(066) oily water separator.pdf

FRV40-226-066-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Oily Water Separator Model: Ultra-Sep US500

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-226-066-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Model: Ultra-Sep US500

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

28 JUNE 2007

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-066-010

TITLE OF MANUAL: Oily Water Separator

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-226 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-066-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________

CHAND, LLC

Mathews, LA 70375

CAGE CODE: 0D5X4

VALIDATION PERFORMANCE

Title of Publication

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-226 Oily Water Separator. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the Oily Water Separator. The text is broken down as follows:

Section 1- Introduction

Section 2- General Description

Section 3- Installation

Section 4- Operation Instructions

Section 5- Maintenance Procedures

Section 6- Troubleshooting

Section 7- Parts List

Appendix A- Figures

Appendix B- System Major Components

Appendix C- Drawings

Appendix D- Certificates

May 2005 Manual No. USMN500

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

BILGE WATER SEPARATOR

ULTRA-SEP* MODEL US500

Coffin World Water Systems Design & Manufacture of Water Treatment Systems

1732 McGaw Ave. Irvine, CA 92614 U.S.A.

WEB: cworldwater.com

TEL: (949)222-5777

FAX: (949)222-5770

TABLE OF CONTENTS

SECTION 1: INTRODUCTION Page

1.1 MANUAL DESCRIPTION 1-1

1.2 THEORY OF OPERATION 1-2

SECTION 2: GENERAL DESCRIPTION

2.1 GENERAL SYSTEM DESCRIPTION 2-1

2.2 PROCESS FLOW DESCRIPTION 2-1

2.3 SPECIFICATIONS 2-3

SECTION 3: INSTALLATION

3.1 UNPACKING 3-1

3.2 INSTALLATION 3-1

3.2.1 SITE SELECTION AND PREPARATION 3-1

3.2.2 PIPING CONNECTION 3-1

3.3 ELECTRICAL REQUIREMENTS 3-3

SECTION 4: OPERATION INSTRUCTIONS

4.1 COMPONENT FUNCTIONAL DESCRIPTION 4-1

4.2 PRESTART CHECKS 4-3

4.3 DESCRIPTION OF HUMAN MACHINE INTERFACE SCREENS 4-4

4.3.1 MAIN SCREEN 4-4

4.3.2 OPERATION SCREEN 4-5

4.3.3 HAND MODE SCREEN 4-6

4.3.4 AUTO MODE SCREEN 4-7

4.3.5 CLEAN MODE SCREEN 4-8

4.3.6 ALARM SCREEN 4-9

4.3.7 OPERATIONAL SETTINGS SCREEN 4-10

4.3.8 CLEANING SETTINGS SCREEN 4-11

4.3.9 INPUT/OUTPUT SCREEN 4-12

4.4 INITIAL START-UP 4-13

4.4.1 INITIAL START-UP PROCEDURE 4-13

4.4.2 INITIAL OPERATION READINGS 4-16

4.5 ROUTINE START-UP & SHUT DOWN PROCEDURES 4-17

4.5.1 MANUAL OPERATION PROCEDURES 4-17

4.5.2 AUTOMATIC OPERATION PROCEDURES 4-20

4.5.3 NORMAL OPERATING CONDITIONS 4-21

4.5.4 ROUTINE SHUTDOWN PROCEDURES 4 22

4.6 ALARMS 4-23

4.7 SAFETY FEATURES 4-24

SECTION 5: MAINTENANCE PROCEDURES

5.1 SYSTEM FLUSHING 5-1

5.1.1 SPIR-O-LATOR® FLUSH 5.1

5.1.2 SEPARATOR FLUSH 5-2

5.1.3 FLUSHING THE SMARTCELL 5-2

5.2 OIL DISCHARGE 5-3

5.3 FILTER BAG REPLACEMENT 5-4

5.4 SPIR-O-LATORS® CLEANING 5-5

5.4.1 PREPARATION FOR CLEANING 5 5

5.4.2 CLEANING PROCEDURES 5-6

5.4.3 CHANGE OUT PROCEDURES 5-9

5.5 SPIR-O-LATORS® PRESERVING 5-10

5.5.1 PREPARATION FOR PRESERVING 5-10

5.5.2 PRESERVING PROCEDURES 5-10

5.6 CLEANING THE OIL SENSING PROBE 5-11

5.7 SEPARATOR SOLIDS & SLUDGE DUMP 5-11

5.8 CLEANING THE SEPARATOR 5-12

SECTION 6: TROUBLE SHOOTING

6.1 TROUBLE SHOOTING GUIDE 6-1

SECTION 7: PARTS LIST

7.1 SPARE PARTS 7-1

APPENDICES

FIGURES Appendix'A'

SYSTEM MAJOR COMPONENTS Appendix 'B'

DRAWINGS Appendix'C

CERTIFICATES Appendix 'D'

WARRANTY

Coffin World Water Systems, LLC (CWWS) warrants the purchaser that each ULTRA-SEP®, Bilge water Separator System, as delivered to the purchaser, shall be free from defects in material or workmanship for a period of eighteen (18) months from date of delivery or twelve (12) months from date of installation, whichever comes first.

All vessels and parts thereof that are claimed to be defective by the purchaser must be returned to an authorized CWWS service depot, at the expense of the purchaser, for inspection prior to the allowance of any credit or replacement.

This warranty does not apply to damage resulting from accident, neglect, or misuse. The foregoing warranty is the only warranty extended by CWWS and is in lieu of all other warranties, express or implied, or for fitness of a particular purpose.

Section 1: Introduction

1.1 MANUAL DESCRIPTION

This instruction manual describes the function, operating procedures, maintenance and installation requirements for the CWWS ULTRA-SEP® Bilge Water Separator.

NOTES, CAUTIONS, AND WARNINGS are included in the operating procedures. A NOTE indicates an operating procedure or condition that is essential to highlight or which provides an explanation for a given procedure. A CAUTION indicates an operating procedure or practice that, if not strictly observed, may result in damage to, or destruction of equipment or degradation of the water quality. A WARNING indicates an operating procedure or practice that can result in bodily injury or loss of life if not correctly followed. NOTES, CAUTIONS, and WARNINGS always precede the paragraphs to which they apply. Under normal operating conditions, adherence to the procedures described in this manual will assure trouble-free operation.

It is important that the operator of the ULTRA-SEP® System reads and fully understands this entire manual. By understanding the functions and normal operation of each component in the system, the operator can diagnose and correct operating problems as they develop. Please take the time to read this manual, study the process flow diagram, and understand the system before attempting to install and operate the system.

Section 1: Introduction

1.2 THEORY OF OPERATION

The ULTRA-SEP® Bilge Water Separator is a dual stage bilge water separation system. The first stage utilizes a system generated vacuum, differential specific gravity and high efficiency two stage coalescer for the removal of the majority of free oil and dirt separation. The second stage uses a micron filtration for removal of trace solids and small oil droplets followed by ultra-filtration to separate and remove emulsified oils, along with the remaining minute solids and entrained air from bilge water. The system is designed for continuous and/or intermittent operation. After the system has been started, it is capable of automatic operation.

The innovative design of the CWWS Bilge Water Separator eliminates the need for flocculants and chemical additives to remove the emulsified oily bilge water

Stage 1 Incoming bilge water passes through a basket strainer (customer provided) to remove oversized solid contaminants. From there it is drawn into the first stage consisting of a well proven coalescing HELI-SEP® Oily Water Separator, where the free oil droplets coalesce as they pass through the permanent matrix. This oil rises to the top of the vessel and it is collected for discharge during the oil discharge cycle. The water is then drawn through a pack of oleophillic polishing beads, which trap the remaining fine oil droplets. These oil droplets are washed out and discharged during the oil discharge cycle.

Stage 2 Processed water from the HELI-SEP® is then directed through particulate filtration, which further reduces solids contamination. This semi-treated water is then fed into the process pump; this pump increases the flow and pressure to the optimum conditions for the SPIR-O-LATORS®. The Spir-O-Lators® are engineered to produce clean water in compliance with MEPC 107 (49), and a reject stream, which is re-circulated back for re-processing.

The system has been designed to be installed as a single skid assembly or in separate modules to accommodate various engine room layouts.

CWWS BILGE WATER SEPARATOR

1-2

Section 2: General Description

2.1 GENERAL SYSTEM DESCRIPTION

The ULTRA-SEP® Bilge Water Separator is an ultra-filtration process designed for separating a wide variety of chemically or mechanically emulsified bilge water solutions. At the heart of the system are the CWWS HELI-SEP® and the CWWS SPIR-0-LATOR® (which are designed and developed specifically for bilge water and industrial waste applications and are impervious to most chemicals). The ULTRA-SEP®'s major components are the HELI- SEP®, Feed Pump, Bag Filter, Process Pump, the SPIR-O-LATORS® and must also include an approved MEPC 107

(49) Oil Content Detector. The system is also available with optional influent heater for enhanced cold water operation. The ULTRA-SEP® is designed to be fully automatic, eliminating the need for attended operation. The controls provide two basic modes of operation; an operate mode and a clean mode. The displays provide operating pressures and visual indicators of operating conditions. The ULTRA-SEP®'s components are of heavy duty industrial grade quality for long service life and are assembled in three basic configurations. 1 - The typical configuration is where all the components are installed on one powder-coated structural steel skid and arranged for ease of installation and servicing. 2 - A modular configuration is available which divides the typical configuration into two basic modules, the Control Module with Spir-O-Lator® Rack and the Separator Module, to allow for more installation flexibility and constraints. 3 - A retrofit configuration is available which provides the Control Module with Spir-O-Lator® Rack and a Heli-Sep® Retrofit Kit to retrofit an existing approved MEPC 60 (33) HELI-SEP® Oily Water Separator to be utilized as the Separator Module. In all three configurations, the Spir-O-Lator® Rack can be removed from the system for installation purposes and remounted, or it may be mounted remotely from the system if necessary.

2.2 PROCESS FLOW DESCRIPTION

The bilge water to be processed is pulled from the bilge or holding tank by the Feed Pump. The water is pulled through a customer supplied basket strainer to remove large solids. The influent then enters the separator near the bottom of the solids sludge collecting chamber. Most of the free oil separates from the influent immediately due to the difference in specific gravity and the reduced flow velocity inside the separator. The flow travels upward through the separating media matrix. This path maximizes contact with the separating media to enhance coalescence of the oil. The flow exits the top of the separating media matrix where the oil continues to flow upwards to the top of the separator's oil collecting chamber due to the difference in specific gravity. The influent less the majority of free oil is then drawn downward by the Feed Pumps' vacuum through the polishing pack. The polishing pack removes the small oil droplets. When sufficient oil has been collected in the oil collecting chamber, the oil sensing probes located in the top of the separator deactivate the Feed Pump and open the clean water inlet valve. Pressurized water, sea water or fresh water, (warm water is recommended if available 37.8°C (100°F). maximum) enters from the bottom of the separator and displaces the accumulated oil in the collection chamber top of the HELI-SEP® which is discharged through the oil discharge line. After the accumulated oil has been discharged and the oil sensing probe is again immersed in water, the separator returns to the separating mode. The semi cleaned influent less the majority of free oils, but with some emulsified oils, exits the HELI-SEP® through the Feed Pump.

The Feed Pump pressurizes the influent for processing through the process Bag Filter before supplying the Process Pump with a positive suction head. The Bag filter removes suspended solids and oil droplets of approximately 5 microns and larger from the flow.

This semi-cleaned influent is supplied to the Process Pump for processing by the CWWS SPIR-O-LATORS®. The process pump increases the influent pressure and drives the emulsions across the surface of the SPIR-O-LATOR® at a high velocity. Water, salts and detergents are forced through the SPIR-O-LATOR® by back pressure created by the system and the systems operating pressure control valve while oils and other waste larger than or greater than twenty thousandths (20,000) in molecular weight are rejected. The portion of the influent forced through the SPIR-O- LATOR® is referred to as the processed water (clean water or permeate) while the remainder is referred to as the concentrate or reject. The processed water is discharged from the system. This system is being constantly replenished by the influent supplied by the Feed Pump. The concentrate with the rejected oils and waste is returned to inlet of the Bag Filter, for de-oiling and polishing before being fed to the Process Pump inlet for reprocessing through the

2-1

SPIR-O-LATORS®. This reject reprocessing allows for a higher velocity flow rate across the SPIR-O-LATORS® which maximizes the process water output by minimizing fouling because the higher velocity shears off the excess oils and waste of the surface of the SPIR-O-LATORS®. The process flow rate is the combination of the process water flow and the concentrate flow.

The ULTRA-SEP® is equipped with additional features and functions to maintain optimum operating conditions.

The process water, concentrate and concentrate bleed to bilge flows are factory set and can be manually checked for verification. Liquid filled pressure gauges are provided and identified to help monitor operating conditions. A flush sequence is provided to automatically flush the SPIR-O-LATORS® with clean water periodically, when a low process water flow is detected and upon each automatic shutdown of the system. Or it can be also performed manually at any time. During a flush, the water is drawn from the clean water source by the Process Pump and is pumped across the SPIR-O-LATORS® for a short duration of time then discharged out the bilge where it can be reprocessed.

In summary, the processed water, the output of the ULTRA-SEP®, is equal to the systems emulsified influent minus the small concentrate bleed outlet stream. The concentrated bleed is continuously discharged from the recirculation line, where concentrated oils can be further coalesced in the bilge, or holding tank, or in the HELI-SEP when being reprocessed through the ULTRA-SEP®. This process allows the ULTRA-SEP® produce one stream of processed water that is less than 15 parts per million that can be discharged overboard per IMO Resolution MEPC.107 (49).

The system is equipped with an oil content monitor, which continuously monitors the processed water for oil content if the oil content exceeds the alarm set point the water will automatically be re-directed to re-circulate to the bilge.

2-2

2.3 SPECIFICATIONS

Type: Fully automatic ULTRA-SEP® system with a HELI-SEP® bilge water separator, Bag Filter for solids, and SPIR-O-LATORS® for enhanced waste/oil separation.

Model Number:

Capacity:

General Design Data:

Electrical Power Input:

US500

0.5 M3/H (2.2 GPM)

All standard voltages. Refer to Electrical Requirements Consumption: 3.4 kW

Clean Water Supply Ranges

Temperature Ranges:

Design Data:

Influent:

Effluent:

Operating Pressure Range:

: (Flow) (Pressure)

(Influent) (Ambient)

(Primary)

(Secondary)

Weights and Dimensional Data:

Weight-Dry:

Weight-Wet:

Length:

Width:

Height:

0.2 M7h Min.

275-550 kPa l°C-50°C l°C-50°C

0.9 GPM Min

40-80 PSI

34°F -122°F 34°F - 122°F

A solution of water contaminated with petroleum products, soaps, and detergents.

Processed water, Clean Water < 20,000 molecular weight

Waste oils and other compounds.

345-690 kPa

400 kg

440 kg

1625 MM

965 MM

1230 MM

50-100 PSI

885 Pounds

960 Pounds

64 Inches

38 Inches

48 1/2 Inches

2-3

Piping Connections:

System Inlet:

Processed Water Outlet:

Recirculate Outlet:

Oil Outlet Clean Water Inlet:

Filter Drain Outlet:

Separator Drain Outlet:

25 MM

15 MM

15 MM

25 MM

15 MM

20 MM

20 MM

1" 1/2" 1/2" 1" 1/2" 3/4" 3/4"

Control Valve Settings:

(Typical values, Refer to documentation on system or consult factory for actual values)

Membrane Inlet Pressure Control Valve (GVl): 0.7 - 1.3

Operating Pressure Control Valve (GV2): 2.4 - 3.8

Product Flow Control Valve(GV3): 0.35 - 1.2

Concentrate Bleed Control Valve (GV4): 0.55 - 1.25

2-4

Solenoid Valve Chart:

Operation Mode

Overboard Recirculation Heli-Sep Oil

Discharge Spir-o-lator

Flush Cleaning

* Heli-Sep Flush

Solenoid SVl

ON

OFF

OFF

OFF

OFF

OFF

SV2

OFF

ON

OFF

ON

OFF

OFF

SV3

ON

ON

OFF

ON

OFF

OFF

SV4

OFF

OFF

ON

ON

ON

(FOR 10 SEC.)

ON

Monitor Feed Line

N/A

MVl Motor Valve

OFF

OFF

ON

OFF

OFF

ON

* To clean matrix & remove solids, open BV3 during this procedure.

If fitted with optional lighted Din Plugs, each Solenoid's Din Plug of SVl thru SV4 will illuminate when its respected solenoid is ENERGIZED / OPEN.

N/A = Not Applicable

2-5

Section 3: Installation

3.1 UNPACKING

Carefully remove top and sides of the crating. Inspect the system for any damage that may have occurred during shipping. Unbolt the system from the crate. Padding on fragile item should remain in place to protect fragile items during rigging of the system into the ship. When the system is securely installed on the ship the padding on fragile items should be removed.

3.2 INSTALLATION

Installation in accordance with the recommendations that follow will ensure long and trouble-free operation from the equipment. Refer to Appendix "C" for the Installation drawing for dimensional and orientation information, and to the Piping & Instruments Drawing for piping arrangements.

3.2.1 SITE SELECTION AND PREPARATION

NOTE

Allow ample room for servicing units electrical controls, pump motor, SPIR-O-LATORS® and other components. Reference the drawings in Appendix "C" for required clearances.

CAUTION

BE SURE THAT THE BILGE HAS BEEN THOROUGHLY CLEANED

OF ALL DEBRIS, LIQUIDS AND CONTAMINANTS REMAINING

FROM THE SHIPS' FABRICATION BEFORE START UP.

Securely install the system as level as possible with the interface connections positioned to permit the most direct route to the piping connections. Eliminate as many 90 degree turns as possible. System should be fully supported and bolted down through holes provided in skid.

3.2.2 PIPING CONNECTIONS

NOTE

The suction source should be located so as to lift the fluid the shortest distance possible and not to exceed 7 Meters (23 Feet) vertical. Do not draw suction from a point less than 300 Millimeters (12 inches) above the sludge level in bottom of the bilge or holding tank. Ascertain that the suction lines are air-tight. Keep the horizontal run under 30 Meters (100 Feet) and it must be the same or larger than the ULTRA-SEP interface.

CAUTION

INSTALL A FOOT VALVE (USER SUPPLIED) AT THE SUMP OR

HOLDING TANK END OF THE SYSTEM'S INLET SUCTION LINE.

1. Connect a line to the Oily Water Inlet from the (user supplied) sump or holding tank which is to supply the oily water to the ULTRA-SEP® for processing. Ascertain that a foot valve (user supplied) is installed at the (user supplied) sump or holding tank end of the line. A bleed port should be provided as close to the foot valve end of the suction line as possible for priming purposes. The source for the inlet should be in an area that will provide the best quality solution possible to the system. Ensure that piping is capable of supplying the inlet to the system as required by the specifications.

3-1

NOTE

The processed water vertical lift to overboard can not exceed 20 Meters (65 feet). If a higher head is required an optional pump maybe required.

2. Connect the Processed Water Outlet to the discharge line going overboard.

3. Connect a line to the Recirculation to return the re-circulate preferably to the bilge for complete reprocessing, or to a holding tank which is acceptable, but connecting this line right back to the system's Oily Water Inlet is un-acceptable and must be avoided.

4. Connect the Clean Water Inlet to a clean pressurized water source (Sea or Fresh) for flushing the HELI- SEP®, and for flushing or filling the ULTRA-SEP®. PRESSURE MUST NOT BE LESS THAN 2.7 bar (40 PSI) or exceed 5.5 bar (80 PSI).

5. Connect a line to the Oil Discharge to discharge the Separator's accumulated oil to a slop tank for waste disposal or storage.

NOTE

For Gravity Drain, the drain lines must be higher than the (user supplied) sump or bilge into which they are to discharge.

6. Connect lines to the Drains to gravity drain the system back to the (user supplied) sump or bilge.

3-2

3.3 ELECTRICAL REQUIREMENTS

Refer to Appendix "C" for the appropriate Electrical Drawing for the system being installed. The electrical power requirements are given on the serial plate.

WARNING

ELECTRICAL INSTALLATION AND CONNECTION TO THE MAIN

POWER SOURCE MUST BE PERFORMED BY A FULLY QUALIFIED

ELECTRICIAN IN ACCORDANCE WITH THE PERTINENT CODES

AND REGULATIONS. TURN OFF FACILITY POWER BEFORE

MAKING ANY ELECTRICAL CONNECTIONS. SYSTEM MUST BE

GROUNDED IN ACCORDANCE WITH APPLICABLE ELECTRICAL

CODES. FAILING TO FOLLOW THE PERTINENT ELECTRICAL

SAFETY REGULATIONS CAN CAUSE THE DAMAGE OF THE

SYSTEM, PERSONAL INJURY OR DEATH.

CAUTION

INSTALL A SUITABLE CIRCUIT BREAKER (USER SUPPLIED) TO

MAIN LINE CONNECTED TO THE SYSTEM. SEE WIRING DIAGRAM

DRAWING IN APPENDIX "C".

1. Connect incoming power for the system to the main Power Disconnect Switch (2SW1) located in the MCC (Motor Control Center).

CAUTION

SYSTEM SHOULD BE VENTED AND FULL OF WATER PRIOR TO

STARTUP OR ROTATION CHECK.

CAUTION

CHECK ROTATION OF SYSTEM'S PUMP/MOTORS PRIOR TO

INITIAL START-UP.

2. Prior to start-up, ascertain that the system pump/motors are rotating in the proper direction as indicated by the rotation arrow located on each pump/motor.

FEED PUMP PROCESS PUMP

3. If required, connect the REMOTE EMERGENCY STOP (Normally closed contact required) by removing the factory jumper located in the Control Box Panel.

4. If required, connect the Oil Content Detector High Content Alarm and the System Shut Down Signal alarm to the required location. Normally Closed and Open Contacts are provided for these features. Under alarm condition, the respective relays are activated.

5. If required, connect the High/Low Bilge float devices to the ULTRA-SEP® by using the appropriate terminal blocks located in the Control Panel.

3-3

Section 4: Operation Instructions

4.1 COMPONENT FUNCTIONAL DESCRIPTION

This table describes the function of the components as illustrated on the figures in Appendix "A".

ITEM COMPONENT NAME

1. Skid Base

FUNCTION

Provides a rigid foundation for mounting system components.

2. HELI-SEP® Separator Vessel

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Oil Content Detector, Bilge Alarm - OCD SB

Feed Pump (PU1)

Process Pump (PU2)

Control Panel

SPIR-O-LATOR®Rack

Process Filter Housing (FIL1)

Low Process Pump Suction Pressure (PSL1)

Low Product Pressure (PSL2)

High SPIR-O-LATOR® Temperature (TSH)

Bilge Tank Low Level (LSL)

Bilge Tank Low Level (LSH)

Power Disconnect Switch

(2SW1)

Vessel that provides the initial bulk separation of the free oils and senses when enough oil has accumulated to be discharge automatically to a customer supplied oil slop tank. The vessel contains a separating media matrix, a polishing pack, the oil sensing probe (OSP) and the Oil Discharge Motor Valve

(MV1).

Monitors the processed water for oil content and controls the two processed water outlet valves: Factory Set 15 PPM.

Overboard - oil content less than 15 PPM.

Re-circulate - oil content 15 PPM and above.

Creates a suction on the HELI-SEP® pulling in the bilge water from Bilge or holding tank. Pressurizing the feed to the process Bag Filter and to the Process Pump suction.

Boosts the pressure and flow for proper processing through the

SPIR-O-LATORS®.

Contains the Touch Screen Human Machine Interface for activating, monitoring, operating and stopping the system.

Pressure housing(s) with mounting brackets for installation of the spiral wound SPIR-O-LATORS®.

Contain replaceable filters, the final polishing filter for the influent before being processed by the SPIR-O-LATORS®.

Activates alarms when low pressure on the process pump suction is detected.

Activates warning/alarm when low SPIR-O-LATORS® Product pressure is detected.

Activates alarm when high SPIR-O-LATOR® temperature is detected.

Customer provided switch shuts down the system when low bilge water level is detected if the system is in Auto Mode.

Customer provided switch starts the system when high bilge water level is detected if the system is in Auto Mode.

3-pole disconnect switch disconnects the system power.

Prevents opening the door with the power on.

4-1

ITEM COMPONENT NAME FUNCTION

15. Touch Screen Human Machine Operator interface that provides the following functions:

Interface • Operation screens and controls to operate the

ULTRA-SEP®.

• Useful fully alarm descriptions that will help the operators to identify the cause of a problem.

• Time setting screens.

• Input / Output troubleshooting screens.

16. Emergency Stop Switch. Shuts down the system when activated. Terminals are supplied for a customer supplied Remote Emergency Stop switch, the system is shipped from the factory with a jumper in place to allow operation if remote switch is not installed.

4-2

4.2 PRE-START CHECKS

Perform the following checks and verifications prior to system start-up. Refer to the Process Flow Diagram in Appendix "C" for the location of the referenced valve callouts shown in parenthesis.

1. Ensure that all manual valves (user supplied) leading to and from the ULTRA-SEP® are open.

2. Ensure that the following ULTRA-SEP® valves are OPEN or set to a predetermined operating position.

a) Process Filter (FILl)Vent Valve BV4.

b) Processed Water Sample Valve BV10.

3. Ensure that the following ULTRA-SEP® valves are CLOSED.

a) Process Bag Filter (FIL1) Drain Valve B V5.

b) HELI-SEP® Drain Valve BV3.

c) SPIR-O-LATOR Feed Sample Valve BV9.

4. Ensure that the following ULTRA-SEP® valves are NOT TOUCHED.

a) SPIR-O-LATOR Inlet valve GV1.

b) Operating Pressure Control Valve GV2.

c) Processed water Control valve GV3.

d) Re-circulate Outlet Valve GV4.

NOTE.

All these valves are factory set and should be checked upon commissioning per control valve settings located in the 2.3 Specifications.

5. For initial Shut Down or after the system has been drain, the Initial Start Up Procedures MUST be performed.

4-3

4.3 DESCRIPTION OF HUMAN MACfflNE INTERFACE SCREENS

4.3.1 MAIN SCREEN.

Upon machine power up this is the initial screen that will be displayed on the Human Machine interface. This screen has UP and DOWN buttons that will allow the operator to select from different screen options. The screen options are located within the SCREEN LIST SELECTOR. When either the UP or DOWN button is pushed, a POINTER will scroll up or down indicating the screen that can be selected. Once the desired screen has been selected, depress the ENTER button.

The screen has on its left section a MACHINE STATUS INDICATOR, FEED PUMP INDICATOR, PROCESS PUMP

INDICATOR.

4-4

4.3.2 OPERATION SCREEN.

GO TO ALARM

SCREEN BUTTON

SPIR-O-LATOR

FLUSH

BUTTON

OIL

DISCHARGE

BUTTON

GO TO MAIN

MENU

SCREEN

BUTTON

The OPERATION SCREEN is the one from where different operational modes can be selected. These modes are Hand Mode (HAND button), Auto Mode (AUTO button) and Clean Mode (CLEAN button). The system can be shut down by pushing the SYSTEM OFF button.

When performing the INITIAL START UP procedures (Section 4.4), use this screen to perform a HELISEP FLUSH and / or a SPIR-O-LATOR FILL.

The OPERATION SCREEN can also be used to do a Heli-Sep® manual OIL DISCHARGE or a SPIR-O-LATOR® FLUSH while the system is in HAND or AUTO operation.

The lower section of the screen has a Message Display, Machine Active Mode Display, Pumps Status and buttons to go to the Alarm Screen or the Main Menu.

4-5

4.3.3 HAND MODE SCREEN.

FEED PUMP

START BUTTCtt

PROCESS PUMI

START BUTTOP

PROCESS PUMP

STOP BUTTON

MESSAGE <S

DISPLAY

GO TO ALARM

SCREEN BUTTON

GO TO PREVIOUS

SCREEN BUTTON

FEEDPUMP

ON COUNT

DOWN

PROCESS PUMP

ON COUNT

DOWN

GOTO

OPERATION

* SCREEN

BUTTON

Within the HAND MODE SCREEN the feed and process pumps can be started/stopped using the corresponding start/stop buttons. When the pump are going to be started, a timer message right next to the pump status indicator shows the pump on count down timer.

The lower section of the screen has a Message Display, Machine Status Indicator and buttons to go to the Alarm Screen, Previous Screen or the Operation Screen.

4-6

4.3.4 AUTO MODE SCREEN.

FEED PUMP STATUS

INDICATOR

PROCESS PUMP STATUS

INDICATOR

AUTO MODE

START BUTTON

AUTO MODE

STOP BUTTOf

MESSAGE

DISPLAY

OPERATION

HOUR

• COUNTER

MACHINE ACTIVE MODE

DISPLAY

GO TO ALARM

SCREEN BUTTON

GO TO PREVIOUS

SCREEN BUTTON

SGOTO

OPERATION

SCREEN

BUTTON

The AUTO MODE SCREEN allows the operator to set the machine in the AUTO mode by pushing the AUTO START button. In this mode the feed and the process pumps will get the start / stop commands from the high / low bilge float switches. The operator can also start the auto operation only if the bilge level is above the bilge low level float switch.

This screen also displays an operation hour counter.

The lower section of the screen has a Message Display, Machine Status Indicator and buttons to go to the Alarm Screen, Previous Screen or the Operation Screen

4-7

4.3.5 CLEAN MODE SCREEN.

PRE-CLEAN

SEQUENCE START

BUTTON

START CLEAN

SEQUENCE BUTTON

PROCESS PUMP STATUS

INDICATOR

PAUSE CLEAN

SEQUENCE

BUTTON

CLEAN

MESSAGE

DISPLAY

CLEAN

STATUS S

INDICATOR

MACHINE ACTIVE

MODE DISPLAY

GO TO ALARM

SCREEN BUTTON

GO TO PREVIOUS

SCREEN BUTTON

CANCEL

CLEAN

MODE

BUTTON

CIRCULATION

/SOAK COUNT

DOWN

INDICATOR

GO TO

OPERATION

SCREEN

BUTTON

The CLEAN MODE SCREEN allows the operator to run a PRE-CLEAN sequence, START CLEAN sequence, PAUSE CLEAN MODE and CANCEL CLEAN MODE. During the cleaning sequence, different messages will be displayed on the CLEAN MESSAGE DISPLAY, CLEAN STATUS and CIRCULATION / SOAK COUNT DOWN INDICATOR.

The lower section of the screen has a Message Display, Machine Status Indicator and buttons to go to the Alarm Screen, Previous Screen or the Operation Screen.

4-8

4.3.6 ALARM SCREEN.

ALARM DATE ALARM TIME ALARM DESCRIPTION

ALARM SCROLL

UP

BUTTON

ALARM

SCROLL DOWM

BUTTON

ACKNOWLEDGE

ALARM BUTTO

GO TO PREVIOUS

SCREEN BUTTON

CLEAR HISTORY

ALARM BUTTON

RESET ALARM

BUTTON

GO TO PREVIOUS

SCREEN BUTTON

ALARM

HISTORY

DISPLAY

GO TO

MAIN MENU

SCREEN

BUTTON

The ALARM SCREEN is the one on which the operator will reset whichever alarm is generated during the Ultra-Sep® operation. To reset an alarm push the RESET ALARM button.

The ALARM SCREEN also permits the operator to visualize the Alarm History. The ALARM HISTORY DISPLAY will show the date and time when the alarm was generated as well as the alarm description.

The ALARM HISTORY DISPLAY can be erased by pushing the CLEAR HISTORY button.

The lower section of the screen has a Go To Previous Screen and a Go To Main Menu buttons.

4-9

43.7 OPERATIONAL SETTINGS SCREEN.

MACHINE

ACTIVE MODE

DISPLAY

GO TO ALARM

s SCREEN

' BUTTON

GO TO MAIN

MENU

SCREEN

BUTTON

The OPERATIONAL SETTINGS screen allows the operator to modify the following settings:

DESCRIPTION Minimum Maximum Factory Set

SPIR-O-LATOR FLUSH 60 sec 300 sec 60 sec

DURATION

AUTOMATIC

SPIR-O-LATOR

FLUSH FREQUENCY

1,800 sec 10,800 sec 3,600 sec

HELI-SEP AUTO OIL

DISCHARGE DURATION

60 sec 180 sec 60 sec

HELI-SEP PROLONGED OIL

DISCHARGE DURATION

15 sec 180 sec 15 sec

4-10

4.3.8 CLEANING SETTINGS SCREEN.

MACHINE

ACTIVE MODE

DISPLAY

The CLEANING SETTINGS screen allows the operator to modify the following settings:

DESCRIPTION Minimum Maximum Factory Set

CIRCULATION DURATION 600 sec 3,600 sec 1,800 sec

SOAK DURATION 600 sec 3,600 sec 600 sec

GO TO

PREVIOUS

SCREEN

BUTTON

GO TO MAIN

MENU

SCREEN

BUTTON

4-11

43.9 INPUT/OUTPUT SCREENS.

MACHINE

ACTIVE MODE

DISPLAY

GO TO ALARM

SCREEN BUTTON

GO TO PREVIOUS

SCREEN BUTTON

GO TO MAIN

MENU

SCREEN

BUTTON

The INPUT SCREENS 1 & 2 / OUTPUT SCREENS 1,2 &3 allow the operator or maintenance personnel to check the field devices connected to its correspondent Programmable Logic Controller (PLC) Input / Output.

The lower section of the screen has a Go To Alarm Screen, Go To Previous Screen, Go To Next Screen and a Go To Main Menu buttons.

4-12

4.4 INITIAL START-UP

Upon initial start-up or after the system has been drained, the ULTRA-SEP® must be filled and the Feed Pump and System Inlet Line primed before commencing operation. With the pre-start checks performed, follow the procedures below to fill and prime the system. Refer to the Process Flow Diagram in Appendix "C" for the location of the referenced valve callouts shown in parenthesis.

4.4.1 INITIAL START UP PROCEDURE.

1. Turn the Power Disconnect Switch (2SW1) located in the Motor Control Center (MCC) Box to the ON position. The HELI-SEP® will automatically start filling, via the oil discharge valves SV4 and MV1. After booting up for approximately 30 seconds the Touch Screen Human Machine Interface on the Control Panel will display the MAIN SCREEN. Once the HELI-SEP® is full and the oil sensing probe detects water, SV4 and MV1 will automatically close.

ULTRA-SEP"

COFFIN WORLD WflTER SYSTEMS

NOTE.

If the Remote Emergency Stop is used, remove factory jumper installed on the Control Panel. Refer to Section 3.3 Electrical Installation.

2. Check that the Local and/or Remote Emergency Stop Switches (3PB1 & Remote Emergency Stop) are not activated, if they are, deactivate them, go to the ALARM SCREEN and reset the alarm condition by pushing the RESET ALARM button.

3. If there is any other alarm condition, correct it and push the RESET ALARM button.

4-13

4. After the HELI-SEP® automatic fill has concluded (Machine Active Mode Display switches from Oil Discharge to Machine Off), make sure the Heli-Sep® is completely full by opening the HELI-SEP® Vent Valve (B V2) and pushing the HELISEP FLUSH button on the OPERATION SCREEN. Once water is flowing out of the Vent Valve (BV2), close it and push the HELISEP FLUSH button again to stop the HELI-SEP® flush.

5. Prepare to purge the SPIR-O-LATORS® housings and the Process Filter (FILl). OPEN the Process Bag Filter (FILl) Air Vent Valve (BV4), OPEN the Processed Water Sample Valve (BV10) and push the SPR-O-LTR FILL button on the OPERATION SCREEN to begin the filling of the SPIR-O-LATORS®.

6. During the SPIR-O-LATORSC following screen.

fill procedure, the Touch Screen Human Machine Interface will display the

7. When the air has been purged from the Process Filter (FILl) housing, CLOSE the air vent valve (BV4). When the air has been purged from the SPIR-O-LATORS® housings, CLOSE the Processed Water Sample Valve

(BV10).

4-14

8. Once the system is full of water and all the air is purged, terminate the SPIR-O-LATOR fill by pushing again the SPR-O-LTR FILL button on the OPERATION SCREEN.

UPE.KH1IOM

HflMD RUTO CLEfiN

DI

rrn

PUI

PU2 Goto

Rlarm Screen

GoTo Main Menu

9. It is now safe to check the rotation of both pump motors per their rotational arrows using the HAND MODE screen. To verify pump rotation, see section 3.3 Electrical Installation.

10. Follow the Manual Operation Procedures on Section 4.5.1 steps 4 through 9 to start the system on Hand Mode.

11. After operating the system for one hour, record the Initial Operation Readings. Use the Initial Operation Readings format provided on section 4.4.2 .

12. The initial start-up is now complete and the ULTRA-SEP® is now ready for Start Up and Shut Down procedures.

4-15

4.4.2 INITIAL OPERATION READINGS

The initial operation readings should be recorded to establish a reference for evaluating the performance of the ULTRA- SEP®. To record an accurate reference, allow the system to operate for approximately twenty four (24) hours before recording the initial operation readings.

DATE

TEMPERATURE

AMBIENT INLET

4-16

4.5. ROUTINE START-UP & SHUTDOWN PROCEDURES

With the Pre-Start checks performed and the Initial Start-Up having been completed, the ULTRA-SEP® is now ready for operation. Refer to the Process Flow Diagram in Appendix "C" for the location of the referenced valve callouts shown in parenthesis.

4.5.1 MANUAL OPERATION PROCEDURES

Operator attended operation of the ULTRA-SEP®.

1. Place the Power Switch into the ON position. After the Touch Screen Human Machine Interface has booted up, the MAIN SCREEN will be displayed.

ULTRA-SEP"

/by COFFIN WORLD WRTER SYSTEMS

2. Check the Local and Remote Emergency Stop Switches are not activated, if they are, deactivate them. If there is any other alarm conditions correct it and push the RESET ALARM button on the ALARM SCREEN.

3. Go back to the MAIN MENU by depressing the GO TO MAIN MENU button on the ALARM SCREEN. Once on the MAIN MENU screen, use the UP/DOWN buttons to point to the OPERATION SCREEN and push

ENTER.

ULTRA-SEP"

by COFFIN WORLD WflTER SYSTEMS

4-17

4. The OPERATION SCREEN will pop up. Go to the HAND MODE SCREEN by pushing the HAND button on the OPERATION SCREEN.

5. On the HAND MODE SCREEN push the FEED PUMP START button

6. The Machine Active Mode Display will now show the Machine to be in HAND MODE. The Feed Pump On Count Down Message will pop up. After a short delay to allow the valves to open, the Feed Pump (PUl) will start.

7. If the suction side of the Process Pump (PU2) is pressurized, the Process Pump (PU2) would be ready to start.

Push the PROCESS PUMP START button. After a 5 second delay the Process Pump (PU2) will turn on.

4-18

8. The Process Pump (PU2) turns on.

9. All the following valves are factory set (per Control Valve settings on Section 2.3 Specifications) and must be verified during commissioning. If any adjustment of system pressures is required, consult factory before adjusting.

a) Spir-O-Lators ® Inlet Pressure Control Valve (GV1)

b) Operating Pressure Control Valve (GV2)

c) Product Flow Control Valve (GV3)

d) Concentrate Bleed Flow (GV4)

10. When processing is complete, stop the ULTRA-SEP® by following the Routine Shutdown Procedures on Section 4.5.4.

4-19

4.5.2 AUTOMATIC OPERATION PROCEDURES

With the Pre-Start checks performed and the Initial Start-Up having been completed, the ULTRA-SEP® is now ready for operation. Refer to the Process Flow Diagram in Appendix "C" for the location of the referenced valve callouts shown in parenthesis.

Unattended operation of the ULTRA-SEP® Separator

1. Go to the AUTO MODE SCREEN. Push the AUTO START button to activate the AUTO MODE.

2. The Machine Active Mode Display will now show AUTO MODE.

NOTE.

As long as the bilge or holding tank low level float is maintained, the ULTRA- SEP® can be manually started by depressing the AUTO START button.

3. The ULTRA-SEP® will continue its automatic operation as dictated by the Start/Stop Float Switches in the bilge or oily water holding tank as long as the Machine Active Mode is in AUTO MODE.

4. When a shutdown is required, follow the Routine Shutdown Procedures on Section 4.5.4.

4-20

4.5.3 NORMAL OPERATING CONDITIONS

The normal operating condition of the system is as follows.

1. The Power Disconnect Switch (2SW1) is in the ON position.

2. The Touch Screen Human Machine Interface is ON and displaying the following screen.

3. The Machine Active Mode Display is shown as in AUTO MODE but may be displaying the current machine mode which could be HAND MODE, FLUSH MODE or OIL DISCHARGE.

4. The Feed Pump indicator (PU1) is ON.

5. The Process Pump indicator (PU2) is ON.

6. No alarm message is displayed on the Touch Screen Human Machine Interface.

7. The Oil Content Detector digital display reading should be less than 15 ppm.

8. The following solenoid valves are open; SV1 and SV3.

4-21

4.5.4 ROUTINE SHUTDOWN PROCEDURES

Prior to system shutdown, it is recommended that the operator observes and compares the performance of the system with the normal operation specifications and initial operation readings recorded in this manual. Doing so will enable the operator to identify and take corrective action during shutdown to ensure a proper functioning of the system at all times.

CAUTION

THE SPIR-O-LATOR® MUST REMAIN MOIST AT ALL TIMES. IF THE

SPIR-O-LATORS® ARE ALLOWED TO DRY OUT, THEY MAY BE

DAMAGED. BY FOLLOWING THE SHUTDOWN PROCEDURES, THE

SPIR-O-LATORS® PRESSURE VESSELS WILL REMAIN FULL OF

WATER.

1. Push the SYSTEM OFF button on the OPERATION SCREEN

2. If the ULTRA-SEP® has been running for more than 45 minutes, it will perform an automatic SPIR-O- LATORS® flush at the time it is shut down. If the ULTRA-SEP® is shut down before 45 minutes of operation do a manual SPIR-O-LATORS® flush by pushing the SPR-O-LTR button on the OPERATION SCREEN. The system will flush the SPIR-O-LATORS® for X minutes then it will shut off. The SPIR-O-LATORS® flush durations is determined by the SPIR-O-LATOR FLUSH DURATION setting located on the OPERATIONAL

SETTINGS SCREEN.

3. The Main Disconnect Switch (2SW1) located on the Motor Control Center (MCC) can be left on the ON position. For maintenance or prolonged shut down procedures, ALWAYS switch the Main Disconnect Switch (2SW1) to the OFF position.

4-22

4.6 ALARMS

The following chart lists the alarms, activating device, and possible cause of the alarm. A shutdown alarm must be reset through the ALARM SCREEN before the Ultra-Sep can be restarted.

ALARM DISPLAY

(Type of Alarm)

LOW PROCESS PUMP

SUCTION PRESSURE

ALARM

(Shutdown Alarm)

LOW PRODUCT PRESSURE

WARNING

(Warning Alarm)

LOW PRODUCT

PRESSURE ALARM

(Shutdown Alarm)

HIGH SPIR-O-LATOR®

TEMP ALARM

(Shutdown Alarm)

MOTOR OVERLOAD

ALARM

(Shutdown Alarm)

E-STOP ALARM

(Shutdown Alarm)

EXCESSIVE HELI-SEP OIL

DISCHARGE ALARM

(Shutdown Alarm)

THREE CONSECUTIVE OIL

DISCHARGES WITHIN

10 MIN ALARM

(Shutdown Alarm)

HIGH OIL CONTENT

SMART CELL ALARM

(Warning Alarm)

ACTIVATING DEVICE

PSL1

Activated after 30 Seconds of the Process Pump Suction Pressure being below the PSL1 Set Point.

For Factory set point check P&ID

PSL2

Activated after 30 Minutes of the Product Pressure being below the PSL2 set point For Factory set point check P&ID

PSL2

Activated after 2 Hours of the Product Pressure being below the PSL2 set point For Factory set point check P&ID

TSH1

Activated when Process Temperature exceeds the TSH1 set point.

For Factory set point check P&ID CBlo rCB2 Activated when a motor overload device is triggered.

For set points see motor name plate for

FLA.

3PB1 or Remote E-Stop push button.

Activated when either the Local or Remote E-Stop push button is engaged.

Release E-Stop before resetting.

HELI-SEP® Oil Sensing Probe.

Activated when an oil discharge cycle exceeds its pre-set time limit.

2 Min. above prolonged oil discharge duration (ref 4.3.7) HELI-SEP® Oil Sensing Probe.

Activated when more than 3 oil discharge cycles occur within 10 minutes.

OIL CONTENT DETECTOR

Activated when oil content exceeds the Smart Cell alarm 1 set point and delay.

(See Appendix "B", Section 7)

POSSIBLE CAUSE

1. System Inlet Strainer Restricted.

2. HELI-SEP® Vessel Restricted.

3. Process Bag Filter (FIL1) Plugged.

4. Process Filter isolation valve closed.

5. Worn or inoperable Feed Pump.

6. Defective actuating device PSL.

1. Improperly set flow control valves GV1, GV2,GV3orGV4.

2. Defective sensor.

3. Worn / Defective process pump.

4. Fouled Spir-O-Lators®.

5. Concentration.

1. Improperly set flow control valves GV1, GV2, GV3 or GV4.

2. Defective sensor.

3. Worn / Defective process pump.

4. Fouled Spir-O-Lators®.

5. Concentration.

1. High inlet temperature.

2. Low product flow.

1. Low incoming voltage.

2. Flow rates to high.

3. Defective pump motor.

1. Local E-Stop activated.

2. Remote E-Stop activated.

1. Air being introduced to system inlet.

2. Air leak in HELI-SEP® vessel.

3. Fouled or inoperable oil sensing probe.

4. Excessive oil in bilge water inlet.

1. Air being introduced to system inlet.

2. Air leak in HELI-SEP® vessel.

3. Fouled or inoperable oil sensing probe.

4. Excessive oil in bilge water inlet.

1. Large amount of detergent.

2. Circulation loop high in oil concentration.

3. Oil Content Detector being out of the

MAIN INFORMATION SCREEN.

(See Appendix "B", Section 7)

4-23

ALARM DISPLAY

(Type of Alarm)

EXCESSIVE ULTRA-SEP

HIGH OIL CONTENT

DISCHARGE ALARM

(Shutdown Alarm)

ONLY FEED PUMP

RUNNING TIME LIMIT

ALARM

(Shutdown Alarm)

ACTIVATING DEVICE

OIL CONTENT DETECTOR

Activated when oil content exceeds the Smart Cell alarm 2 set point and delay, plus one minute (See Appendix B, Section 7)

PLC

Activated when the Feed Pump is operating in Hand Mode for more than 30 seconds without activating the Process Pump.

POSSIBLE CAUSE

1. Spir-O-Lators® damaged.

2. Spir-O-Lators® adapter damaged.

3. Spir-O-Lators® inter-connector damaged (Ultra Sep Models 5000 and higher).

4. Fouled Spir-O-Lators® .

5. Oil Content Detector Monitor Cell dirty.

1. Only FEED PUMP START button activated on the HAND MODE SCREEN for longer than 30 Seconds.

4.7 SAFETY FEATURES

The following chart lists the safety display, activating device, and possible cause.

SAFETY DISPLAY

WARNING: MAY RUN

BILGE TANK DRY WHILE

IN HAND MODE.

Depress CLEAR SCREEN to acknowledge

HSEP FLUSH SHUTDOWN

DEPRESS HSEP FLUSH

BUTTON

SPROLTR FILL SHTDWN

DEPRESS SPROLTR FILL

BUTTON

ACTIVATING DEVICE

PLC

This warning appears to alert the operator that they must pay attention to the bilge tank level when operating in the HAND MODE.

PLC

Automatically shuts down the Heli-Sep flush if active for more than 3 minutes to prevent adding an excessive amount of water into the bilge if left on.

PLC

Automatically shuts down the Spir-o-lator flush if active for more than 3 minutes to prevent adding an excessive amount of water into the bilge if left on.

POSSIBLE CAUSE

1. Starting System in the HAND MODE.

1. HELISEP FLUSH button on the OPEATION SCREEN being activated for more than 3 minutes.

1. SPROLTR FILL button on the OPEATION SCREEN being activated for more than 3 minutes.

4-24

Section 5: Maintenance Procedures

5.1 SYSTEM FLUSHING

Refer to the Wiring Diagram & Schematic Drawing in Appendix "C" for electrical component designations.

5.1.1 SPIR-O-LATOR® FLUSH

The UTRA-SEP® Bilge Water Separator includes a system flush for flushing out the SPIR-O-LATORS®. The system flush can be triggered by three different methods, which are:

1. Manually at any time by pushing the SPR-O-LTR FLUSH button on the OPERATION SCREEN.

2.

3.

Any time the Process Pump (PU2) has been running for 45 minutes and the system is shut down manually or by a non critical alarm such as; low feed pressure, oil discharge overtime, low product pressure, low process pump suction pressure or high SPIR-O-LATOR® differential pressure.

Automatically every X hours. The frequency of the automatic SPIR-O-LATORS® flush is determined by the SPIR-O-LATOR AUTOMATIC FLUSH setting on the OPERATIONAL SETTINGS SCREEN.

During flushing the solenoid valve SV4 opens and the Feed Pump (PUl) starts. The pressurized clean water is directed to the Process Pump (PU2). The Process Pump boosts the pressure and flow rate. The flush water passes across the SPIR-O-LATORS® removing any loose particulates that may have been deposited during the process. The flush water is re-circulated though the Bag Filter and into the inlet of the Process Pump. This maintains a high flow rate across the SPIR-O-LATORS® allowing the process water to be diluted removing excessive contaminate though the recirculation line. The flush water is returned to the bilge through the solenoid valve SV3; where solids and oil can coalesce before the water used for flushing is reprocessed during normal system operation. The system flush duration is controlled by the PLC and is factory programmed for 60 seconds of flushing. The SPIR-O-LATORS® flush durations can be changed through the SPIR-O-LATOR FLUSH DURATION setting located on the OPERATIONAL SETTINGS SCREEN.

5-1

5.1.2 SEPARATOR FLUSH

The UTRA SEP® Bilge Water Separator includes a second system flush process for flushing of the HELI SEP3 separator vessel The process for flushing of the separator vessel is as follows

1 Stop the system by pressing the SYSTEM OFF button on the OPERATION SCREEN

2 Push the HELISEP FLUSH button on the OPERATION SCREEN this will start the flush

3 Allow the system to flush via the oil discharge line for approximately 3 minutes until or the HELISEP FLUSH SHUTDOWN safety warning occurs

4 Push the HELISEP FLUSH button on the OPERATION SCREEN a second time to end the flush cycle and/or clear the warning message

5.1.3 FLUSHING THE SMARTCELL (OIL CONTENT DETECTOR)

1 On the OCD SMART-CELL use the DOWN and UP Keys to view the Menu options

2 Scroll down to Diagnostics then press the ENTER key The screen will change as shown

4 Select' View disp PPM" and press enter The clean water solenoid valve now is activated and clean water is introduced to the monitor You must then open BV7 to allow the clean water to flow thru the monitor and to dram This will flush out the SMART CELL The display will appear as below and the ppm reading of the clean water will be displayed This reading should be less than 2 ppm

5 Let the SMART-CELL flush for 30 60 seconds then close BV7 and press the ENTER key twice to leave the diagnostics screen, set the clean water solenoid valve back to sample and return to the operation screen of the

SMART CELL

5-2

5.2 OIL DISCHARGE

Refer to the Wiring Diagram & Schematic Drawing in Appendix "C" for electrical component designations.

The ULTRA-SEP® includes an Oil Discharge cycle. This Oil discharge cycle will get rid of the waste/oils accumulated in the HELI-SEP®. The Oil Discharge cycle can be triggered by three different sources.

1. The standard automatic Oil Discharge cycle is triggered once enough waste/oils has accumulated in the HELI-SEP® to activate the oil sensing probe.

2. An additional automatic Oil discharge cycle is triggered based on a time span from a previous Oil Discharge cycle. The time span (frequency) of this Oil Discharge cycle is determined by the AUTO OIL DISCH DUR parameter found in the OPERATIONAL SETTINGS SCREEN.

3. A manual Oil Discharge cycle can be triggered at any time by pushing the OIL…