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Microsoft Word - JOWA 3 SEP OWS-1 Manual rev 0.doc1
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2.0 Technical specification ......................................................................... 7 Technical data for JOWA 3Sep OWS 1,0m3/h............................................................ 7
3.0 Installation.............................................................................................. 8 3.1 Delivery ............................................................................................................ 8 3.2 Placement of the skid........................................................................................ 8 3.3 Pipe connections............................................................................................... 8 3.4 Separator pump................................................................................................. 9 3.5 Electric connections.......................................................................................... 9 3.6 Air supply pipes and connections................................................................... 10 3.7 Filter media JOWA F - 200 C ........................................................................ 10 3.8 Quantity of filter media .................................................................................. 10
4.0 System Function.................................................................................. 12 4.1 Manual shut-off valve positions ..................................................................... 12
4.4.0 Optional features on the 3SEP OWS.............................................................. 13 4.4.1 Bilge clean mode (optional) ................................................................... 13 4.4.2 Transfer mode (optional) ........................................................................ 13 4.4.3 Level switches in 2 bilge tanks (optional).............................................. 13 4.4.4 3SEP OWS with JOWA Emulsion Breaking Unit EBU (Optional) ...... 14
5.0 Operation.............................................................................................. 15 5.1 General ........................................................................................................... 15 5.2 Start/Stop the 3SEP OWS .............................................................................. 15
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6.0 Maintenance......................................................................................... 26 6.1 Back flushing procedure for filter tanks T2, T3. ........................................... 26 6.2 Changing JOWA F - 200 C filter media in filter tanks T2, T3. ..................... 27
6.2.1 Removing the filter media ...................................................................... 27 6.2.2 Filling the tanks T2, T3 with filter media............................................... 27
6.3 Checking the anode protection ....................................................................... 28 6.3.1 Position of anodes in the tanks. ............................................................. 28
6.4 Regular maintenance timetable ...................................................................... 29 6.4.1 Before start ............................................................................................. 29 6.4.2 After every operation.............................................................................. 29 6.4.3 Every month ........................................................................................... 29 6.4.4 Every six months .................................................................................... 29 6.4.5 Every 12 months..................................................................................... 29
7.0 Trouble Shooting................................................................................. 30 7.1 General ........................................................................................................... 30 7.2 Operation errors.............................................................................................. 30
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1.0 Introduction The 3SEP OWS is an oily bilge water separation system designed to separate free/emulsified oil from the bilge water and check that the oil residues in the treated water do not exceed 15ppm before discharge overboard. The 3SEP OWS complies with IMO Resolution MEPC 107(49). According to MARPOL 73/78 all vessels above 400 DWT require an approved bilge water separator and alarm. The treated water released by the 3SEP OWS contains not more than 15- ppm oil in water. The system has been designed to meet the requirements prescribed by IMO MEPC 107 (49). For bilges with heavily emulsified oil in the bilge water a 3SEP OWS coupled to a JOWA EBU (Emulsion Breaking Unit) offers the best solution and ensures treated water under 5ppm. The 3SEP OWS is supplied standard with the necessary inlet for connecting a JOWA EBU. For additional information about the EBU system contact JOWA.
1.1 General
To obtain all the advantages from operating a 3SEP OWS ensure that all users have adequate education for the equipment, ensure that the installation is correct and ensure that the 3SEP OWS is maintained and operated in accordance with the instructions in this manual. The correct function of the equipment cannot be guaranteed if the user fails to follow these instructions. We reserve the right to make changes to the 3SEP OWS without previous notice. Before installation and start-up read this manual carefully. Supplier and manufacturer: JOWA AB Tulebovägen 104 S-428 34 Kållered , Göteborg Sweden Phone: +46-31 726 54 00 Fax: +46-31 795 45 40 Internet:: www.jowa.se
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1.2 System overview , normal flow and oil release through the OWS
(See flow diagram)
The 3SEP OWS is designed for a continuous flow with automatic operation, the system does not require any chemicals. The following text gives an overview of the 3SEP OWS separation process and the 3SEP OWS general arrangement. In the first stage, tank T1, oil release is controlled by an oil sensor, CT03. The sensitivity of the oil sensor CT03 is operator adjustable in order to minimise the amount of treatable water released from T1 to the sludge tank. To adjust the sensitivity of the oil sensor CT03 see chapter 5.3 and 5.6. In the second stage emulsified oil is removed in the two filter tanks and the ppm value is monitored continuously by an oil content meter before the treated water is discharged overboard. The pneumatically controlled valves V02 and V03 release the free oil at the top of T2 and T3 to the concentrated sludge tank. Oil is released from V02 every five minutes, for a time period of 20 seconds (adjustable). Oil is released from V03 every hour for a fixed period of 5 seconds. When the JOWA 3SEP OWS is started an automatic oil release from V02, and V03 occurs for a fixed period of 3 seconds. This ensures that the pure oil that has gathered at the tops of the tanks while the unit has been in stand by mode is now released. When a 15 ppm alarm occurs, the 3SEP OWS will automatically close the overboard line V04 and open re-circulate valve V05. When the contamination falls below 15 ppm the valve for re-circulate valve V05 close and valve for overboard line V04 will open automatic. The recirculation cycle occurs for 5 minutes and is adjustable (See Chapter 5.3.3). If the treated water remains above 15ppm at the resumption of normal flow after the recirculation cycle, the 3SEP OWS will stop and an alarm will occur. The 3SEP OWS can be back flushed and restarted. See Chapter 6.1 for back flushing instructions. The system is designed as a compact skid assembly with all connection points collected, for easy “Plug n’ Play” installation. When the unit reaches the customer the only remaining thing to do is to connect water inlets/outlets, the electrical power supply and air connection, facilitating quick and easy installation onboard. Before leaving our workshop each unit has to pass a quality-test, where all functions are tested and checked. All equipment has the highest quality; the tanks are made of acid proof stainless steel, AISI 316L. Our pumps are supplied by internationally recognised brands. Spare parts are easily available from one of our offices or representatives worldwide.
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1.3 Guarantee and service. The JOWA 3SEP OWS is covered by a guarantee period. Guarantee claims can be made according to JOWA’s Guarantee claim procedure. The JOWA 3SEP OWS contains components with no user serviceable parts which are sealed. Breaking the seals placed on these components automatically voids the warranty. Contact JOWA for assistance. Service should only be carried out by an authorised JOWA service engineer.
1.4 Note on recycling.
In the design and manufacture of the JOWA 3SEP OWS all Efforts have been made to use components that can be recycled. This product or the parts of it must be disposed of in an environmentally sound manner. Use the local public or private waste collection service
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2.0 Technical specification This chapter contains a quick reference table with the main technical specifications for the 3SEP OWS.
Technical data for JOWA 3Sep OWS 1,0m3/h Type: 3Sep OWS-1m3/h Capacity: 1,0 m³/h Influent: Bilge water Effluent oil content. < 15 ppm acc. IMO MEPC 107(49) Ambient temperature: 5 - 55°C Operation Pressure: Normal 0,5 – 2 Bar, Safety Valve: 4 bar Volume (total): 225 L Weight (total): excl. Filter mtrl & pump
225 kg (dry) 450 kg (wet)
Total power consumption: 2 kW (standard) Air supply: 4 – 6 Bar dry clean instrument air
Common alarm. 15 ppm alarm.
Long time run alarm. (option) Alarm outputs:
Transfer alarm (option) Tank material: AISI 316L Gaskets: Nitrile Tank volumes: 3 x 75 L Filter media: JOWA F200 Filter media quantity: 50 kg Type Approval: Type approval by U.S.C.G Number 162.050/9057/0
DNV,CCS,RMRS,KR Bilge Pump
Type: Mono Screw Pump Flow rate: 1 m³/h Weight: 21 kg Suction: Max. 4,5 m lift capacity Voltage: 230 – 480 VAC, other available on request. Frequency: 50 - 60 Hz
Power consumption: 0,55 - 0,66 kW 1,51 - 2,77 A
R.P.M. 885 - 1060 Protection class: IP55 Thermal insulation class: F
Prime water & dry running protection as standard.
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3.0 Installation This chapter contains step-by-step information detailing how the 3SEP OWS is installed. At the end of the chapter is a quick reference check list to aid in start- up after installation or service.
3.1 Delivery
The 3SEP OWS is delivered complete with all valves, pipes, necessary fittings and an oil content meter mounted on a single skid ready for installation onboard. The unit has passed a work-shop tested before delivery.
3.2 Placement of the skid
The 3SEP OWS skid should be placed on a plane surface and welded or bolted using the pre drilled holes in the skid. When installing the unit it is important to leave a minimum of 500mm working space in front of the unit (see mechanical drawings).
3.3 Pipe connections
All connection points are collected together for easy “Plug n’ Play” installation:
Piping connections: Oily bilge water
inlet: 1” – DN25
Water outlet (overboard) 1” – DN25
Drain and Re- circulate water
(to bilge) 1” – DN25
1” – DN25
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3.4 Separator pump The pump is delivered as a separate unit. To be installed as close to the bilge water tank as possible and not more than 4,5 meters suction height to avoid suction problems. Use piping with the same dimension as the pump is designed for. Refer to the flow diagram chapter and the recommended installation drawing. Use pipe connections according to specification below. 1” ( DN 25 )
3.5 Electric connections
The electrical equipment of the separator is ready for installation when delivered. The power supply should be three phase 380-480 VAC 50/60Hz. Other power supplies on request. See the electrical drawings for further information. The mains supply should have a 10A fuse. Cable for pump, mains supply and 3 pole circuit breaker are not included in the delivery. Voltage: 3 phase 380-400-415-440-460-480 VAC 50/60 Hz. Other power supplies on request.
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3.6 Air supply pipes and connections Air supply is connected to the pneumatic solenoid control valves. The solenoid block is located just below the control cabinet. The counter connector is supplied for attaching of 8 mm Cu-pipe. The pressure should be 4-6 bar dry instrument air.
Fig 3.6.1 Air inlet to solenoids.
3.7 Filter media JOWA F - 200 C
The filter media, JOWA F – 200 C, for the filter tanks T2 and T3 is delivered fully prepared in sacks of 25 kilos each. The Separator is always empty by delivery. Filter media for the first filling is included in the delivery. NOTE! For guaranteed function we recommend the JOWA F - 200 C filter media.
3.8 Quantity of filter media Model Tank size quantity (2 Tanks) 1.0m3/h 75l 50kilo
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3.8.1 Filling the tanks T2, T3 with filter media NOTE! Before filling check that the internal strainers are carefully fastened. Fill the tanks T2 and T3 through the upper hatches to 60-70 % of the tank volume, approximately 10-15 centimetres below the upper strainers. When the tanks are filled with filter media mount the upper hatches and back flush each filter one by one until clean fresh water is coming through the sample valves V18 and V19 (See Chapter 6.1 for detailed back flushing instructions). We recommend back flushing with fresh water at a pressure of no more than 4 bar. Maintain low water pressure and speed during back flushing to avoid losing filter media from V30. Throttle V15 and V16 to about 30%open to control water speed and pressure during back flushing.
3.9 Initial start-up checklist
Use the following start-up checklist after installation or service. Fill tank T2 and T3 with filter media Make sure the bilge pump is filled with water before start, to prevent
running dry. Check that the manual valve positions on the 3SEP OWS are correct for
normal operation (See System function chapter 4) Open all valves between the bilge water tank and the separator. Open all valves on the separator discharge line.
Back flush filter tanks 2 and 3 for a short while.(See Maintenance Chapter 6).
Turn the power on at switch S1. Check rotation of the pump Now the separator is ready for normal operation.
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4.0 System Function. This chapter provides a detailed description of the unique functions of the 3SEP OWS. The material provided in this chapter gives the operator the possibility to gain an good understanding into how and why the 3SEP OWS performs its functions. It is intended that the information in this chapter may be used to help the operator optimise the 3SEP OWS performance to his or her specific bilge requirements.
4.1 Manual shut-off valve positions
The following tables indicate which of the manually controlled valves are open and closed during normal operation of the 3SEP OWS.
4.2 High level start switch/ Low Level stop switch
Automatically starts the 3SEP OWS when the bilge water level is high and stop the OWS when bilge water level is low, using level switches located in the bilge tank. (the OWS need to be in AUTO mode)
4.3 Low Level switch only.
In some installations there are only a low level switch installed in the bilge tank. To control the OWS by this switch please connect it to the terminals for low level switch and make a jumper on terminals for high level switch. The OWS will now start when the low level switch is high and stop when the low level switch is low. (the OWS need to be in AUTO mode)
4.4 Dry running protection
Protects the 3SEP OWS pump from running dry. (see electrical drawings)
4.5 Prime water
Opened V10 V12
Closed V11 (If no EBU) V13 V14 V15 V16 V17 V18 V19 V30
Partly Closed FR01 Adjust so there is sample to the bilge alarm, se the flow diagram.
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4.4.0 Optional features on the 3SEP OWS. The following are optional features for the 3SEP OWS:
4.4.1 Bilge clean mode (optional) In bilge clean mode the flow from the bilge only passes through the first stage tank T1 and then returns to the bilge tanks. The bilge water is pumped into the top of T1 thru valve V10 where most of the free oil is gathered on the coalescence surfaces. When the oil senor CT03 detects oil it is released through the pneumatically controlled valve V01 and is delivered to the concentrated sludge tank. The flow then passes through V13 and returns to the bilge.
4.4.2 Transfer mode (optional)
Some vessels have more than one bilge tank. Transfer mode uses the OWS bilge pump to transfer water between these different bilge tanks without flow passing through the 3SEP.
4.4.3 Level switches in 2 bilge tanks (optional)
It is possible to control level switches in more than 1 bilge tank. If this option is at the OWS, a switch for tank selection is mounted. With this switch it is possible to run the OWS in Auto from 2 tanks. Standard delivery is 1 tank.
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4.4.4 3SEP OWS with JOWA Emulsion Breaking Unit EBU (Optional)
A JOWA EBU system may be coupled to the 3SEP OWS as an extra pree- treatment stage. The JOWA EBU & 3SEP OWS package can achieve treated water with in 5ppm. It is strongly recommended that the operator consider a 3SEP OWS coupled with JOWA EBU if the bilge water contains high levels of emulsified oil. The JOWA EBU is a chemical treatment of the emulsified oil in water. The chemical is a flocculent that helps the small particles of oil coalesce together and thus separate by gravity. The 3SEP OWS skid is ready supplied with the connection for a JOWA EBU (See Flow Diagram).
Fig 4.4 JOWA EBU schematic.
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5.0 Operation This chapter gives the operator detailed information on how the major control components of the 3SEP OWS are operated and adjusted.
5.1 General
General operation of the 3SEP OWS is facilitated by the PLC user interface and the switches located on the door of the main control box. All of the electric and pneumatic control equipment is located on the control cabinet stand at the side of the 3SEP OWS skid frame. • All electric equipment is connected to the main control box and the 3SEP
OWS is operated from here. The main power switch, S1, for the 3SEP OWS is located on the side of the main control box.
• The electronic parts for the oil content meter are located inside the oil content meter control box.
• The pneumatic solenoids for the pneumatic control valves are located on the side of the 3SEP OWS skid frame control stand
5.2 Start/Stop the 3SEP OWS
After the actions in section 3.9 ‘Initial Start-up Checklist’ have been completed the unit can be started and run in normal operation.
5.2.1 Start/Stop OWS manual mode
To start, please turn switch S2 to position OWS MAN. To stop, switch S2 to position 0. It is possible to start the OWS by a remote signal in manual mode. Se chapter for remote operation.
5.2.2 Start/Stop OWS auto mode
To start, please Turn switch S2 to position OWS Auto In this mode the OWS is controlled by the high/low level switches located in the bilge tank. To stop, switch S2 to position 0.
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5.2.3 Start/stop transfer mode (optional) Transfer mode can be operated in both auto and manual mode. In Auto mode the pump is controlled by the level switches in the tank and in manual mode the operator need to start and stop the system. However, the operator must exercise caution and see that the manual ball valves between the bilge tanks are in the correct position for transfer mode function correctly. It is possible to start the transfer by a remote signal in manual mode. Se chapter for remote operation.
5.2.4 Start/stop transfer manual Mode
To start, turn switch S2 to position TRANS MAN. To stop, switch S2 to position 0. It is possible to start the transfer by a remote signal in manual mode. Se chapter for remote operation.
5.2.5 Start/stop transfer auto mode
To start, turn switch S2 to position TRANS AUTO. In this mode the OWS is started by the high/low level switches located in the tank. To stop the transfer, switch S2 to position 0.
5.2.6 Start/Stop bilge clean mode (optional)
To start, turn switch S5 to position 2 for bilge clean mode. To stop, switch S5 to position 0.
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5.3 The PLC User Interface
The PLC user interface facilitates the running and understanding of the 3SEP OWS. Through the user interface and display on the main control cabinet door you receive all messages concerning the 3SEP OWS such as operational status, alarms, and pre-set times.
Fig 5.3 PLC Interface The user moves up and down through the menu display tree using the up/down and left/right keys. Information such as timers is input using the number keys. The input value is confirmed by pressing the enter key.
Left/ Right Keys
Up/ Down Keys
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OWS Man/Auto Select Man/Auto Mode
Electric Power has been connected or Electric Power has been shut down and returned. Stand by Waiting for mode select. Mode selected Waiting for start signal OWS running OWS Stopped
OWS AUTO OWS MAN
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OWS man mode
Select Local or Remote Start Electric Power has been connected or Electric Power has been shut down and returned. Stand by Waiting for mode select. Man mode selected Select Local or Remote start. Waiting on remote start OWS running When remote is activated in service mode it is also…