.5.1 Storing and preserving the pump/pump unit

For storage times up to 6 weeks, the pump is protected by the measures taken ex factory:

– Pump is preserved with test oil after the test run.

– Pipe connections are sealed with protective caps.

– External parts are preserved with PU-based two-component paint.

For storage times up to 60 months, e.g., for spare parts inventory:

– Manufacturer offers a long-term preservation.

– For long-term preservation, the pump is packed in an air-tight manner in-side anti-corrosion paper.

Preserving the pump/pump unit

Preservation must be performed if

– The storage time is longer than 6 weeks

– The storage conditions are unfavourable, e.g., high humidity or salt-laden air

– The long-term preservation packaging has been opened or damaged

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Preserving the inner surfaces of the pump

• Seal the suction-side connection of the pump with a blank flange.

• Fill the pump with resin-free and acid-free oil via the pressure flange until it reaches a level 2 cm below the edge of the filling opening. While doing this, slowly rotate the pump by hand in the direction of rotation.

• Seal the pressure flange with a blank flange.

• Check the oil level every 6 months and add oil, if necessary.

Preserving the outer surfaces of the pump

Aids: Preservation agent, e.g., Castrol Rustilo DWX 33 or similar agent with comparable protection properties.

• Apply preservation agent to all bare unpainted surfaces using a paint brush or spray gun.

• Check the preservation every 6 months and repeat, if necessary.

• Store the preserved pump in a cool and dry location and protect it from direct sun radiation.

2011-9601-000 / 0113 25

4 Assembly and installation

4.1 Installation of the system

4.2 Space requirement

4.2.1 Operating area of standard BilgeMaster BM-D

4.2.2 Operating area of standard BilgeMaster BM-E

4.3 Space requirement for removal of filter elements (optional)

4.4 Space requirement for separators

4.4.1 Separators with belt drive

4.5 Transporting the bowl parts

4.5.1 Bowl dimensions and weights

4.5.2 Note regarding required hoisting equipment for separators

4.6 Ventilating the separator room

4.7 Foundation work and vibrations

4.7.1 Vibration values for separators

4.8 Securing the foundation plate

4.8.1 Securing the foundation plate on board

4.8.2 Securing the foundation plate onshore

4.8.3 Welding the foundation plate to the steel structure

4.9 Installing supply lines

4.9.1 Heating medium

4.9.2 Compressed air

4.10 Operating water

4.10.1 Operating water quality

4.10.2 Supply pressure and temperature of operating water

4.10.3 Operating water flow rate

4.11 Product lines

4.11.1 Pipe cross-sections

4.11.2 Functional description of centripetal pump (gripper)

4.11.3 Information on pressure monitoring

4.11.4 Maximum suction head of the pump

4.12 Electrical installation

4.12.1 Control cabinet

4.12.2 Installing and securing the control cabinet

4.12.3 Electrical connection

4.12.4 Connecting external voltages

4.12.5 Electrical connection for shipboard operation

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4.12.6 Electrical connection for onshore operation

4.12.7 Electromagnetically-compatible installation

4.12.8 Electrical design

4.12.9 Equipotential bonding of the pumps

4.12.10 Equipotential bonding of the electric heater

4.12.11 Equipotential bonding of the foundation plate

4.12.12 Installing and operating controllers

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4.1 Installation of the system

Fig. 8 Installation example

Special specifications of classification societies or other authorised organisa-tions must be complied with.

Operator control elements must not be mounted higher than 2300 mm above the working platform.

The system must be arranged in such a way that it does not restrict the working area and it can be safely serviced and operated.

All fixed piping and fittings must be firmly supported to reduce vibrations and movements to a minimum.

Contact points or supports must be fitted so that the pipes are able to move with changing temperatures without creating tension in the pipes.

Lines and line connections must be accessible for maintenance.

Pipes must not be used for supporting distributors or appliances.

This does not apply to small purpose-built parts whose durability, accessibility and operation are not influenced. They must be installed in accordance with the manufacturer's recommendations.

Zinc-plated parts must not be installed in product-carrying lines (e.g., bilgewater, thermal oil and steam lines). This does not apply if type-tested pipe couplings are used in pipe heat-tracing systems.

Y-strainers should preferably be installed horizontally with the strainer insert pointing downwards or to the side (rotated 90°).

If this is not possible for space reasons, the strainer can be installed vertically with a flow from top to bottom. With this type of installation, special attention must be paid that the strainer insert can be removed.

4.2 Space requirement

The operating area of the BilgeMaster system must remain clear for operation, maintenance and repair. Pipes must not be laid in the operating area, except for feed lines and discharge lines for the BilgeMaster system.

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4.2.1 Operating area of standard BilgeMaster BM-D

The operating area is shown in colour in the figure below.

• See the following table to determine the operating area.

Fig. 9 BilgeMaster system BM-D, top view

Table for determining the operating area for BilgeMaster system BM-D:

Dimensions in mm

BilgeMaster system A B C D

BM-D 750/1000 cd 800 600 600 600 BM-D 1500/2000 cd 800 600 600 600 BM-D 3000/4000 cd 800 600 600 600

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4.2.2 Operating area of standard BilgeMaster BM-E

The operating area is shown in colour in the figure below.

• See the following table to determine the operating area.

Fig. 10 BilgeMaster system BM-E, top view

Table for determining the operating area for BilgeMaster system BM-E:

Dimensions in mm

BilgeMaster system A B C D

BM-E 400/500 cd 800 600 600 600 BM-E 900/1200 cd 800 600 600 600 BM-E 2000/2500 cd 800 600 600 600 BM-E 4000/5000 cd 800 600 600 600

4.3 Space requirement for removal of filter elements (optional) Before installing the BilgeMaster system, pay special attention to the height di-mension (E +750 mm) for removal of the filter elements! The height dimension E must be obtained from the order-specific installation diagrams!

4.4 Space requirement for separators

Pipes must not be laid in the operating area of the separator, except for feed lines and discharge lines for the separator.

4.4.1 Separators with belt drive

The hatched area represents the operating area.

• See the following table to determine the operating area.

• Before installing the separator, pay special attention to the removal dimension “X” of the electric motors!

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Front view of separator

Fig. 11

Side view of separator

Fig. 12

Top view of separator

Fig. 13

Table for determining the operating area for separators with belt drive

Separator mo-del

Dimensions in mm A B D E F G X Y

WSD 8 1400 600 1400 550 1450 540 180 150

WSD 18 1400 600 1400 550 1550 630 180 150

WSD 35 1800 700 1800 650 1950 850 230 200

2011-9601-000 / 0113 31 del

Dimensions in mm A B D E F G X Y

WSE 5 1400 600 1200 400 1250 375 500 150

WSE 10 1400 600 1400 550 1450 540 180 150

WSE 20 1400 600 1400 550 1550 630 180 150

WSE 50 1800 700 1800 650 1950 850 230 200

4.5 Transporting the bowl parts

If the separator bowl must be removed, the following weights and dimensions must be noted. The design of the hoisting equipment must be suitable for the specified loads.

4.5.1 Bowl dimensions and weights

Bowl dimensions

Fig. 14

Table with data for the lifting device design

Separator model b h Bowl weight [kg]

WSD 8 255 270 42

WSD 18 300 320 72

WSD 35 425 420 190

WSE 5 220 225 33

WSE 10 255 270 42

WSE 20 300 320 72

WSE 50 425 420 190

4.5.2 Note regarding required hoisting equipment for separators

Flat belt separators

– The hoisting equipment must be mobile or swivel-type.

The hoisting equipment must be arranged so as to enable the following:

– Vertical installation and removal of the bowl (see section “Space require-ment for removal of separators”, table - dimension F).

– Vertical removal and installation of the drive motor (see section “Space re-quirement for removal of separators”, table - dimension X).

4.6 Ventilating the separator room

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• Pay attention to the correct arrangement of the air feed and discharge lines so that

– the separator room is effectively ventilated and exhausted,

– the permissible room temperature – normally max. 45 °C (113 °F) – is not exceeded.

The rating of the electrical equipment is critical for this.

NOTE: If the permissible temperatures are exceeded, additional measures must be taken. Maintenance intervals and maintenance measures may have to be adjusted accordingly.

Installation example of a ventilation system and exhaust system

1 Ventilation 2 Exhaust

Fig. 15

Guide values for number of air changes For small closed separator rooms 30 – 50 h-1 For large separator rooms 15 – 20 h-1 For niches in engine rooms 50 – 70 h-1

Table for air flow rates del

Air flow rate [m³/h]

WSD 8 10

WSD 18 30

WSD 35 100

WSE 5 10

WSE 10 10

WSE 20 30

WSE 50 100

4.7 Foundation work and vibrations

Vibrations are an example of dynamic loads.

They involve periodic motions in which a body constantly alternates between rest and motion.

Many of these phenomena are generally known, such as vibrations produced by engines, movements of ships at sea, etc.

2011-9601-000 / 0113 33

Fig. 16

1 Vibrations

The following must be ensured when installing the BilgeMaster system:

– Vibrations that can be transferred to the system must be prevented.

– This applies to the foundation as well as to all connected piping.

The manufacturer makes no warranty for malfunctions, damage, etc. caused by vibrations.

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4.7.1 Vibration values for separators

Fig. 17

Table for vibration values of separators

Separator model

Tolerable vibration values at the separator contact surface 1) max. [mm/s] permissible vibra-tion value at the reference point 2) [mm/s]

Limits for Vibro 1 with installed vibration sensor

3) [mm/s]

WTC 2 1.8 2.8 2.8

WSD 8 2.8 4.5 4.5

WSD 18 2.8 4.5 4.5

WSD 35 2.8 4.5 4.5

WSE 5 3.5 5.5 5.5

WSE 10 2.8 4.5 4.5

WSE 20 2.8 4.5 4.5

WSE 50 2.8 4.5 4.5

1) measured when separator is at standstill and normal ship operation

2) measured when separators in operation

3) The Vibro sensor is attached in this range

4.8 Securing the foundation plate

The following sections present the securing of the foundation plate of the Bilge- Master system.

4.8.1 Securing the foundation plate on board

Mounting of the BilgeMaster system on board of a ship.

2011-9601-000 / 0113 35

Fig. 18

Z = foundation

The foundation plate can be welded directly to the steel structure of the ship-yard, if it can be ensured that vibrations will not affect the system.

4.8.2 Securing the foundation plate onshore

Mounting of the BilgeMaster system onshore.

The foundation plate can be screwed directly to the provided foundation.

Fig. 19

4.8.3 Welding the foundation plate to the steel structure

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Fig. 20

Example 1

– The length of the weld seams should be 100 mm.

– The distance between the weld seams should be approx. 350 mm.

– This means that there are 3 weld seams with a length of 100 mm along a length of one metre.

Example 2

– The foundation plate can likewise be welded all the way round.

Detail view X

Example of welding the foundation plate to the steel structure.

Z = fillet weld

Fig. 21

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4.9 Installing supply lines

The following points must be observed when installing the supply lines.

4.9.1 Heating medium

In the case of steam operation, proper drainage of condensate must be en-sured.

When thermal oil and hot water are used, the minimum flow rate of the heating medium must be ensured.

4.9.2 Compressed air

The compressed air must be free from impurities.

Supply pressure Recommended set-up of compressed air line per treatment system:

Fig. 22

1 0.3 - max. 1.0 MPa

A supply pressure of 0.3 to max. 1.0 MPa is permissible.

Downstream of the reducing station, a pressure of 0.3 MPa must still be availa-ble to the consumers.

If other separate pneumatic components are operated, the corresponding oper-ating instructions relating to air quality and air lubrication must be observed.

Compressed air consumption of the WSD and WSE separators

The maximum compressed air consumption per separator is approx. 0.01 Nm³/h.

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4.10 Operating water

4.10.1 Operating water quality

The operating water should be as pure as possible and meet the following guide values:

Hardness:

– up to 55 °C (131 °F) separating temperature < 12° dH

– above 55 °C (131 °F) separating temperature < 6° dH Note:

– When using demineralised water or condensate, corrosion must be reckoned with.

– The use of boiler feed water is not permissible!

– Land water is not recommended because the degrees of hardness are normally too high.

The different hardness data are interrelated as follows:

1° dH = 1.79° fH = 1.25° eH = 17.9 ppm CaCO3 pH 6.5 - 8.5 Chloride ions < 100 mg/l Suspended matter max. 10 mg/l Particle size max. 50 µm

4.10.2 Supply pressure and temperature of operating water

Fig. 23

1 P = 0.3 - 1.0 MPa

2 Min. temperature = 10 °C, Max. temperature = 85 °C

NOTE:

The pressure downstream of the water pressure reducer must not drop below

0.2 MPa when the operating water valve is open.

4.10.3 Operating water flow rate

2011-9601-000 / 0113 39

For exact program control, the following water flow rates are required in the manifold, given simultaneous actuation of the valves:

Separator model

V2 V2 V3 Total con-sumption per cycle

Total con-sumption per cycle without filling wa-ter

Filling water Displace-ment water

Operating water l/s l/s l/s Approx. l

WSD 8 0.1 0.1 0.5 3 2

WSD 18 0.1 0.1 0.8 5 3.5

WSD 35 0.1 0.1 0.8 10 6.5

WSE 5 0.1 0.1 0.5 1.6 1.1

WSE 10 0.1 0.1 0.5 3 2

WSE 20 0.1 0.1 0.8 5 3.5

WSE 50 0.1 0.1 0.8 10 6.5

* Ejection cycle = Σ (filling water + displacement water + operating water)

4.11 Product lines

Observe the following points when installing the product lines:

– The suction lines should be as short as possible to avoid pressure losses.

– The pipes must be installed with adequate clearance from the electronic parts.

– Pipe pockets must be avoided!

– Piping must be cleaned after installation and must not contain any welding or machining residues.

– When different products are run through the same separator, it must be en-sured that the corresponding product lines cannot be interchanged.

4.11.1 Pipe cross-sections

The following must be observed when laying out the piping:

– All pipes, valves, fittings and instruments must be laid so that an insulation of 40 mm is possible.

– The dimensioning of the pipes is specified on the respective P&ID.

– The pipes can be selected with the aid of the following diagram. The spe-cifications on the dimension drawings have priority!

– Pipe resistances must be kept as low as possible.

Taking into account the total pressure losses, the flow velocities should be

– between 0.5 m/s and < 1 m/s in suction lines

– between 1 m/s and 3 m/s in pressure lines

4.11.2 Functional description of centripetal pump (gripper)

The liquid is discharged from the separator by means of a centripetal pump, in the following referred to as a gripper. At small capacities, the discharge can oc-cur without pressure. In the case of large capacities the gripper generates the required pressure to convey the liquid out of the separator through the down-stream lines by immersing more deeply into the liquid.

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The pressure values can differ significantly. The following rule applies:

– The values are lower for smaller separators than for large separators.

Other influencing factors are:

– Capacity

– System resistances (valve position, tank position)

– Production properties

– Process specifications

4.11.3 Information on pressure monitoring

When the liquid is discharged from the separator under pressure, the operator knows that the separator bowl is hydraulically closed.

A discharge pressure arises given a constant capacity or it is adjusted to the desired value by throttling in the discharge.

In the standard application, the pressure sensor responds to falling discharge pressure; an alarm is triggered via the controller. Deviating from this, the con-troller can also evaluate the rising pressure and trigger an alarm.

Generally, the discharge pressure is set to 0.1 - 0.5 MPa.

The magnitude of the pressure can deviate from this if necessitated by the

– Separator size

– Separator capacity

– Production properties

– Process specifications

For more detailed information, see the order-specific documentation.

The following conditions can be the cause of the change in the discharge pres-sure:

– Switchover from tank cleaning operation to over-board operation and vice versa

– Change in feed capacity

– Change in product data such as temperature, density, viscosity

– Change in discharge resistance

– Leakage from the separator bowl

These data represent important information for the plant operator.

2011-9601-000 / 0113 41

Selection diagram

Fig. 24

Pos. Variable Value Unit 1 Q Flow [l/s] 2 Q Flow [l/min] 3 Q Flow [m³/h] 4 V Velocity [m/s]

Example:

A flow rate of 5 m3/h produces a velocity of 1.2 m/s for a nominal diameter of 40.

42 2011-9601-000 / 0113

4.11.4 Maximum suction head of the pump

The suction head of the feed pump (progressive cavity pump) is max. 0.05 MPa.

When dimensioning the suction line, it must be ensured that the total pressure loss in the pipe does not exceed the maximum suction head of the pump.

The maximum feed pressure in the suction line must not exceed 0.05 MPa.

2011-9601-000 / 0113 43

4.12 Electrical installation

4.12.1 Control cabinet

Fig. 25

1 Process display, operator panel

2 Inlet pump Start/Stop

3 Filter/ fan

4 Main switch

5 Separator Start/Stop

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4.12.2 Installing and securing the control cabinet

The following points must be observed when installing the control cabinet:

Select the installation site so that

– the control cabinet door can be opened wide so that the door checking de-vice can engage (note section “Space requirement”)

– operability and inspection is ensured at all times

– an ambient temperature of 45 °C (113 °F) is not exceeded If necessary, make sure there is an adequate supply of fresh air.

Buttons, switches, and the electronic control unit are protected from moisture by protective film and door sealing. Nevertheless, do not install the control cabinet in a moist environment or in a direct wet area.

Note: To keep the temperature inside the unit constant by the cabinet heater after commissioning, the main switch should remain turned on even when the system is at a standstill.

Securing the control cabinet

Mounting example:

Wall mounting for control cabinet

Fig. 26

1 Gasket 10.5 x 23.5

2 Threaded bolt M8 (inserted into wall)

3 Washer

4 Rear panel of control cabinet

5 Washer

6 Wall

4.12.3 Electrical connection

The control system is designed for the nominal input voltage specified on the nameplate inside the control cabinet.

4.12.4 Connecting external voltages

The electrically-isolated contacts of the output modules

– carry external voltage (even when the main switch is switched off!)

– can be identified by the orange-coloured wiring inside

– can be used in external control systems up to 250 VAC

A cross-section of 1.5 mm2 Cu is adequate for all interlock and signalling ca-bles.

2011-9601-000 / 0113 45

4.12.5 Electrical connection for shipboard operation

For shipboard operation

– only "MGCH"-type armoured cables according to DIN 89158 may be used

– brass glands according to DIN 89280 must be used

– power cables and control cables can be laid jointly without clearance

Cable glands for shipboard installation

Female thread

∅ Cable ou-ter

[mm] Gland

Earthing device + inner parts type

M 20 x 1.5 7.0 - 8.5 M 24 x 1.5 for data cable without shield M 20 x 1.5 8.5 - 10.5 M 24 x 1.5 A4 + Z10 M 20 x 1.5 10.5 - 12.5 M 24 x 1.5 A6 + Z12 M 20 x 1.5 12.5 - 14.5 M 24 x 1.5 A6 + Z14 M 25 x 1.5 14.5 - 16.5 M 24 x 1.5 A7 + Z16 M 25 x 1.5 16.5 - 17.5 M 24 x 1.5 A8 + Z17 M 25 x 1.5 17.5 - 18.5 M 30 x 2 A9 + Z18 M 32 x 1.5 18.5 - 20.5 M 30 x 2 A10 + Z20 M 32 x 1.5 20.5 - 22.5 M 36 x 2 A11 + Z22 M 40 x 1.5 22.5 - 24.5 M 36 x 2 A12 + Z24 M 40 x 1.5 24.5 - 26.5 M 36 x 2 A13 + Z26 M 40 x 1.5 27 - 28.5 M 45 x 2 A14 + Z28 M 40 x 1.5 30.5 - 32.5 M 45 x 2 A15 + Z32 M 50 x 1.5 39.0 - 41.5 M 56 x 2 A17 + Z41

4.12.6 Electrical connection for onshore operation

The following points must be observed for the electrical connection of the con-trol cabinet when the system is operated onshore:

– The local regulations at the owner's location must be observed!

For onshore operation

– unarmoured "Ölflex" cables are normally used, for outside installation

"NSSHÖU" cables are used

– commercially available cable glands can be used

– separate cable routing must be used for the power cables and control ca-bles

– cable entries with plastic or metal glands are permissible

4.12.7 Electromagnetically-compatible installation

The control cabinet is designed to meet requirements for electromagnetic com-patibility (EMC).

The following must be taken into consideration as appropriate for the electro-magnetically-compatible installation:

– Earthing straps

– Equipotential bonding

– Shielding of cables

– Separate cable routing

– Use of fuses for inductances

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4.12.8 Electrical design

The following standards and recommendations must be taken into consideration in the electrical installation unless the specifications and standards of classifica-tion societies have to be met:

For GEA Westfalia Separator, the following applies in principle:

– EN 60204 – Part 1, or

– VDE 0113 – Part 1

4.12.9 Equipotential bonding of the pumps

The installed pumps are integrated to the equipotential bonding of the sys-tem using the equipotential bonding connection on the motor side.

This applies always.

Note: If there is no protective conduc-tor incorporated in multi-core cables (e.g., in the armoured marine cable), the drive motor must also be integrat-ed in the equipotential bonding.

Fig. 27

The cross-section of the equipotential bonding conductor, normally insulated end-to-end in green-yellow, is based on the largest phase conductor con-nected to the respective consumer.

In practice, table 1 in EN 60204-1 is used for this.

GEA Westfalia Separator chooses:

10 mm2 < S < 25 mm2 Cu

Fig. 28

4.12.10 Equipotential bonding of the electric heater

• Implement the equipotential bonding for the heater as shown.

Fig. 29

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4.12.11 Equipotential bonding of the foundation plate

The foundation plate or foundation trough must be fitted with a marked connector bolt for equipotential bond-ing on the customer siding.

Fig. 30

4.12.12 Installing and operating controllers

– Outdoor installation is not permitted!

• Select the installation site so that

– the controller is not exposed to dust or corrosive atmosphere

– the controller is not installed in an excessively moist environment or in a di-rect wet area

– the sun cannot shine on the control panel or displays and impair operator control and monitoring

– heating up of the controller is avoided

– If necessary, check screwed connections and plug-in connections for relia-ble contact.

– Connect the thermostatically-controlled cabinet heater to the external volt-age and switch it on.

– Check that the mains voltage and frequency conform to the connection data of the controller (see nameplate).

• Observe the permissible installation and operation data:

Voltage fluctuations +/-10% of the mains voltage

Frequency fluctuations +/-2% of the mains frequency

Ambient temperatures +5 to +45 °C (41 to 113 °F)

Air humidity max. 50% at 40 °C (104 °F) max. 90% at 20 °C (68 °F)

Installation height up to 1000 m above sea level

Transport temperatures -25 to +55 °C (-13 to 131 °F)

NOTE:

Improper installation and improper operation release the supplier from the war-ranty!

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