Technical Manual
Instructions for installation,
operation and maintenance
641
OILCON® MARK 6M
According regulation 31 Annex I of MARPOL 73/78,
IMO Resolution MEPC.108(49) and IMO Resolution MEPC.240(65)
Oil Discharge Monitoring and Control System
Publication nr TIB-641-GB-1117
Supersedes TIB-641-GB-0617
1
CONTENTS
1 PREFACE ....................................................................................... 6
1.1 General ...................................................................................................... 6
1.2 Symbols ..................................................................................................... 7
1.3 Copyright .................................................................................................... 7
2 PRODUCT DESCRIPTION ............................................................. 8
2.1 Principle of operation ................................................................................. 8
2.2 Product configuration ................................................................................. 9
2.2.1 Main Control Unit (MCU) ................................................................................ 9
2.2.2 Electro Pneumatic Unit (EPU) ...................................................................... 10
2.2.2.1 Intrinsically safe signal cable ................................................................. 10
2.2.2.2 Starter box ............................................................................................. 10
2.2.3 Skid assembly .............................................................................................. 11
2.2.4 Pump/motor assembly .................................................................................. 11
2.2.5 Flowmeter system ........................................................................................ 11
2.2.6 Sample probe valve assembly ...................................................................... 12
2.3 Sampling system arrangements ............................................................... 12
3 TECHNICAL SPECIFICATION ..................................................... 14
3.1 General .................................................................................................... 14
3.2 Main Control Unit (MCU) .......................................................................... 14
3.3 Electro Pneumatic Unit (EPU) .................................................................. 15
3.4 Skid .......................................................................................................... 16
3.5 Sample pump ........................................................................................... 16
3.6 Reference table of products which may be measured ............................. 17
3.7 Biofuel guidelines and definitions ............................................................. 18
4 SAFETY INSTRUCTIONS ............................................................ 19
4.1 Safety precautions ................................................................................... 19
5 UNPACKING ................................................................................. 20
6 INSTALLATION ............................................................................. 22
6.1 Introduction .............................................................................................. 22
6.2 Utilities...................................................................................................... 22
6.2.1 Fresh water supply ....................................................................................... 22
6.2.2 Air supply ...................................................................................................... 23
6.2.3 Electrical supply ............................................................................................ 23
6.3 Pipework general ..................................................................................... 23
6.3.1 Sample pump unit ......................................................................................... 24
6.3.2 Installation of the sample pump .................................................................... 24
6.3.3 Electrical installation pump ........................................................................... 25
6.3.4 First start ....................................................................................................... 25
6.3.4.1 Self priming ........................................................................................... 25
6.3.4.2 Direction of rotation ............................................................................... 25
6.3.5 Skid ............................................................................................................... 26
6.3.6 Sampling probes ........................................................................................... 26
6.3.7 Orifice plate .................................................................................................. 27
6.3.7.1 General information ............................................................................... 27
6.3.7.2 Installation of flow sensor ...................................................................... 27
6.3.8 dP/I transmitter ............................................................................................. 28
6.4 Bulkhead penetrations general ................................................................. 29
2
6.4.1 Sample pump ............................................................................................... 29
6.4.2 Air pipelines .................................................................................................. 29
6.4.3 Intrinsically Safe signal cable ....................................................................... 30
6.5 Electrical installation general .................................................................... 31
6.5.1 Electro Pneumatic Unit (EPU) ...................................................................... 31
6.5.2 Starter box .................................................................................................... 32
6.6 Control room equipment – Main Control Unit (MCU) ................................ 32
6.6.1 Speed input .................................................................................................. 32
6.6.2 Overboard valve control ............................................................................... 32
6.7 Installation checklist ................................................................................. 33
6.7.1 General installation checks ........................................................................... 33
6.7.2 Check of Flowmeter and automatic control .................................................. 33
6.7.3 Starting interlock and/or overboard valve control ......................................... 34
6.7.4 Pipework response time calculation ............................................................. 35
6.7.5 Final check ................................................................................................... 36
6.8 Overview installation check ...................................................................... 37
6.8.1 Cable connection Main Control Unit ............................................................. 37
6.8.2 Cable connection Electric Pneumatic Unit .................................................... 37
6.8.3 Intrinsically safe ground points, measurement cell and EPU ....................... 38
6.8.4 Power supply starter box and cable connection skid .................................... 39
6.8.5 Multi Cable Transit (Bulkhead Penetration) .................................................. 40
6.8.6 Water and Airline connections Skid .............................................................. 41
6.8.7 System settings. ........................................................................................... 42
7 OPERATING INSTRUCTIONS ..................................................... 43
7.1 Layout of the MCU ................................................................................... 43
7.1.1 Control key switch ........................................................................................ 43
7.1.2 USB connector ............................................................................................. 44
7.1.3 Printer port .................................................................................................... 44
7.1.4 Reset button ................................................................................................. 44
7.1.5 Touch screen panel ...................................................................................... 44
7.2 Operating the MCU and menu layout ....................................................... 45
7.2.1 Standby mode (menu 1) ............................................................................... 47
7.2.1.1 Information mode (menu 1.1) ................................................................ 48
7.2.1.2 Configuration mode (menu 1.2) ............................................................. 49
7.2.1.3 Data mode (menu 1.3) .......................................................................... 51
7.2.1.4 Selftest mode (menu 1.4) ...................................................................... 52
7.2.1.5 Setup mode (menu 1.5) ......................................................................... 53
7.2.1.5.1 Information mode (menu 1.5.1) .......................................................... 53
7.2.1.5.2 Setup mode (menu 1.5.2) .................................................................. 55
7.2.1.5.3 Calibration flush mode (menu 1.5.3.0) ............................................... 57
7.2.1.5.4 Idle mode (menu 1.5.3) ...................................................................... 58
7.2.1.5.4.1 Information mode (menu 1.5.3.1) ................................................ 58
7.2.1.5.4.2 Shutdown mode (menu 1.5.3.2) .................................................. 59
7.2.1.5.4.3 Idle setup mode (menu 1.5.3.3) ................................................... 60
7.2.1.5.4.4 Self test mode (menu 1.5.3.4) ..................................................... 61
7.2.1.5.4.5 Sample mode (menus 1.5.3.5) .................................................... 61
7.2.1.5.4.5.1 Information mode (menu 1.5.3.5.1) ....................................... 62
7.2.1.5.4.5.2 Shutdown mode (menu 1.5.3.5.2) ......................................... 62
7.2.1.5.4.5.3 Manual flush mode (menu 1.5.3.5.3) .................................... 63
7.2.1.5.4.5.4 Manual window wash mode (menu 1.5.3.5.4)....................... 63
7.2.1.5.4.5.5 Self test mode (menu 1.5.3.5.5) ............................................ 64
7.2.1.5.4.5.6 Sample setup mode (menu 1.5.3.5.6) ................................... 64
7.3 Short reference guide for operating the MCU ........................................... 65
3
7.3.1 Discharging ballast water ............................................................................. 65
7.3.2 Shutdown of discharging operations ............................................................ 67
7.4 Miscellaneous .......................................................................................... 68
7.4.1 Oil content reading higher than expected ..................................................... 68
7.4.2 Oil level alarm ............................................................................................... 68
7.5 Operational alarms ................................................................................... 69
7.6 System failures ......................................................................................... 70
7.6.1 Auto/manual operation ................................................................................. 70
7.6.1.1 Flowmeter .............................................................................................. 71
7.6.1.2 Ship’s speed indicator ........................................................................... 71
7.6.1.3 Oilcon
®
Oil Discharge Monitoring and Control System .......................... 71
7.6.1.4 Main Control Unit (MCU) ....................................................................... 71
7.7 System overrides ..................................................................................... 72
7.7.1 Transducer override ..................................................................................... 72
7.7.2 Discharge control .......................................................................................... 72
7.7.3 Discharge control answer-back .................................................................... 73
8 MAINTENANCE ............................................................................ 74
8.1 Maintenance general ................................................................................ 74
8.2 Routine maintenance ............................................................................... 75
8.2.1 Sample pump/motor lubricator ..................................................................... 75
8.2.2 Air regulators ................................................................................................ 76
8.2.3 Cleaning the detector cell windows .............................................................. 76
8.2.4 Window wash pump ..................................................................................... 76
8.2.5 Skid shuttle valve .......................................................................................... 76
8.2.6 2-Way pneumatic valve(s) ............................................................................ 76
8.2.7 Zero output check of the differential pressure transmitter ............................ 76
8.3 Test and check-out procedure .................................................................. 77
9 REPAIR OR REPLACEMENT ....................................................... 84
9.1 Detector cell ............................................................................................. 84
9.1.1 Removing the detector cell ........................................................................... 84
9.1.2 Reinstalling the detector cell ......................................................................... 84
9.2 Window wash pump ................................................................................. 85
9.2.1 Disassembling the window wash pump ........................................................ 85
9.2.2 Air side maintenance .................................................................................... 85
9.2.3 Water side maintenance ............................................................................... 85
9.2.4 Re-assembling the window wash pump ....................................................... 85
9.3 Sample pump ........................................................................................... 86
9.3.1 Disassembling the pump/motor .................................................................... 86
9.3.2 Reassembling the pump/motor ..................................................................... 87
9.4 Differential pressure transmitter – FUJI .................................................... 88
9.4.1 Zero adjustment of DPT – FUJI .................................................................... 88
9.4.2 Span adjustment of DPT – FUJI ................................................................... 88
9.5 Differential pressure transmitter – ABB .................................................... 89
9.5.1 Zero adjustment of DPT – ABB .................................................................... 89
9.5.2 Span adjustment of DPT – ABB ................................................................... 89
10 TAKE OUT OF SERVICE .............................................................. 90
11 REMOVAL AND STORAGE OF EQUIPMENT ............................. 90
12 MALFUNCTION AND SEND FOR REPAIR .................................. 90
13 ENVIRONMENT ............................................................................ 90
4
14 DISPOSAL .................................................................................... 90
15 TROUBLE SHOOTING AND FAULT FINDING ............................. 91
15.1 Introduction fault finding guide .............................................................. 91
15.2 Fault finding guide ................................................................................. 92
15.3 Calibration alarms ................................................................................. 94
15.3.1 Zero error alarm ............................................................................................ 94
15.3.2 Path dirty alarm ............................................................................................ 95
15.4 System alarms ...................................................................................... 96
15.4.1 No air ............................................................................................................ 96
15.4.2 No flow .......................................................................................................... 96
15.4.3 Power failures ............................................................................................... 96
15.4.4 Communication failure .................................................................................. 96
15.4.5 Led feedback error ....................................................................................... 96
15.4.6 Flow overrange failure .................................................................................. 97
15.4.7 Flow underrange failure ................................................................................ 97
15.4.8 Overboard arrangement failure .................................................................... 97
15.4.9 Discharge rate failure ................................................................................... 98
15.4.10 Total discharge oil limit alarm ................................................................... 98
15.5 GPS problems ...................................................................................... 98
15.5.1 No GPS signal visible ................................................................................... 98
15.6 Power supply problems ......................................................................... 99
15.6.1 MCU Power failure ....................................................................................... 99
15.6.2 Electro Pneumatic Unit power failure ........................................................... 99
15.7 Air supply problems ............................................................................ 100
15.7.1 Air supply failure ......................................................................................... 100
15.7.2 Water found in the monitors of the air system ............................................ 100
15.8 Solenoid valve problems ..................................................................... 100
15.8.1 Valve not working ....................................................................................... 100
15.9 Pneumatic valve problems .................................................................. 101
15.9.1 Valve not functioning .................................................................................. 101
15.9.2 Valve gland leakage ................................................................................... 101
15.9.3 Valve leakage ............................................................................................. 101
15.10 Window wash pump problems ............................................................ 102
15.10.1 Pump does not work ............................................................................... 102
15.10.2 Pump cycles without pumping or does not stall ...................................... 102
15.10.3 False cycle .............................................................................................. 102
15.10.4 Fluid appears at muffler .......................................................................... 102
15.11 Sample pump problems ...................................................................... 103
15.11.1 Electrical problems .................................................................................. 103
15.11.1.1 Pump runs but the green indicator on the starter box is off ................ 103
15.11.1.2 Pump should be running but is off ...................................................... 103
15.11.2 Pump related problems ........................................................................... 103
15.11.2.1 No flow ................................................................................................ 104
15.12 Differential pressure transmitter problems .......................................... 105
15.12.1 No line current ......................................................................................... 105
15.12.2 Current of 21.0mA or 3.9mA ................................................................... 105
15.12.3 Incorrect output ....................................................................................... 106
15.13 Fault finding form ................................................................................ 106
16 CERTIFICATES ...........................................................................110
16.1 Certificates of Ex-proof ....................................................................... 110
16.2 Certificates of type approval ............................................................... 125
5
17 DRAWINGS ..................................................................................126
18 ABBREVIATIONS ........................................................................168
18.1 Abbreviations ...................................................................................... 168
18.2 Symbol list .......................................................................................... 168
19 SPARE PARTS ............................................................................169
19.1 Standard spares .................................................................................. 169
19.2 Servicing spares ................................................................................. 169
20 WARRANTY CONDITIONS .........................................................171
6
1 PREFACE
1.1 GENERAL
The Oilcon® Oil Discharge Monitoring and Control System is used for monitoring and controlling the
discharge of ballast water overboard. The system comprises the following main components:
Oilcon
®
Oil Discharge Monitor
Flowmeter system
The purpose of the Oilcon
®
Oil Discharge Monitor is to calculate and record:
the instantaneous rate of discharge of oil, in litres per nautical mile
the total quantity of oil discharge into the sea on each voyage
and also to control the ship’s overboard discharge system as necessary to reduce the
possibility of discharging excessively oily water
Oil content discharge
This manual contains instructions for installation, operation and maintenance (IOM) of the
Oilcon
®
Oil Discharge Monitor and Control System.
For IOM information of associated equipment supplied by VAF Instruments, refer to the separate
manual supplied with those products.
This manual contains important information for the installer, the operator and for your maintenance
department.
NEVER USE THE EQUIPMENT OUTSIDE ITS SPECIFICATIONS OR BEYOND
COMMON ENGINEERING PRACTICE NOR USE THE EQUIPMENT FOR OTHER
APPLICATIONS OR MAKE CONNECTIONS TO OTHER EQUIPMENT THAN
EXPLICITLY DESCRIBED IN THE ORDER ACKNOWLEDGEMENT AND/OR
TECHNICAL MANUALS OF VAF INSTRUMENTS.
CAUTION:
TO ENSURE SAFE AND CORRECT INSTALLATION AND HANDELING, OPERATION
AND MAINTAINING, READ THIS MANUAL COMPLETELY BEFORE INSTALLING
THE EQUIPMENT AND STARTING OPERATIONS.
For any additional information contact:
VAF Instruments B.V. Tel. +31 78 618 3100
Vierlinghstraat 24, 3316 EL Dordrecht Fax +31 78 617 7068
P.O. Box 40, NL-3300 AA Dordrecht E-mail: sales@vaf.nl
The Netherlands Internet: www.vaf.nl
Or your local authorized VAF dealer.
Their addresses can be found on www.vaf.nl
7
1.2 SYMBOLS
The following symbols are used to call attention to specific types of information.
A WARNING TO USE CAUTION!
IN SOME INSTANCES, PERSONAL INJURY OR DAMAGE TO THE OILCON
®
OIL
DISCHARGE MONITORING AND CONTROL SYSTEM MAY RESULT IF THESE
INSTRUCTIONS ARE NOT FOLLOWED PROPERLY.
AN EXPLANATION OR INFORMATION OF INTEREST.
1.3 COPYRIGHT
This Technical Manual is copyrighted with all rights reserved.
While every precaution has been taken in the preparation of this manual, no responsibility for errors
or omissions is assumed. Neither is any liability assumed for damages resulting from the use of the
information contained herein. Specifications can be changed without notice.
Oilcon
®
is a registered trademark of VAF Instruments B.V.
8
2 PRODUCT DESCRIPTION
The Oilcon® Oil Discharge Monitoring and Control System continuously samples ballast water being
discharged overboard and measures the oil content and controls the discharge of the ballast water
and plays therefore a central role in the Oil Discharge Monitor and Control System.
A schematic arrangement of the entire Oilcon
®
Oil Discharge Monitoring and Control System is
shown in drawing 0806-8035.
2.1 PRINCIPLE OF OPERATION
The measurement technique used in the Oilcon® Oil Discharge Monitoring and Control System is
based on scattered light. The sample of discharge water passes through a detector cell while light
enters and leaves the measurement area of the cell. The sample flow is at right angles to the optical
path. When no particles or oil droplets are present in the water, light can pass straight through the
cell (Direct beam). When oil is present in the form of a homogeneous mixture, light is scattered at
different angles (Scatter beam). The intensity of scattered light at a specific angle depends on the
density of oil droplets and their particle size relative to the wavelength of radiation. The intensity of
light of the direct beam decreases logarithmically with an increasing oil concentration, while the
scatter beam increases linearly but passes through a maximum before decreasing logarithmically.
The maximum occurs because of the increase in attenuation blocking out the scattered light at high
concentrations. The variation of light refraction by oil droplets only is quite different to that refracted
when solid contaminants are also present and this fact can be used to obtain an accurate indication
of oil content whilst disregarding solid particles up to a point.
The light source used in the Oilcon
®
Oil Discharge Monitoring and Control System is a near infra red
diode which is operated in a pulsed mode so that the average power dissipation is very low,
although the intensity is high. The light signal is processed and transmitted along a signal cable
from the detector cell to the EPU where the three detection signals are used to compute the oil
concentration levels present in the sample passing through the detector cell.
The response in the optical detection is instantaneous and most of the delays when reading oil
levels lie in the sampling pipework. High velocity, short sampling length and minimum pipework
bends give fast response times. During periods of inactivity the pipework may become fouled and
when the system is started up, erroneous readings could occur as oil is stripped from the pipework.
Automatic sequential control of forward and backward flushing at start up and shut down of the
monitor prevents erroneous readings and keeps the sampling lines clean. This also ensures reliable
start up, minimises system deterioration and ensures that the pipework is left in clean condition prior
to the next use of the monitor. At the end of the start up flushing cycle a system zero check is
performed, this automatic zero setting compensates for any small deposits on the cell windows. The
window wash pump cleans the cell windows at regular intervals.
All operating controls and system alarms are situated on the MCU. Manual system flush and
window wash controls are available to make these two operations possible at any time. With the
exception of selecting the sample point and the oil type, the system works automatically once
sampling has been initiated. The oil level together with the discharge flow rate and ships speed are
input to the MCU to give a permanent record of oil discharged overboard. Both calibration alarms
and operational alarms are provided and the alarm philosophy employed follows normal marine
practice. When a fault occurs, both audible and visual alarms are activated. The audible alarm can
be silenced by fault acceptance but the visual alarm cannot be extinguished. It is only after the fault
has been rectified that the visual alarm is extinguished. Should a second alarm occur during this
sequence, both audible and the visual alarms would be reactivated.
9
2.2 PRODUCT CONFIGURATION
The Oilcon® Oil Discharge Monitoring and Control System comprises the elements labelled as:
Main Control Unit (MCU).
Electro Pneumatic Unit (EPU)
o I/S signal cable
o Starter box
Skid assembly
Pump/motor assembly
Flowmeter system
Sample probe valve assembly
2.2.1 Main Control Unit (MCU)
Reference drawings
Dimensional drawing MCU Mark 6M 0806-1285
The Main Control Unit is the central part of the Oilcon
®
Oil Discharge Monitoring and Control System
and is designed for mounting in the cargo control console. Its function is to compute and record:
The instantaneous rate of discharged oil, in litres per nautical mile
The total quantity of oil discharged into the sea on each voyage
To control the ships overboard discharge system
The oil content
The Main Control Unit receives the following input signals to control the ship’s overboard discharge
system:
Ship’s GPS input
Ship’s speed in knots
Overboard valve position
Oil content of ballast water in ppm *
Rate of discharge of ballast water in cubic metres per hour *
Inputs marked * are received from the EPU via a serial data link.
The MCU processes these inputs and records and displays all the necessary information.
Figure 1
The data is displayed on the LCD touch screen and is also logged to an internal memory.
Control of the MCU is through the LCD touch screen.
The MCU also displays a number of menus with information about the system’s status, configuration
and settings. The various menus are designed to help the operator to control the Oilcon
®
Oil
Discharge Monitoring and Control System and to give a wide range of information.
CONTROL Sample point: 1 22-11-11
standby Oil type: 5 10:38
Concentration A 0 PPM discharge
Flow A 0 m3/h dirty
Skid Flow 0 l/h com: C
Speed A 10.0 kts pos: C
Dischar ge rate 0.0 l/nm s egregated
Total oil 0.0 l com: C
Latitude 5321.756N pos : C
Longitude 00711.854E
EPU: OK
free: 1927296 kB
SETUP? DATA SELFTESTCONFIG
10
2.2.2 Electro Pneumatic Unit (EPU)
Reference drawings
Dimensional drawing and parts list EPU 1-2 sample valves Mark 6M 0806-1287
The Electro Pneumatic Unit (EPU) contains the control electronics and the solenoid valves to switch
the pneumatic signals. It also contains the Zener barriers for the input signals from the flowmeter(s),
skid flow meter and measurement cell. There is a single electronic card installed, and a power
supply in the cover of the upper section of the cabinet.
The EPU is designed for mounting in the engine room opposite the Skid on the engine room/pump
room bulkhead or in another suitable location.
2.2.2.1 Intrinsically safe signal cable
The engine room mounted EPU is connected to the pump room mounted detector cell located within
the skid assembly via an intrinsically safe (I/S) signal cable. The cable carries the following signals
from the skid:
Oil content signals generated by the detector cell
Flow rate of sample water through the skid
LED feedback signal
2.2.2.2 Starter box
Reference drawings
Dimensional drawing motor starter box Ballast Monitor Mark 6 0806-1075
The control of the sample pump motor is from the EPU via the starter box. This unit contains a relay
to switch the 3-phase supply to the pump motor and a thermal trip to protect the pump motor. It also
has a main switch to isolate the pump motor from the 3-phase supply in case of maintenance.
Location for the starter box is the engine room in the proximity of the sample pump motor.
11
2.2.3 Skid assembly
Reference drawings
Dimensional drawing and parts list ballast skid Mark 6M 0806-1288
The skid assembly contains the necessary items to handle the sampled ballast water and to
measure the oil content. In the skid assembly there is a pneumatically operated shuttle valve (5),
and a window wash pump (1).
The shuttle valve (5) selects between fresh water, forward or backward flush and sample water.
Also contained within the skid assembly is the detector cell (6) which contains the electronic sensing
system to determine oil content. On the left hand side of the skid assembly is the window wash
pump (1). This is a pneumatically operated pump which provides a 1 to 10 pressure boost to the
window flushing water. Also included in the skid assembly is a flow shuttle valve (5), which sets a
back pressure on the sample pump and a magnetic flow sensor (3) to determine flow through the
skid assembly.
The skid assembly is normally mounted in the pump room opposite the EPU on the engine room
side of the bulkhead.
2.2.4 Pump/motor assembly
Reference drawings
Dimensional drawing sample pump/motor Ballast Monitor Mark 6 0806-1076
Assembly drawing sample pump Ballast Monitor Mark 6 0806-1260
The pump/motor assembly comprise a high shear vortex pump, a gas tight bulkhead seal and a
motor. The pump provides a degree of sample water conditioning as the shearing effect tends to
produce droplets of oil of roughly similar size. The pump has a mechanical seal to provide sealing
on the shaft. This shaft fits directly on the motor shaft and is inter-connected by a lantern ring. The
shaft passes through a bulkhead seal, which consists of a number of rubber lip seals which are oil
lubricated to form a gas tight seal. The motor is directly bolted to the bulkhead seal. The motor is
suitable for 380V or 440V at 50Hz or 60Hz, runs at 2850rpm or 3420rpm respectively and is
constructed to IP55 and isolation Class F, IEC 34-1.
2.2.5 Flowmeter system
Reference drawings
Installation flowmeter Ballast Monitor Mark 5/6 0806-8016
Bulkhead penetration and piping diagram Mark 6M 0806-8038
The flow of water through the orifice plate causes a pressure difference across the plate. This
differential pressure is converted into a mA signal and transmitted to the EPU by the dP/I
transmitter.
The manifold valve block fitted to the differential pressure transmitter, has three shut-off valves. The
two outer valves are for blocking off the pressure sensing lines from the sensor. The centre valve
serves as an equalizing valve to balance the pressure at both sides of the transmitter.
See drawing 0806-8038 (sheet 2 of 4) for configuration of the system.
12
2.2.6 Sample probe valve assembly
Reference drawings
Dimensional drawing sample valve Mark 6 0806-1077
Part list sampling probe pipe connection Ø15 mm Ballast Monitor Mark 6M 0806-1265
Part list isolating valve Ø15 Ballast Monitor Mark 6 0806-1268
For taking a representative sample of the ballast water to measure the oil level content, a sample
probe valve assembly is provided. It comprises:
a probe, for penetration in the selected discharge line;
a gate valve, for manual closure upon completion of monitoring;
a pneumatic valve, for remote selection of the discharge line, so the line can be changed
whilst the monitor is in operation.
2.3 SAMPLING SYSTEM ARRANGEMENTS
Reference drawings
Dimensional drawing and parts list ballast skid Mark 6M 0806-1288
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
A suggested installation configuration of the Oilcon
®
Oil Discharge Monitoring and Control System is
given in drawing 0806-8035. Up to 6 sampling points can be catered for, although most ships will
have much less than this. The total number of valves that are contained in the system is depending
on the particular configuration on the ship.
The sample point is selected from the MCU in the ship’s cargo control room (CCR). This causes the
selected valve to open. When the system is in operation, water is drawn from the sample point by
the sample pump, passed through the detector cell and then discharged to the slop tank or
discharged overboard, depending on the installation.
The accuracy of the monitor is improved by the use of a flushing sequence before sampling
commences, at intervals during sampling and when the system is shut down after use. All the
flushing sequences are carried out automatically by the system.
The flushing sequence serves 3 purposes:
to clean the pipework
to keep the detector cell windows clean, which keeps the optical path un-obscured
to perform a zero check every time a flush sequence is activated
The flushing sequences can be operated manually from the MCU, if required.
The skid assembly, see drawing 0806-1288, contains a pneumatically operated shuttle valve, which
facilitates the forward flush and backward flush. During the automatic flushing sequences on start
up, and on shut down, the valve activates to flush all the pipework using the fresh water supply and
sequentially selects between backward and forward flush. When the manual flush is operated,
valves are activated to allow fresh water into the system and an additional zero check is performed.
During sampling every 3 minutes, an automatic cleaning of the windows in the detector cell is
carried out. A pneumatic pump mounted in the skid assembly supplies high pressure fresh water
which is sprayed across each window. It will be noticed that the window wash sequence is indicated
on the MCU in the top left corner by “window wash”.
13
Figure 2
For correct operation of the system it is important, that during operations an un-interrupted supply of
fresh water is available. The fresh water used must also be free of any contaminants or air bubbles.
The typical installation in drawing 0806-8038 shows a number of manual valves. These are used for
isolation the system or maintenance purposes. The valves are:
fresh water pressure reducing/isolator valve
sample discharge valve skid
isolation valve to slop tank *YARD SUPPLY* (usually a non-return valve, as the slop tank will
most likely be pressurised due to an inert gas system)
sample grab cock mounted on the sample pump discharge
injection point (for onboard calibration by an approved service engineer)
NOTE:
There is an unmarked valve inside the skid assembly on the outlet side of the
measurement cell. This valve is used to provide back pressure for the sample pump. If
the valve is open fully, there will be little or no back pressure on the pump, possibly
causing the pump to cavitate and resulting in erroneous reading of oil content.
The correct setting for the valve is almost closed. In this position the pump discharge
will be in the region of 450–550 litres per hour. This skid-flow can be checked when
sample-mode is entered, in the MCU menu 1.5.3.4.
CONTROL Sample point: 1 22-11-11
window wash Oil type: 5 10:38
Concentration A 200 PPM dischar ge
Flow A 165 m3/h dirty
Skid Flow 0 l/h com: O
Speed A 10.0 kts pos: O
Dischar ge rate 3.3 l/ nm segregated
Total oil 2.1 l com: C
Latitude 5321.756N pos : C
Longitude 00711.854E
EPU: OK
free: 1927296 kB
14
3 TECHNICAL SPECIFICATION
3.1 GENERAL
Range 0 – 1000 ppm
Type of oils In accordance with type approval certificate oils as per MEPC
108(49) and biofuel blends as per MEPC 240(65)
Accuracy In accordance with IMO Resolution MEPC 108 (49),
the system response is within the accuracy specified.
Response time Less than 40 s, in accordance with IMO Resolution
MEPC 108 (49)
Zero noise Less than 2 ppm
Response to oils In accordance with IMO Resolution MEPC 108 (49),
the system response is within the accuracy specified.
Sensitivity to solids In accordance with IMO Resolution MEPC 108 (49),
the system response is within the accuracy specified.
Fouling In accordance with IMO Resolution MEPC 108 (49)
Alarm adjustment 0 - 1000 ppm.
Sample points 2 standard, (optional 6 maximum)
3.2 MAIN CONTROL UNIT (MCU)
Electrical supply 24VDC – 0,1A
Emergency supply 24VDC – 0,1A (Source independent from source main supply)
Power consumption 2,4W
Ambient temperature -20 °C – +55 ºC
Humidity range 0 – 95 % RH
Mounting panel mounted, see drawing 0806-1285 for dimensions
Wiring 24V-supply (X8) (X9) 2 x 0,5 mm
2
cable
Wire size output-connectors Min-max 0,2 – 2,5 mm
2
Wire size input-connectors Min-max 0,2 – 2,5 mm
2
Installation category II
Pollution degree I acc. to IEC 664
Ventilation requirements no special requirements
Communication (X13) RS422/485 4-wire to EPU. Baud rate: 9600, Data bits: 8, Parity:
none, Stop bits: 1, Flow control: None
Input signals
Feedback Discharge-
segregated-ballast (X10)
NC contact, rating 2,2 mA
Feedback Dischargedirty/clean-ballast (X11)
NC contact, rating 2,2 mA
Ship’s log (X12) 100, 200, or 400 p/NM, rating 5 mA
GPS (X14) GPS NMEA 0183, RS485 2-wire, Baud rate: 4800, Data bits: 8,
Parity: none, Stop bits: 1, Flow control: None
MCU is reading following strings:
RMC, GLL and/or GGA for ships’ position
VTG for ships’ speed
15
Output signals
USB USB Flash drive with a type A connector
USB 1.0 compatible and formatted according to FAT16
Serial output Alarm relay (X3) NO/NC contact, rating 250 VAC – 5 A or 30 VDC – 5 A
Failure-24V relay (X4) NO/NC contact, rating 250 VAC – 5 A or 30 VDC – 5 A
Auto/manual relay (X5) NO/NC contact, rating 250 VAC – 5 A or 30 VDC – 5 A
Dirty/clean discharge valve (X6) NO/NC contact, rating 250 VAC – 5 A or 30 VDC – 5 A
Segregated discharge valve (X7) NO/NC contact, rating 250 VAC – 5 A or 30 VDC – 5 A
3.3 ELECTRO PNEUMATIC UNIT (EPU)
Electrical supply 115/230 VAC, 50/60 Hz
Power consumption 60 W
Air supply 4 – 7 bar, dry clean air (0,4 MPa – 0,7 MPa)
average consumption 6 l/min
max. consumption 50 l/min
Ambient temperature -20 °C – +55 ºC
Humidity range 0 – 95 % RH
Protection class IP 65
Mounting wall mounting, see drawing 0806-1287 for dimensions
Output signals
Communication RS422/485 to MCU
Pump start/stop signal 24 VDC, to sample pump starter relay
Pneumatic supply 4 bar to skid and sample valve
Cable glands
See drawing 0806-2050 for options
(1) Mains supply M20 x 1,5 (cable diameter 6 – 12 mm)
(2) Communication to MCU M20 x 1,5 (cable diameter 6 – 12 mm)
(3) Pump starter box M20 x 1,5 (cable diameter 6 – 12 mm)
(4) Ballast skid M20 x 1,5 (cable diameter 10 – 14 mm)
(5) Flowmeter dP/I M20 x 1,5 (cable diameter 6 – 12 mm)
(6) Spare M20 x 1,5 (cable diameter 6 – 12 mm)
Wire size supply-connectors Min-max 0,2 – 2,5 mm
2
Wire size output-connectors Min-max 0,2 – 2,5 mm
2
Wire size input-connectors Min-max 0,5 – 4,0 mm
2
Installation category II
Pollution degree II acc. To IEC 664
Ventilation requirements no special requirements
16
3.4 SKID
Sample flowrate between 450 and 550 l/h
Sample inlet pressure 3 bar (nom.), 6 bar (max.) (0.3 MPa nom., 0.6 MPa max.)
Fresh water supply 3 bar (nom.), 6 bar (max.) (0.3 MPa nom., 0.6 MPa max.)
average consumption 0,13 l/min
max. consumption 8 l/min
Water temperature range 10 °C – 65°C, in accordance with IMO Resolution MEPC 108 (49)
Ambient temperature -20 °C – +55 ºC
Humidity range 0 – 95 % RH
Protection class IP 65
Mounting wall mounting, see drawing 0806-1288 for dimensions
Connections
Fresh water and sample water 15 mm tube coupling
Air to valves 6 mm tube coupling
Air to pneumatic pump 8 mm tube coupling
Cable to EPU M20 x 1,5 (cable diameter 10 – 14 mm)
Wire size connectors Min-max 0,2 – 2,5 mm
2
3.5 SAMPLE PUMP
Electrical supply 3-phase 380–420 VAC, 50Hz, 1.1 kW, 2.5 A
or 3-phase 440–480 VAC, 60 Hz, 1.3 kW, 2.5 A
Power consumption 1300 W
Isolation class F, IEC 34-1
Protection class IP 55
Mounting wall mounting, see drawing 0806-1076 for dimensions
Connections
Sample water 15 mm tube coupling
Cable M20 x 1,5 (cable diameter 10 – 14 mm)
Wire size connectors Min-max 0,2 – 2,5 mm
2
17
3.6 REFERENCE TABLE OF PRODUCTS WHICH MAY BE MEASURED
Crude oils, and “black” and “white” products (Annex I)
Range number Product
0
Marine Distillate Fuel oil
1
Category 1 crude oil
2
Category 2 crude oil
3
Category 3 crude oil
4
Category 4 crude oil
5
Category 5 crude oil
6
Category 6 crude oil
7
Automotive Gasoline
8
Kerosine
9 Not used
Biofuel blends (Annex I) according Resolution MEPC.240(65)
Range number Product
10
Biofuel blends of Diesel/gas oil and vegetable oil (25% vegetable oil, 75% Diesel/gas oil)
11
Biofuel blends of Diesel/gas oil and vegetable oil (1% vegetable oil, 99% Diesel/gas oil)
12
Biofuel blends of Diesel/gas oil and Alkanes C10-C26 linear and branched Flashpoint >60C
(25% Alkanes, 75% Diesel/gas oil)
13
Biofuel blends of Diesel/gas oil and Alkanes C10-C26 linear and branched Flashpoint >60C
(1% Alkanes, 99% Diesel/gas oil)
14
Biofuel blends of Diesel/gas oil and Alkanes C10-C26 linear and branched Flashpoint ≤60C
(25% Alkanes, 75% Diesel/gas oil)
15
Biofuel blends of Diesel/gas oil and Alkanes C10-C26 linear and branched Flashpoint ≤60C
(1% Alkanes, 99% Diesel/gas oil)
16
Biofuel blends of Gasoline and Ethyl alcohol (25% Ethyl alcohol, 75% Gasoline)
17
Biofuel blends of Gasoline and Ethyl alcohol (1% Ethyl alcohol, 99% Gasoline)
18
Biofuel blends of Diesel/gas oil and FAME (25% FAME, 75% Diesel/gas oil)
19 Biofuel blends of Diesel/gas oil and FAME (1% FAME, 99% Diesel/gas oil)
Note: The aforementioned percentages (%) are by volume
20/29 Range number 20 till 29 are not used.
30 Orimulsion
31 Calibration VAF
18
3.7 BIOFUEL GUIDELINES AND DEFINITIONS
According MEPC.1/Circ.761 the following definitions are given.
Bio-fuels are ethyl alcohol, fatty acid methyl esters (FAME), vegetable oils (triglycerides)
and alkanes (C10-C26), linear and branched with a flashpoint of either 60°C or less or more
than 60°C, as identified in chapters 17 and 18 of the IBC Code or the MEPC.2/Circular/tripartite
agreements. Following the distribution of these guidelines, further bio-fuels identified as falling
under the scope of the guidelines, will be recorded in annex 11 of the MEPC.2/Circular which
deals with bio-fuel/petroleum oil blends.
When containing 75% or more of petroleum oil, the bio-fuel blend is subject to Annex I of MARPOL.
When containing less than 75% of petroleum oil, the bio-fuel blend is subject to Annex II of
MARPOL.
19
4 SAFETY INSTRUCTIONS
4.1 SAFETY PRECAUTIONS
All precautions have been taken to ensure, in so far as reasonable practical, that the equipment has
been designed and constructed to be safe and without risk to health or the environment when
properly used.
Provided that the recommendations contained in this manual are carefully adhered to, no
circumstances are foreseen where the equipment will present a health or safety hazard.
To ensure the safety of personnel, equipment and the environment:
Always follow the safety, installation, repair and maintenance recommendations in this
manual.
All personnel who installs, operates, repairs or maintains the equipment should read this
manual completely and make themselves acquainted with the equipment before installing,
operating, repairing or maintaining the equipment.
Make sure that all safety requirements are met before installing, operating, repairing or
maintaining the equipment.
Always use personal protective means when necessary.
Always use the adequate tools to perform the work.
Make sure that all equipment is isolated from the electrical-, water and air supplies before
installing, repairing or maintaining the equipment.
Never assemble or disassemble electrical equipment or remove or install printed circuit
boards with power switched ON.
Always handle printed circuit boards with CMOS components according to the correct
procedures for such components, to prevent any damage due to electrostatic discharges.
Only use cleaning solvents in a well ventilated area. Avoid breathing fumes. Keep away from
open fire. Do not use solvents on plastic components or parts.
20
5 UNPACKING
Let the equipment acclimatize inside the closed box for at least one hour at the location where the
Oilcon
®
Oil Discharge Monitoring and Control System will be installed.
When the equipment is taken out of the box, please leave the special protection supplied with the
equipment as long as possible in place to avoid any damage.
Disposal of the packaging material should be done according to local laws or regulations, or
according to the rules that are applicable on the vessel.
Details of main components of the Oilcon
®
Oil Discharge Monitoring and Control System:
Main Control Unit (MCU)
Weight: 1.5 kg
Dimensions: 257 mm x 157 mm x 126 mm (W x H x D)
Figure 3: Main Control Unit
Electro Pneumatic Unit (EPU)
Weight: 9.5 kg
Dimensions: 500 mm x 263 mm x 114 mm (W x H x D)
Figure 4: Electro Pneumatic Unit
Motor Starter Box
Weight: 1 kg
Dimensions: 126 mm x 176 mm x 100 mm (W x H x D)
Figure 5: Starterbox
Electronic Differential Pressure Transmitter (DP/I)
Weight: 8 kg
Dimensions: 225 mm x 195 mm x 194 mm (W x H x D)
Figure 6: Electronic Differential Pressure
Transmitter
21
Orifice Plate
Thickness: 6 mm
Material: Stainless Steel
Diameter and bore: Specific to each installation
Figure 7: Electronic Differential Pressure
Transmitter and Orifice Plate
Skid Assembly
Weight: 20 kg
Dimensions: 500 mm x 420 mm x 177 mm
(W x H x D)
Air Connections: 6 mm and 10 mm tube
Water connections: 15 mm OD tube
Figure 8: Skid Assembly
Sampling Pump
Weight: 30 kg
Length overall: 348 mm
Cut out diameter: 290 mm
Connections: 15 mm OD tube
Figure 9: Sampling Pump
Total weight of the complete system: 87 kg
22
6 INSTALLATION
6.1 INTRODUCTION
This specification sets out the requirements for the installation, operation and maintenance of an
Oilcon
®
Oil Discharge Monitoring and Control System on board a typical tanker. It should be studied
carefully before actually commencing any operation or work.
For the purpose of installation the system can be divided into 4 categories:
1. Pump room equipment and related deck ancillaries (hazardous area)
2. Bulkhead penetrations
3. Engine room equipment * (non-hazardous area)
4. Control room equipment ** (non-hazardous area)
The exact location of the separate elements within these categories will vary from ship to ship but
the specific location of some units relative to others is important.
In addition to safety precautions which must always be strictly observed for work in hazardous
spaces, installation undertaken at sea, with the ship underway, require additional precautions.
* It is recognised that for some vessels the pump room and engine room are not adjacent. If
this is the case, it will be necessary to mount the electrical equipment in some other suitable
non-hazardous space adjacent to the pump room.
** Again, some vessels may not have a cargo control room. If this is the case, some other
convenient area must be identified, such as the navigation bridge, the engine room or the
accommodation area.
CAUTION:
ANY COMPONENTS MOUNTED ON OPEN DECK OR IN AREAS LIKELY TO
ENCOUNTER TEMPERATURE AT OR BELOW FREEZING SHOULD BE
PROTECTED ACCORDINGLY AGAINST FREEZING.
6.2 UTILITIES
For operation of the Oilcon® Oil Discharge Monitoring and Control System the following utilities are
required:
6.2.1 Fresh water supply
An uninterrupted supply of fresh water free of any contamination is important for a correct operation
of the Oilcon
®
Oil Discharge Monitoring and Control System, as the freshwater is used to keep the
pipework and the windows of the detection cell clean and to perform a Zero check prior to operation
of the system.
Fresh water supply conditions
Nominal inlet pressure 1,5 bar (0,15 MPa)
Maximum inlet pressure 6 bar (0,6 MPa)
Average consumption 0,13 l/min
Maximum consumption 8 l/min, during FLUSH
Water temperature range
10°C – 65°C
23
6.2.2 Air supply
For a trouble free and satisfactory operation of the pneumatic components in the Oilcon
®
Oil
Discharge Monitoring and Control System a supply of clean, dry air at a constant pressure is
essential.
Air supply conditions EPU
Valve control 4,0 bar nom., 7 bar max. (0,4 MPa nom., 0,7 MPa max.)
Window wash pump 4,0 bar nom., 7 bar max. (0,4 MPa nom., 0,7 MPa max.)
Average consumption 6 l/min
Maximum consumption 50 l/min
6.2.3 Electrical supply
Electrical supply conditions
Main Control Unit 24 VDC – 0,1 A
Emergency supply 24 VDC – 0,1 A
Electro Pneumatic Unit 115/230 VAC 50/60 Hz, 0,5 A
Sample pump motor 3 phase 380–420 VAC, 50 Hz, 1.1 kW, 2.5 A
or 3 phase 440–480 VAC, 60 Hz, 1.3 kW, 2.5 A
NOTE:
AS REQUIRED BY REGULATIONS THE EMERGENY POWER SUPPLY HAS TO
ORIGINATE FROM A SOURCE INDEPENDENT FROM THE SOURCE OF THE MAIN
POWER SUPPLY.
6.3 PIPEWORK GENERAL
All pipework for water services should be of a suitable material and capable of withstanding working
pressures of up to 16 bar. The pipework has been standardised at 15 mm O.D. with a minimum wall
thickness of 1 mm. For example: ASTM B111-69 alloy 706 - or BS 378/2871 type CN 102-0.
Air signal pipework should be copper, and generally be 6 mm O.D. x 4 mm I.D.
The exception in this sizing is the air supply for the window wash pump mounted on the skid, and
shown as V12. These lines are 8 mm O.D. x 6 mm I.D. (ASTM B75-68 alloy 122 - or BS 2871/1971
type C106-0).
Pipework must be clean and oil free prior to fitting and care must be taken to ensure all joints are
leak tight. Failure to ensure this will adversely affect system function, particularly if air leakage is
evident on pump suction lines. Ideally all joints should be made using brazed couplings. If piping is
being installed during a sea passage then compression fittings may be used. These couplings
should be of a salt water resistant material, and the use of stainless steel compression rings may be
necessary if a non-flared tube end technique is used to make the joints. Mild steel couplings must
not be used. Pipework must be adequately clipped and supported, and shall not impose any strain
or force on equipment, e.g. pump or skid assembly. Pipework must also be protected in exposed
situations. In those cases where the water discharge from the ballast skid is taken to a slop tank, if
the ship has an inert gas system, a loop-seal arrangement must be fitted in the discharge line to
prevent contamination being forced back down the line. Also measures must be taken to prevent the
discharge from free-falling into the tank. This is usually achieved by diverting the flow against the
bulkhead of the tank.
24
CAUTION:
BEFORE THE SYSTEM IS PUT INTO OPERATION OR TESTED ALL PIPEWORK
MUST BE FLUSHED AND CLEARED FROM DIRT OR FOREIGN MATTER.
Reference drawings
Dimensional drawing and parts list ballast skid Mark 6M 0806-1288
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
Bulkhead penetration and piping diagram Mark 6M 0806-8038
6.3.1 Sample pump unit
The sample pump unit comprises a pump, bulkhead mounting flange with integral gastight shaft seal
and a flange mounted motor. For this purpose a hole with a diameter of 290 mm is to be made in
the bulkhead wall. The pump unit shall be fitted to the bulkhead utilising the welding ring as supplied
with the pump. This ring shall be welded to the bulkhead wall.
For the location of this hole verify with the pump dimensional drawing that there will be no obstacles,
and that the pump unit can be accessed for maintenance. Maintain sufficient free space around the
motor for free air circulation to cool the motor.
If possible, the unit should be located below all proposed sampling points and as central to these
locations as possible. Care should be taken to ensure that under all operational circumstances a
zero or positive pressure is present at the suction side of the pump.
The joints of the suction line must be airtight, otherwise air leakage will occur causing reduced
pumping and monitoring performance. If air leakage is considerable, the pump may fail to prime or
pump at all.
It will be observed that a length restriction has been placed on the sample pipes (refer to section
6.7.4 pipe work response time calculation) for two reasons:
a. To ensure that the total response time of the system is less than 40 seconds, as required by
legislation. In fact, since the instrument response time is less than 10.8 seconds and the
sample velocity in the specified pipework is 0.9 m/s, there is some margin here.
b. To ensure that the sample pump is not faced with excessive negative suction pressure due
to high pipe losses.
6.3.2 Installation of the sample pump
WARNING:
IN THE CASE OF AN INSTALLATION AT SEA, WHERE THE PUMP ROOM
CONSTITUTES A HAZARDOUS AREA, PRECAUTIONS FOR HOT WORK AS LAID
DOWN BY THE OWNER MUST BE STRICTLY OBSERVED.
At the selected location a hole with a diameter of 290 mm is to be made in the bulkhead wall. The
installer should note that in some circumstance it may be necessary to construct a “top-hat” device,
to artificially extend the pump room/engine room bulkhead around the pump/motor assembly while
the hole is being cut and the mounting flange fitted.
Weld-on the welding ring; make sure that the bolt holes are in X-position. These holes are not to be
in + - position!
The gasket shall be placed in between the pump main plate and the welded ring.
For easy installation do not fit the oil reservoir yet.
25
Before connecting the system piping to the pump, the unit is to be securely fastened to the
bulkhead. Long or heavy piping sections shall not be supported from the pump but by separate
supports.
ALIGNMENT: No inspection or corrections to pump/motor alignment are necessary.
Install the oil reservoir and top up the reservoir with the supplied oil.
WARNING:
THE OIL RESERVOIR SHALL ALWAYS BE SUFFICIENTLY FILLED WITH OIL, AS
THE PROPER FUNCTIONING OF THE GAS SEAL LOCATED IN THE CENTRE OF
THE PUMP MAIN PLATE RELIES ON THE PRESENCE OF OIL, FOR LUBRICATING,
SEALING AND COOLING PURPOSES.
6.3.3 Electrical installation pump
Verify the power supply. This is to match the data as shown on the electric motor nameplate.
Grounding is to be carried out utilizing the grounding bolt located inside the terminal box, before the
motor is connected to the mains.
6.3.4 First start
CAUTION:
UNDER NO CIRCUMSTANCES SHOULD THE PUMP RUN WITHOUT LIQUID.
THE PUMP HOUSING MUST FIRST BE FILLED WITH LIQUID, OTHERWISE THE
PUMP WILL SEIZE AND DAMAGE WILL OCCUR.
6.3.4.1 Self priming
The pump will not function or prime until the casing is filled with liquid. Make sure any discharge
valve is opened before starting, enabling air to be released. Running the pump with zero capacity
will cause excessive system pressure; heat generated in the pump and may overload the electric
motor. Make sure any system valve should be fully opened when the pump is being started or
stopped.
6.3.4.2 Direction of rotation
This can be seen or checked from the motor side only. Make sure that all piping is installed, and the
pump is filled with water. Switch-on the pump unit for a short moment only! Look at the motor fan
and notice the direction in which the fan spins. This must be clockwise, when looking from the back
cover of the motor. An arrow also indicates correct direction of rotation. If direction of rotation is
wrong, interchange any of two line wires of the power cable in the terminal box.
Reference drawings:
Dimensional drawing sample pump/motor Ballast Monitor Mark 6 0806-1076
Electrical connection diagram Ballast Monitor Mark 6M MEPC 108(49) 0806-2048
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
Bulkhead penetration and piping diagram Mark 6M 0806-8038
26
6.3.5 Skid
The skid is normally located in the pump room and is mounted on the pump room/engine room
bulkhead. The unit should be positioned above the sample pump, but should be kept below the level
of the sampling probe points wherever possible. This is to ensure full pipework and provision of
adequate suction pressure for the pump.
The skid is provided with four mounting points, drilled to accept 12 mm bolts.
A sample point should be fitted between the pump discharge and the skid to facilitate the taking of
grab samples for analysis.
Reference drawings
Dimensional drawing and parts list ballast skid Mark 6M 0806-1288
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
Bulkhead penetration and piping diagram Mark 6M 0806-8038
6.3.6 Sampling probes
WARNING:
IN THE CASE OF AN INSTALLATION AT SEA SAFETY PRECAUTIONS MUST BE
OBSERVED WHILE DRILLING OPERATIONS TAKE PLACE. IN THE CASE WHERE
WELDING IS NOT PERMITTED A SADDLE CLAMP ARRANGEMENT CAN BE
UTILISED. THIS TYPE OF PROBE ARRANGEMENT SHOULD ONLY BE VIEWED AS
TEMPORARY AND ARRANGEMENTS SHOULD BE MADE TO WELD THE PROBE IN
PLACE AT THE NEXT OPPORTUNITY.
Sample point(s) are supplied with the monitor, for location at the selected points on the relevant
overboard discharge lines and contains the following:
A pneumatic operated valve for selection of the sample point;
A sample probe to take the sample from the discharge line.
Each probe is supplied with a hand valve and a compression fitting which can be welded to the
pipeline. Positioning of the sample probe within the pipeline is most important. To prevent excessive
quantities of air being drawn into the sample pump, the probe should ideally be mounted in a rising
vertical pipe section. This will ensure that, provide water is being pumped, the main pipe is always
filled. Where it is not possible to mount into a vertical pipe then a horizontal section may be used
and the probe located as shown in drawing 0806-1265. VAF Instruments recommend that whenever
possible the sample probe should be installed on the upstream side of the orifice plate.
In any case the probe should be located upstream of any diverting line to the slop tank.
The important points to note are as follows:
The probe enters from the bottomside of the pipe.
The probe is mounted a small distance into the pipe. This ensures a representative sample
and reduces the possibility of picking up “sludge” deposited in the pipe.
The probe end is located in the lower section of the pipe, partly to increase the possibility of
obtaining an air-free sample and partly to reduce the obstruction in the pipe.
The sample valve is mounted in the correct orientation. (Air inlet port uppermost)
The sample valve inlet and outlet ports are correctly mounted.
Reference drawings
Dimensional drawing sample valve Mark 6 0806-1077
Part list sampling probe pipe connection Ø15 mm Ballast Monitor Mark 6M 0806-1265
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
27
6.3.7 Orifice plate
6.3.7.1 General information
The orifice plate is a square-edged, concentric bore type, manufactured in stainless steel. It is
designed to be clamped between two flanges, within the PCD of the flange bolts. Working pressure
is up to 24 bar and working temperature is up to 290°C. Width is 3 mm on this vessels line size. In
such cases where a bevel is machined on the bore of the plate, the side with the bevel on should be
facing downstream when installed.
6.3.7.2 Installation of flow sensor
The single most important consideration, when installing an orifice plate type flowmeter is the
amount of straight pipe available on each side of the orifice plate. It is appreciated that long lengths
of straight pipe are not common in the average pump room, but it is essential that the flow through
the orifice plate is not turbulent. The only way to achieve this is, to have a long smooth approach to
the orifice plate. The minimum recommended length of straight pipe upstream of the plate is 10 x
pipe diameters and downstream of the plate, is 5 x pipe diameters. Within these distances there
should be no bends or obstructions such as valves. The effect of reducing these distances is a
considerable reduction of the accuracy of the flowmetering system.
The accuracy of the flowmeter is limited to ±10% and this is easily achieved at high flow rates.
However, at low flow rates, an orifice plate type flowmeter rapidly becomes inaccurate such that the
accuracy limit of ±10% is reached at about 1/10
th
of the maximum flow. If the orifice plate is not
installed with adequate lengths of straight pipe, the effect is a reduction of the effective measuring
range of the flowmeter and a widely fluctuating signal.
The orifice plate should be mounted in such a position so as to ensure a full pipe at all times, which
is usually best achieved in a vertical pipe. The pipeline downstream of the sensor must be arranged
to ensure that no siphoning effect is possible. To prevent siphoning in horizontal installations, the
discharge line must rise by at least 1 x pipe diameter above horizontal centre line. The rise should
be so arranged that it is located at least 5 x pipe diameters after the orifice plate.
It must be stressed that if above installation requirements cannot be met, VAF Instruments should
be consulted for advice. VAF Instruments cannot held be responsible for any flowmetering system
installed incorrectly or without due consultation.
The orifice plate is installed between the flanges using jointing material of 1.5 mm thickness.
Two pressure tapping holes are required, one on each side of the orifice plate. For pipelines larger
than 25 mm diameter, it is advisable to weld a threaded boss to the pipeline. For lines less than 25
mm diameter the pipe itself can be drilled and tapped. In both cases, the hole must be threaded for
¼” BSP. The boss upstream of the orifice plate must be sited 1 x pipe diameter from the centre-line
of the plate. The boss downstream of the orifice plate must be sited ½ x pipe diameter from the
centre line of the plate. In the case of a vertically rising line, the bosses can be sited at any position
on the circumference of the pipe. In a horizontal line, the bosses must be sited on the horizontal
centre line of the pipe.
Reference drawings
Dimensional drawing ball valve flowmeter kit Ballast Monitor 0806-1041
Installation flowmeter Ballast Monitor Mark 5/6 0806-8016
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
28
6.3.8 dP/I transmitter
The electronic differential pressure transmitter is a two- wire transmitter which converts the
differential pressure developed by the flow sensor into a 4–20mA signal.
Select a location for the transmitter that is close to the orifice plate, not exceeding 16m and where
the ambient temperature will not exceed 90°C nor be less than -40°C. The location should be as
free from vibration as possible.
The transmitter must be mounted so that the measuring element is vertical. A mounting bracket and
U-bolt is supplied to mount the instrument on and is suitable for either pipe or surface mounting. For
pipe mounting, the bracket accepts from 30 mm up to 60 mm diameter pipe and can be positioned
on a horizontal or vertical pipe.
The differential pressure sensing lines from the flow sensor are coupled to the transmitter’s 3-way
manifold using ¼” NPT/10 mm couplings which are supplied.
The 3-way manifold contains isolating valves and an equalizing valve.
The pressure sensing lines must be routed with a minimum gradient of 1:10 fall after an initial fall
from the pressure tapping points of 300 mm. The lines should be adequately clipped. Two isolating
valves are supplied; one end threaded ¼” BSP for connection to the pipe.
The dP/I transmitters are certified as II 1 G Ex ia IIC T4 or T5.
EXPLANATION OF EQUIPEMENT MARKINGS:
“Ex” Equipment in compliance with
European standards for potentially explosive atmospheres.
“ia” Equipment in compliance with specific building rules for intrinsically safe
equipment.
“C” Equipment for use with gas of the subdivision C.
“T4” Equipment whose surface temperature does not exceed 135°C when used in an
ambient temperature less than 80°C.
The equipment is suitable for areas classified as:
Zone 0
(an area in which an explosive atmosphere is present continuously or during long
periods);
Zone 1
(an area in which an explosive atmosphere is likely to occur in normal operating
conditions);
Zone 2
(an area where an explosive atmosphere is not likely to occur in normal operation).
29
WARNING:
IN HAZARDOUS ZONES WITH EXPLOSION PROOF REQUIREMENTS THE
COVERS MUST BE TIGHTENED WITH AT LEAST 7 TURNS. IN HAZARDOUS
ZONES WITH INTRINSICALLY SAFE OR NON-INCENDIVE REQUIREMENTS, THE
CIRCUIT ENTITY PARAMETERS AND APPLICABLE INSTALLATION PROCEDURES
MUST BE OBSERVED.
CABLE ACCESS TO WIRING CONNECTIONS IS OBTAINED BY ONE OF THE TWO
CABLE CONDUIT OUTLETS. CONDUIT THREADS SHOULD BE SEALED BY
MEANS OF CODE APPROVED SEALING METHODS. THE UNUSED OUTLET
CONNECTION SHOULD BE PLUGGED ACCORDINGLY. REFER TO SECTION 6.4.3
OF THIS MANUAL FOR FURTHER INFORMATION.
Reference drawings:
Control drawing for Mark 6M Oil Discharge Monitor 0806-0005
Electrical connection diagram Ballast Monitor Mark 6M MEPC 108(49) 0806-2048
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
Bulkhead penetration and piping diagram Mark 6M 0806-8038
Connection diagram dP/I Transmitter type FUJI / ABB 0810-2010
Dimensional drawing dP/I transmitter FUJI flowmeter kit Ballast
Monitor Mark 5/6 0899-1092
Dimensional drawing dP/I transmitter ABB flowmeter kit Ballast
Monitor Mark 5/6 0899-1163
6.4 BULKHEAD PENETRATIONS GENERAL
Great attention has been paid, during the design of the Oilcon® Oil Discharge Monitoring and
Control System to minimise the number of bulkhead penetrations which must be made and to make
the total installation as simple and as straightforward as possible.
Nevertheless, two sets of penetrations which must be made.
6.4.1 Sample pump
The requirements for mounting this pump have been detailed in section 6.3.1 of this manual.
6.4.2 Air pipelines
The recommended method for making these penetrations is, using a proprietary transit system, for
which approvals have been obtained such as the Multi Cable Transit system.
It is anticipated that the penetrations will usually be made with standard 6 mm and 10 mm pipe
provided with a pipe connector at each side.
When the Oilcon
®
installation is required to be proven with oil injection, a commissioning engineer
must make connections to the air supply line V11, on both sides of the bulkhead. The installers are
therefore requested: To make at least the V11 bulkhead penetration using a 6 mm pipe connector,
one on each side of the bulkhead penetration. Note that these components are outside VAF
Instrument’s normal scope of supply.
Reference drawings
Schematic installation diagram Oilcon Monitor System with 1x dP/I
transmitter Mark 6 0806-8035
Bulkhead penetration and piping diagram Mark 6M 0806-8038
Multi cable transit Ballast Monitor Mark 6 0806-8070
Parts list air supply units Ballast Monitor Mark 6 0899-1258
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