Wärtsilä UK Ltd.
TECHNICAL MANUAL
FOR
WATER QUALITY SYSTEM
FOR
NEVSKY SALVAGE VESSEL
Based on G.A. Drawings:
H31102-01
H31102-02
Skid Assembly
Control System
This Manual is protected by copyright vested in Wärtsilä UK Ltd. and may contain information that is confidential to that Company . The Manual is supplied to the customer for its personal use and no part of the
Manual may therefore be copied, lent or otherwise disclosed to any third party without the prior written consent of the Company.
Copyright © 2016 Wärtsilä UK Ltd. All Rights Reserved
Registered Office:
Wärtsilä UK Ltd., Havant, Hants, PO9 1NX.
Registered Number: 1004816
TM-WQS-100076618 Issue C
8th March 2018
CONTENTS
SECTION
SUBJECT
PAGE
1. INTRODUCTION .......................................................................................... 4
2. DESCRIPTION OF THE EQUIPMENT ........................................................ 5
3. STORAGE AND HANDLING....................................................................... 7
4. INTERFACING REQUIREMENTS .............................................................. 8
5. INSTALLATION ........................................................................................... 9
6. COMMISSIONING ..................................................................................... 11
7. CONTROL PANEL OPERATION .............................................................. 12
8. SYSTEM CONTROL PHILOSOPHY ......................................................... 19
9. MAINTENANCE ......................................................................................... 21
10. SPARE PARTS .......................................................................................... 22
11. ATTACHMENTS ........................................................................................ 23
The drawings contained in this manual as well as the drawings provided for information
and assembling purposes, remain the property of Wärtsilä UK Ltd.
They may not be copied or reproduced in any way, used by or shown to third parties
without the written consent of Wärtsilä UK Ltd.
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1.
INTRODUCTION
1.1.
Whilst it is our policy to allow the Installation and Maintenance of this equipment
to be carried out by 3rd parties (in accordance with the guidance contained within
this Technical Manual) we would always recommend that one of our Service
Engineers is present to oversee any Installation or Maintenance.
1.2.
When using this manual refer to the general arrangement drawing(s) in the
“Attachments” section, which give the dimensions and data for the correct
assembly and operation of the equipment.
1.3.
There is no automatic provision to up-date this manual. However, the supply of a
complete new assembly will be accompanied by the latest revision Manual and
Drawing(s).
1.4.
For further assistance please contact your local Wärtsilä office or go to
www.wartsila.com .
1.5.
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2.
DESCRIPTION OF THE EQUIPMENT
Specification:Fluid
Sea water
Ambient Operating Temperature
-5°C to +40°C
Maximum discharged particle size
74 µ
Minimum discharge flow rate
4.0 m3 / hour (66 LPM)
Nominal discharge flow rate
100 LPM
Nominal discharge pressure
1.0 bar
Electrical supply
400 volts, 3 phase, 50 Hz
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Filtering is effected by using a single cyclone separator to remove material coarser
than 74 microns from the fluid.
The unit consists of two identical lines i.e. a duty line and a stand-by line. A
changeover between duty and stand-by lines will occur automatically after the
following:·
A pre-determined length of time
·
Pump failure
·
At every stop / start cycle.
The equipment consists of two units:1.
The Integral Skid Unit
This consists of a frame that supports two separate filtration lines. Each line
consists of a pump, a cyclone separator and a flow meter as the main components.
There is a pressure gauge fitted before and after each cyclone separator which
can be read visually to monitor the system and to indicate if a blockage has
occurred.
The Cyclone Separators are both purged automatically on a set cycle to remove
accumulated particulates or sediment.
The Flow Meter has a local read-out screen and also sends a warning signal when
low flow occurs.
2.
The Control Panel
This is a standard 500 x 500 enclosure supplied separately to the Skid Unit.
The Control Panel contains the following items:·
Mains isolator.
·
Timer for the pump changeover sequence.
·
All the necessary electrical connections required for the Base Unit.
·
Door locked isolator.
·
Contact breakers & power components for pump operation.
·
Facility for remote relaying of all alarm signals.
Please refer to the Control panel drawing H31102-02
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3.
STORAGE AND HANDLING
3.1.
All assemblies and components have been carefully inspected before shipment.
3.2.
Each component is suitably packed and protected to prevent damage or
deterioration during shipment, transit or storage. Any specific storage or handling
requirements will be clearly identified on the package label(s).
3.3.
Goods should be examined on receipt to verify the contents and their condition.
3.4.
Wärtsilä UK Ltd should be immediately advised of any damage or discrepancy in
the scope of supply. Damage clearly due to handling in transit should be notified
to the carrier along with a claim for damages (copy to us).
3.5.
Keep goods in their original packing until just prior to installation in order to best
protect them.
3.6.
If goods have to be stored for long periods, they should be kept in their original
packing, stored flat and unobstructed in a dry, cool and dark environment. To
ensure a satisfactory life expectancy for any rubber components, exposure to
sunlight, ultraviolet light and ozone should be prevented.
3.7.
Care must be taken during handling to prevent any mechanical damage occurring
due to dropping, crushing etc.
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4.
INTERFACING REQUIREMENTS
4.1.
Unit Footprint
Nominally 1050mm x 825mm, refer to G.A. drawing H31102-01 for actual skid unit
envelope dimensions and fixing point geometry.
The Control Panel requires bulkhead mounting space for a standard 600 x 600 x
300 enclosure.
4.2.
System Connections
Pump inlet flange (2 off) – 2” (DN50) PN16
Unit output flange (2 off) – 11/4” (DN32) PN16
Cyclone purge line flange (2 off) – ¾” (DN20) PN16
4.3.
Connecting the Skid Unit to the Control Panel
All electrical connections terminate in the Control Box enclosure as shown in the
control system drawing H31102-02.
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5.
INSTALLATION
Warning – power to the unit is to remain isolated until instructed
otherwise.
5.1.
Main Unit
The unit should be installed such that all the valves are easily accessible.
It should be possible to remove any of the component parts should they need
dismantling or replacement.
The position should also be convenient for connection to the control panel which is
bulkhead mounted separately.
See drawing number H31102-01 (in Section 11 “Attachments”) for flange interface
positions.
The unit has four lifting eyes and four mounting points positioned close to each
corner of the base frame.
Resilient mounts may be used if vibration is expected.
Connect the water inputs to each pump by means of the 2” (DN50) flanges.
Connect both purge lines from the cyclone separators by means of the 3/4” (DN20)
flanges.
Connect both water outlets to the system by means of the 11/4” (DN32) flanges.
All wiring for the skid unit terminates at the Control Panel. See drawing number
H31102-02 in Section 11.
1.
Pump / Motors
Connect to the power supply at the Control Panel and according to the specification
plate on the motor.
This part of the installation should be carried out by a qualified electrician.
Do not run the pump until it has been primed. Failure to prime may result in
immediate or premature seal failure.
Make sure that the direction of rotation is correct.
Specification:2900 RPM @ 50 Hz (2 pole)
3.0 kW
IP54
400V 3 Phase 50 Hz
Top mounted terminal box
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2.
Pressure Dial Gauges
Positioned before and after each cyclone separator and connected via Stainless
Steel isolation valves.
Specification:Stainless Steel casing.
Stainless Steel wetted parts.
1/4” BSP back entry connection.
0 to 10 bar scale.
Glycerine filled.
3.
Flow Meters
Connect each flowmeter as per the system wiring diagram H31102-02.
Specification:IP65 rated.
Local read out screen with remote signals to the control panel.
4.
Purge Valves
Connect each purge valve as per the system wiring diagram H31102-02. They will
also need connecting to a clean dry compressed air supply with a pressure of 6
Bar.
5.
Remote Start / Stop
Connect the remote start (normally open) and remote stop (Normally closed) as
per the system wiring diagram H31102-02.
5.2.
Control Panel
The control Panel should be bulkhead mounted adjacent to the main unit and in a
convenient position for connecting the cabling.
·
Holes are for M8 bolts and on 460 x 460mm Centres
·
Panel may be mounted on resilient mounts if vibration is expected.
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6.
COMMISSIONING
6.1.
Priming the system
It is expected that the Skid Unit is sited below water level and that the head of water
required to prime the system can be supplied directly through the normal intake
system.
The Pressure generated by the system, and hence the actual flow rate, will be
largely determined by the downstream pipe-work within the system but may be
trimmed manually at the discharge side of the unit to achieve the correct flow and
balance between the seal and the bearing.
6.2.
Flow Meter
The flowmeters provide a 4-20 mA signal which converts to the flow rate, displayed
locally and at the Control Panel.
Low flow alarm set to
6.3.
3925 l/hr (65.5 l/min) on falling flow.
Control Panel
Refer to Section 7 (Control Panel Operation) for start-up and general running of
the control system.
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7.
CONTROL PANEL OPERATION
7.1.
On powering up the system for the first time, when the PLC has booted up
successfully the following screen is displayed.
The start screen displays the current status of the system and also allows you to
access the other control screens by pressing the relevant blue tab.
If an alarm is present, Press the ALARM screen access button once to go to the
alarm screen.
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7.2.
On first power up of the system there will be a delay between the screen updating
the alarms and the actual alarm trigger(s). Press the reset button and the system
should update itself. On the alarm screen is a further option which is the alarm
history, which, when pressed will display the last alarm activations with a date
and time stamp. This list is for information only and cannot be reset, there are no
user inputs on this function, and it compiles on a last in first out basis (see
Section 8.5 for alarm detail descriptions).
7.3.
Ensure that the system is ready to operate, and select either Local or Remote
control via the selector switch. Unless it is necessary to change any system
parameters then it is assumed, at this stage, that the defaults settings are
satisfactory.
7.4.
Local mode
In local mode the duty pump is manually stopped and started via the relevant pump
start / stop pushbutton. When a pump is selected the other pump is inhibited from
starting. In local mode the 2nd (non-selected pump) will not start automatically as
a standby if the duty pump fails. Providing that the PLC is healthy, the alarms will
be monitored but only a pump trip will stop the pump, not an alarm trigger event.
7.5.
Remote mode
In remote mode the pumps are started and stopped from the ship control system.
At each start event the pump selection for duty is rotated automatically by the PLC
to obtain even pump wear. Once started there is a delay time before the system
will monitor the instrumentation for an alarm, allowing time for pressure and flow to
stabilise in the system. Once the monitor time times out then the instrumentation
is then monitored for correct operation.
In normal mode the system will operate the pump only. In emergency mode the
system will operate a cyclone purge on a timed basis. During a cyclone purge the
flow monitor alarms are inhibited to prevent false alarms. It is possible to manually
instigate a cyclone purge by going to the purge screen. From the start screen press
the PURGE tab and the following screen occurs.
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The screen displays the current values of the cyclone interval timer or the elapsed
timer if a purge is in operation, along with whether a cyclone purge is on or off and
whether the valve is open or shut. The purple tab marked MANUAL PURGE, if
pressed, will initiate a single manual cyclone purge. If the valve is already open the
manual start button is not displayed on screen.
Press ESCAPE to return to the start screen.
7.6.
From the start screen pressing the VALUES tab will take you to the values
screen.
The screen displays the current values of all the system transmitters. There are no
user inputs on this screen.
Press ESCAPE to return to the main menu.
7.7.
If it is required to change a system setpoint then from the start screen press the
PARAMETERS tab. This will then take you through a series of password
protected screens, which require a user input and password.
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When you press the log in button a series of prompts and user input screens will
commence. It is imperative that you follow the sequence correctly or access will be
denied.
To gain access press the LOG IN button.
Press the small box marked
… between the USER and ESC buttons.
On the next screen ensure the screen is highlighted as above on user position 0
[client] and press the RET button once. This takes you back to the log in screen
where you now press the PASSWORD button.
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At this prompt a keypad appears.
Enter the password [contact Hellan strainers if access to this is required] and
press RET. Password:224466
Now press RET once and the screen will change to the following:-
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Press the NEXT button. The parameter access screen is now available.
To change a setpoint press the relevant data value to the right of the descriptive
text required. A numeric keypad will appear.
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Key in the new required value and press RET. The value is stored in the PLC
retentive memory. Press NEXT to take you to the second parameters screen.
Press ESCAPE or log out to return from the parameters screen, or the parameter
screen will time out after 1 minute if no user intervention takes place.
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8.
SYSTEM CONTROL PHILOSOPHY
8.1.
·
·
·
·
·
·
·
·
·
·
8.2.
System Operation.
The system is designed to operate 2 water pumps, and associated cyclone
separators and purge valves.
Each set will be arranged as working and standby.
In Auto the system will be started and stopped by remote signals from the client.
The control panel will monitor the 2 flowmeters.
The system can be run in Auto or Manual mode.
In Auto mode, the standby pump will come on automatically under certain fault
conditions.
In manual mode each pump will be controlled from start/stop push buttons on the
panel door.
The alarms will be monitored during auto and manual operation. (Only if
controller is healthy in manual operation).
Volt free contacts will provide signals for system alarm.
Flow rates will be displayed locally on each flowmeter and also on the panel
mounted screen.
Purge.
When the system is running, the purging cycles are operated by the preprogrammed timers.
·
·
·
8.3.
·
·
·
Normal mode (Open Sea)
The Purge valve on the running cyclone discharge will be opened for 15 seconds
every 2 hours. The Purge Valve on the non-running cyclone will be opened for
15 seconds 5 minutes after the purge valve on the running cyclone.
Extended mode (Harbour)
The Purge valve on the running cyclone discharge will be opened for 15 seconds
every 15 minutes. The Purge Valve on the non-running cyclone will be opened
for 15 seconds 5 minutes after the purge valve on the running cyclone.
Low flow alarms are inhibited during the purge cycle and for 15 seconds after
purge stops.
Manual Mode.
In manual mode, either pump can be started and stopped via pushbuttons on the
front of the panel.
When one pump is running the non-working pump is inhibited.
In manual mode all alarm conditions will be monitored, but only pump overload
will stop the pump running (Provided the controller is healthy).
(Note there is no provision for manual purge operation, but the valves can be
operated manually).
8.4.
·
·
Auto Mode.
In auto mode a pump will run when the remote run signal is closed. It will stop
when the remote run signal is removed.
The duty /standby pumps will rotate at every stop start cycle (Flip Flop).
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8.5.
·
·
·
a)
·
·
b)
·
·
·
·
·
·
·
c)
·
·
·
·
·
d)
·
Alarms.
All alarm conditions will latch, and reset will be by pushbutton on the screen.
(Except motor overload).
Alarms other than motor overload will only be monitored when a pump is
running.
All alarms with illuminate the alarm LED and open the remote alarm contacts –
failsafe.
Pump Overload Alarm.
In auto mode, if the system is running it will start the standby pump.
Reset will be by opening the panel door to reset the overload device and then
pressing the reset pushbutton. (Note the panel door has a defeatable isolator.
This feature enables the panel door to be opened whilst the system is running to
enable overload reset. This can only be undertaken by a suitably qualified and
competent person).
Low Flow Alarm.
Reset will be by the screen button.
There will be a 15 second delay at pump start-up and changeover and a 3
second smoothing timer when the system is running.
The low flow alarm will be inhibited during cyclone purge.
This alarm will stop the duty pump and run the stand-by pump unless the standby pump has already tripped.
Resetting the alarm will switch back to the duty pump.
If the standby pump has already failed the duty pump will keep running.
In manual mode the pump will keep running.
High Flow Alarm.
Reset will be by the screen button.
There will be a 15 second delay at pump start-up and changeover and a 3
second smoothing timer when the system is running.
This alarm will be a warning only and will not stop any pump running.
In manual mode the alarm will still be monitored provided the controller is
healthy.
The value for the high flow alarm will be preset at the factory as it is designed to
prevent the pump being run at end of curve conditions.
Low inlet Pressure (Only if inlet pressure switch is fitted).
Low inlet pressure will stop any pump already running and inhibit a pump from
starting (Except in manual mode). It will not switch to the standby pump. There is
a 3 second smoothing timer associated with this alarm. This can be linked out
electrically if not required.
Note the controller will be fitted with an Eeprom to allow for the program to be
changed without needing to visit the site.
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9.
MAINTENANCE
9.1.
Pump / Motor
The only practical in-situ maintenance is for a periodical inspection for leakage,
overheating, or any other symptoms of impending failure.
Should a pump / motor unit require repair or overhaul, it is expected that it is
removed complete and replaced with a new unit, or the reconditioned unit reinstalled.
Either pump can be isolated from the system by shutting the appropriate valves on
the suction side and the delivery side of the pump.
Either pump can be run independently while the control panel is in manual mode.
9.2.
Cyclone Separator
The cyclone separators have no moving parts and as such there are no specific
maintenance requirements other than to clear any blockages. This may necessitate
the removal of the separator from the unit. Should the separators become
damaged for any reason, replacement is required.
Note:
Refer to TD-17919 ‘Portable Patch Test Procedure’ for on-board cyclone water
sampling as shown in TD-17589 (Rev C).
9.3.
Flow Meter
No specific maintenance is required for the flow meter.
9.4.
Purge Valve
No specific maintenance is required for the purge valve
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10. SPARE PARTS
The following parts may be supplied as spares:10.1. Pump Spares.
·
·
Seal kit.
Motor bearing kit.
10.2. Control Panel Spares.
·
·
·
·
·
·
·
·
Isolator.
Power supply
Control fuses.
Motor circuit breaker.
Contactor.
Wiring kit.
Relay and base.
Programmable controller with EEPROM.
Refer to Section 3 for storage and handling.
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11. ATTACHMENTS
The following attachments should accompany this Technical Manual
●
H31102-01
Integral Skid Unit
●
H31102-02
Control System
●
TD-17919
Portable Patch Test Procedure
The attachments referenced above, now follow:
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