Consilium Salwico SW2020 User manual

Gas Sampling System
Salwico SW2020
User Manual
çConsilium

The contents of this document are subject to revision without notice due to continued progress in
methodology, design and manufacturing. Consilium assumes no legal responsibility for any error
or damage resulting from the usage of this document.
Consilium Marine & Safety AB
P.O. Box 8763
SE-402 76 GÖTEBORG
SWEDEN
Tel: [phone], Fax: [phone]
E-mail: [e-mail]
Internet: www.consilium.se
Edition 22, 181 E, December 2018.
Document no. S-4-009.433/E
Part no: 070047
© 2001-2018, Consilium Marine & Safety AB

Contents
1. GENERAL INFORMATION
A
2.
1.1 DESCRIPTION OF THE SYSTEM
1.2 GENERAL BLOCK DIAGRAM
INSTALLATION
B
2.1 CONTROL UNIT
2.2 ANALYZING UNIT
2.3 REPEATER UNIT - MN400
2.4 PIPE SYSTEM
2.5 FLAME TRAPS
2.6 MANUAL SHUT-OFF VALVES
2.7 SAMPLING PIPE ACCESSORIES
2.8 SAMPLING POINTS
2.9 OPTIONS
2.10 ELECTRICAL CONNECTION
2.11 COMMISSIONING DOCUMENTS
3. OPERATION C
3.1 GENERAL PRINCIPLES
3.2 DISPLAY MODES
3.3 LISTS: ALARM, FAULT CODES, DISCONNECTION
3.4 SETUP - GENERAL SETTINGS
LEVEL 1 - SET TIME, DATE, TEST OF LEDS & BUZZER, ETC
LEVEL 2 - CALIBRATION, ETC
LEVEL 3 - SYSTEM SETUP AT START UP
3.5 SETUP - SAMPLING POINTS
3.6 REPEATER UNIT - MN400
3.7 GUIDELINES FOR DAILY HANDLING
4. TECHNICALDATA D
4.1 INTERNAL CONNECTION
4.2 INTERNAL CONNECTION ON RIOK-40 AND RIOK-41
4.3 PNEUMATIC BLOCK DIAGRAM, ANALYSING UNIT
4.4 FLOW EXAMPLES
4.5 CALCULATION OF SAMPLING TIME
4.6 VACCUM PUMP
4.7 GAS DETECTORS
5. SPARE PARTS LIST
E
6. PRODUCTS LIST
F
7. MAINTENANCE
G

Salwico SW2020
General Information
A1
1. GENERALINFORMATION

Salwico SW2020
General Information
A2

Salwico SW2020
General Information
A3
1.1 DESCRIPTION OF THE SYSTEM
The SW2020 Gas Sampling System is an automatically
scanning Gas Sampling System permanent installed for
a number of sampling points. The gas detectors are
common for all sampling points, allowing the use of high
quality gas detectors with good accuracy. A gas sample
istakenfromeachsamplingpointinturn,accordingtothe
sampling sequence, andtransported throughthesamp-
lingpipetothegasdetectors.Thesamplingtimeforeach
point is individuallyadjustable corresponding to the pipe
length of each sampling point. This gives an optimally
short cycle time.
The SW2020 Gas Sampling System is intended for
detectionofexplosiveandtoxicgasesincofferdams,pipe
tunnels,stools,ballasttanks,sloptanksandotherareas
adjecent to cargo tanks. A pump room installation is
normallyaseparatesystem.TheSW2020isdesignedto
meettherequirementsofIMO/SOLASandclassification
rules.
Individual sampling point settings
Each sampling point can easily be operated from the
control unit and it hasindividual settings for:
–Sampling time as a function of pipe length.
–Gas detectors (up to 4 ) connected for monitoring
samples. For example %LEL, Vol% and ppm.
–Alarm levels for low andhighalarm for eachdetector
and each sampling point..
–Cleartextinformation.
Programmable scanning sequence
Each sampling point can easily be operated from the
controlpanel.Forpermanentinstallationsinballasttanks
orotherareas, whichmayperiodicallybe filled with fluid,
acounterpressuresystemisautomaticallyprotectingthe
pipeswithagentleflowofair,preventingclogging.
Thesamplingtimeforeachdisconnectedsamplingpoint
is deducted from the cycle time, thus reducing the cycle
time for theremainingsamplingpoints.
The SW2020 Gas Sampling System also gives the
possibility to define the sampling sequence enabling
certain points to besampled morefrequently.
A flow fault on a sample point will activate the Automatic
PipeCleaningSystem(APCS).TheAPCSwillfirstattempt
to remove the cause of the flow fault by flushing the
sampling pipe and then try to obtain a new sample. The
samplingpointisautomaticallydisconnectedandthefault
is transferred to the Fault List if the flow fault remains.
Thelastmeasuredgasvalueforasamplingpointcanbe
viewedintheSamplingPointList.ManualMeasurement
andPurgeonaselectedsamplingpointarealsodonefrom
thislist.
Atestgascylinderisconnectedtoorbuiltintothesystem
for calibration of the gas detectors.
TheSW2020systemconsistsoffourparts
ControlUnit
Thecontrolunitcontainscontrolfunctionsanddisplayfor
the system and is normally located in a cargo control
room.
AnalysingUnit
Theanalysingunitcontainsallfunctionsfordetectingand
transporting the test samples, as well as an internal
samplingpointformonitoringofinternalgasleakage.The
analysingunitisinstalledinaventilatedareawithcontrolled
temperature above main deck level, normallythe Cargo
ControlRoom.
Repeater Unit(s)
The repeater unit contains a clear text display for
alarm and fault messages. One unit is normally
located in the WheelHouse.
Pipe System
The pipe system transports the test samples from the
sampling points to the analysing unit. The pipe system
includesshutoffvalves,flametraps,filtersandcones(for
WB tanks).
Recommended pipe size: OD 8 mm, ID 6 mm.
Connection of suitable portable gas detection
and measuring equipments
Provided that the gas scanning and suctionis
running normallyand there isa needfordetection of an
optional gas, it is possible to connect a portable gas
detector to the sampling system.
In the analysing unit the portable gas detector can
beconnected to thesampled flowfrom the scanning
suction system by connecting the hose to the portable
gas detector in serial with the outlet pipe from one of
the detectors just before the connection to the outlet.
This connection is situated at the bottom of the
cabinet at cabinet inside of the outlet connection.
If the sampling system for some reason is shut
off, there is a possibility inside the analysing unit, to
connect a portable gas detector to one byone of the
pipes from the gassampling points.
By disconnection of the plastic pipe on top of the
samplingvalves(R-port),ahoseconnectioncanbe
mounted.
Previousversionshavethepossibilitytoconnect
the hose to the portable gas detector directly to the
sampling pipefrom eachsampling point at the inside of
the analysing unit cabinet.

Salwico SW2020
General Information
A4
1.2 GENERALBLOCKDIAGRAM
REPEATER UNIT
CONTROL UNIT
ALTERNATIVE: TWO SEPARATE WALL MOUNTED
CABINETS OR ONE SINGLE
CABINET
ANALYSINGUNIT
MEASURING
POINT INSIDE
ANALYSING UNIT
S-4-005.285/E
Conceptual drawing
(Testgas connection is
located inside the cabinet)

Salwico SW2020
Installation
B1
2. INSTALLATION

Salwico SW2020
Installation
2.1 CONTROL UNIT
DETECTOR
The control unit is the man-machine interface and controls the electronics in the
analysing unit. It consist of a LCD clear text Display, LED Display, LED's,
keyboard, microprocessor and memory for the software, definitions, additional
texts etc. The unit is normally made for wall mounting and should be placed in
a well visible position e.g. cargo control room. Electrical connection terminals
to the analysing unit, the repeater unit and the optional printer are placed in the
bottom of the control unit cabinet.
As an alternative both the control unit and the analysing unit can be delivered in
one single cabinet.
The SW2020 control unit is divided into two parts; the gas alarm panel and the
operating panel.
The gas alarm panel is activated when a gas alarm situation is detected in the
system. The sampling point number, alarm level (LO or HI) and the actual gas
detector in alarm are displayed.
There are three keys on the operating panel. The Alarm Mute key is used to
acknowledge the gas alarm and the Alarm Reset key is used to reset the gas
alarm. The third key Alarms in Queue is used to toggle the sampling points in
alarm.
The Operating Panel continuously shows, in the clear text display, sampling
point and the last measured value.
The Fault LED is lit and a fault message is shown in the clear text display when
a fault alarm is generated.
The List and Setup keys are used to manage the gas sampling system. The
numeric keypad is among other things used for value settings and clear text
setup.
B2

Salwico SW2020
Installation
B3
2.2 ANALYSINGUNIT
The analysing unit contains all functions for detection and transport of the test
samples. Its components comprise: gas detectors, solenoid valves, sampling and
transport pump, flame traps, flow meter, remote I/O - PCB-boards, power
supply unit and terminals for power supply, alarm outputs connection to the
control unit and repeater unit as well as connections for all piping included in
the system.
The analysing unit should be installed not less than 3 metres above the main
deck in order to avoid air locks in the pipes and ensure the correct work of the
automatic flow watching function. The area should be ventilated and
temperature-controlled.
The analyzing unit is designed to be off a gas-tight construction and this
needs to be considered during installation of the equipment onboard when
cables are entering into the bottom of the cabinet.
There must not be an opening that could potentially ventilate Explosive or
Toxic gases to a safe area onboard.
For installation and for the future service work, there must be enough space,
approx. 0.5m, at the pipe connection side, normally the left side.
There are removable plates intended for the installation of cable inlets on the
underside of the cabinet, for electrical connections.
The electrical connections are made in accordance with the electrical drawing
in this chapter.
Analysing Unit
Inlet instrument air 5-16 Bar
Pipe connections and flame
traps

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Installation
B4
2.2.1 PIPE CONNECTIONS
Suction Pipes
The sampling pipes from the manual shut-off valves are connected to the pre-
mounted and numbered flame trap on the side of the analysing unit by means of
the stainless steel connection nipples on the flame traps.
NB! These nipples should be tightened with a spanner, 1.25 turn only, from the
hand-tightening stop. If dismounted the nipple should be retightened to exactly
the same position during re-mounting.
The pipes between the analysing unit and the normal shut-off valves should be
mounted in such a way that air locks do not occur.
Also note that the pipes should be installed in such a way that service can be
performed on an individual flame trap as well as on On-Line Filters without
unnecessary dismounting of other pipes.
Exhaust Pipe
The exhaust pipe from the analysing cabinet is connected via a nipple at the
intended site and should be mounted with a slope towards the exhaust point.
Refer to picture on previous page.
Fresh Air Pipe
The fresh air pipe to the analysing cabinet should be connected via a nipple at
the intended site. The air inlet can open up directly into the room where the
analysing unit is installed, provided that the atmosphere in the room is clean
and temperature controlled. Otherwise a pipe leading tosuch a space mustbe
installed. Refer to picture on previous page.
.
Instrument air 5 - 16 Bar inlet
The inlet pipe for dry instrument air is connected to the analysing unit via a
nipple at intended site. Refer to picture on previous page.
.
2.2.2 CALIBRATION GAS CYLINDER
The calibration gas cylinder is mounted next to the analysing cabinet and fixed
in the conventional manner for pressure vessels. The gas cylinder can
alternatively be mounted inside the cabinet.

Salwico SW2020
Installation
B5
2.3 REPEATER UNIT - MN400
The function of the LCD repeater units is to indicate alarms and faults to the
duty watch personnel. The unit is designed for wall or panel mounting and
should first of all be placed on the bridge in a well visible and easily accessible
location.
The LCD-display indicates in clear text the sampling point(s) in alarm, alarm
level(s) and fault messages.

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Installation
B6
2.4 PIPE SYSTEM The pipe system transports the test samples from the sampling points to the
analysing unit. In addition to the piping, the system includes: shut-off valves,
flame traps, pipe couplings, sleeves, filters and pipe terminations.
When the sampling pipes are installed, care should always be taken that the
pipes are installed in such a way that the risk of air locks is avoided.
There are two main ways of installing the piping from the analysing unit to the
various sampling points; either the pipes are installed above deck or through the
pipe tunnel, or a combination of both methods. Note that pipes installed above
deck must be protected against mechanical damage. Refer to drawing Pipe
installation example in this chapter.
All pipe couplings with conical seals forming part of the pipe system should
always be sealed with Loctite 577. (NB! Not thread tape).
2.4.1 PIPE SUSPENSION
Suspension of the pipe assembly or individual pipes should be made in such a
way that the distance between the suspension points does not exceed 1 metre.
The pipes should also be fixed in such a way that vibrations or other similar
actions do not damage them. When installing the pipes, care should be taken
not to allow them to become deformed.
The drawing Suspension and fixing in this chapter shows a proposed method of
suspension and fixing.
2.4.2 SLEEVES AND BULKHEAD PASSAGES
Some type of passage arrangement must be used when passing through deck or
bulkhead plates. Such proposed units are shown on drawings Deck bulkhead
passage and Suspension and fixing in this chapter.
2.4.3 PIPE COUPLINGS
Efforts should be made to ensure that as few pipe couplings as possible are used
for each sampling pipe. This will avoid unnecessary air resistance in the pipes,
caused by turbulence due to unevenness of the joints, and also to reduce the
possibility of leakage to a minimum.
When a pipe cut is necessary, make sure that the pipe is not deformed at the cut
and that the airflow resistance is not increased. Also note that capillary
connections have to be carefully soldered to avoid unnecessary airflow
resistance.
Each manufacturer’s individual recommendations on tightening should be
observed when installing those pipe couplings that must be used.

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Installation
B7
2.4.4 BENDING OF SAMPLING PIPES
In order to avoid unnecessary air resistance in the sampling pipes and risk of
deformation and the formation of fractures, a minimum bending radius of
approx. 150 mm is recommended.
Refer to separate instructions for installation of other components of the pipe
system.
-Flame Trap (analysing unit)- Chapter 2.5
-Manual shut-off valves - Chapter 2.6
2.4.5 PIPE INSTALLATION CHECK
NB. 1.
Before connection of the sampling pipes to the Analysing Unit and to the
On-Line-Filters:
Always flush the pipes with compressed air in order to clean them from
dust and water. After cleaning, finish the complete connection between the
Analysing Unit, Shut Off Valves, On Line Filters and Pipe end
Accessories.
NB. 2.
A test has to be performed on every sampling pipe to verify that there are
no leakages. Also verify that each sampling point is correctly connected to
the Analysing Unit. It is possible to do a test of the air tightness by
disconnecting the tubes one by one on the inside of the cabinet and
perform the test by connecting a manometer, shut-off valve and
compressed air.

Salwico SW2020
Installation
B8
SHUT-OFF VALVES

B9
Salwico SW2020
Installation
DECK BULKHEAD PASSAGE

Salwico SW2020
Installation
SUSPENSION & FIXING
CLAMP FOR PIPE
on the deck/deckhouse
CLAMP FOR PIPE
in the pipe tunnel/
cofferdams etc.
12
3
"JIRVA" PIPE FITTING
ALTERNATIVE:
PIPE
PIPE
PIPE
B10

Salwico SW2020
Installation
PIPE INSTALLATION EXAMPLE
B11

B12
Salwico SW2020
Installation
2.5 FLAME TRAPS
The flame traps are normally supplied fitted to the analysing unit. Refer to the
installation instructions for the analysing unit in this chapter for pipe
connection instructions.
NB! The flame trap must be of an approved type.
R 1 / 4" Female thread R 1 / 4" Female thread
Inlet instrument air 5-16 Bar
Pipe connections and flame traps

B13
Salwico SW2020
Installation
2.6 MANUAL SHUT-OFF VALVES
The task of the manual shut-off valves is, where necessary, to shut off the pipe
system in an explosion risk zone from the system in a safe zone. This may
occur when a certain sampling area has a temporary high gas concentration or is
filled with inert gas. The shut-off valves should also be used for service needs,
such as replacement of flame traps, or if a certain sampling pipe is disconnected
from the analysing unit.
When there is no compressed air in the counter pressure system combined with
water in the ballast tanks, a closing of the shut-off-valves is recommended to
avoid water and dirt inside the sampling pipes. Notice that as long as there is
compressed air to serve the counter pressure system in water filled ballast tanks,
the shut off valves shall remain open.
Installation of the valves shall be made in the wall between the safe and
explosive zones. Holes are cut for the insertion of welding sleeves with an
internal thread, the shut-off valve then being screwed on from inside a safe
zone by means of taper thread couplings supplied and sealed with ”Loctite
577”.
NB!
All valves should be marked with the number of the corresponding sampling
point.
It is important that the mutual distance between the valves is taken into
consideration, and that the sampling pipes from the analysing unit are installed
in such a way that any service on an individual shut-off valve can be carried out
without any unnecessary dismounting of other pipes.
Stainless steel type Brass type