DVZ OILCHIEF 150 FSU User manual

Operating Manual
DVZ-FSU-„OILCHIEF
®
“
Document- o. FSUOC001_E
Volume I/I
Subject to technical modification without notice
Responsible for the content:
DVZ-SERVICES GmbH
Boschstra e 9
D-28857 Syke
Germany
FON [phone]
FAX [phone]
WEB www.dvz-services.de
MAIL [email protected]

OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten -
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Betriebshandbuch
Inhaltsverzeichnis
I/I TOC 2
JUL 15
TOC Table of contents ........................................................................................................................... 2
Part A Introduction, general information .............................................................................................. 1-14
Part B Storage, transport, installation .................................................................................................. 1-18
Part C Commissioning, operation (MECH) ............................................................................................ 1-11
Part D Commissioning, operation (ELEC) ............................................................................................. 1-13
Part E Maintenance ........................................................................................................................... 1-69
Part F Trouble Shooting ....................................................................................................................... 1-4
Part G Spare Parts ............................................................................................................................. 1-10

OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten -
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
Table of contents
I/I A-TOC 1
JUL 15
A-TOC Table of contents .......................................................................................................................... 1
A-1 Introduction, general information ................................................................................................... 3
A-1.1 Preface .......................................................................................................................................... 3
A-1.2 Hazard and safety notes, general notes, definitions ....................................................................... 3
A-1.3 Indexing and pagination system .................................................................................................... 4
A-1.4 Change system.............................................................................................................................. 4
A-1.5 Contents and structure volume I/I .................................................................................................. 5
A-1.6 Abbreviations and initials ............................................................................................................... 6
A-2 Change index I/I ............................................................................................................................ 7
A-3 Preliminary Change Index I/I .......................................................................................................... 9
A-4 List of valid pages ....................................................................................................................... 11

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OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
Introduction, general information
I/I A-1 3
JUL 15
A-1 Introduction, general information
A-1.1 Preface
This operating manual is a part of the product. With this operating manual, you, as the customer, the
operator of the oily water separator and as the installer or operator of the oily water separator
nominated and instructed by the operating company, receive all information necessary for the safe
operation of the oily water separator. Please read part A carefully in order to be able to use the
information offered in the operating manual in an optimal way. After that please carefully read all
parts of this operating manual. The purpose of this operating manual is:
1. to explain the function of the oily water separator
2. to state the technical data and the operating limits
3. to offer hazard notes and safety notes
4. to provide all necessary information for the handling of the oily water separator
This operating manual is exclusively intended for qualified specialist staff. Qualified specialist staffs
are persons, who have a qualification reflecting their activity, e.g.:
1. Training or instruction as a skilled worker in the areas of ship engine technology, shipboard
electrical systems or oily water separating for seagoing vessels and offshore installations.
2. Training or instruction with respect to the use of personal protection equipment according to
the acknowledged rules of safety engineering.
3. Training and instruction with respect to work and health protection as well as with respect to
the Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
4. Training and instruction with respect to the IMO International Safety Management Code (ISM
code).
A-1.2 Hazard and safety notes, general notes, definitions
In all places where texts in the operating manual is marked with pictograms and the signal words
“Danger”, “Caution” or “Note”, these have the following meanings.
Danger - general danger
Danger - danger due to electrical current
Danger - danger due to circumstances which could cause hand injury
Caution - prohibitions, requirements, warnings with respect to damage or destruction
Note - general notes, useful hints for the entire product life cycle

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DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
Introduction, general information
I/I A-1 4
JUL 15
A-1 Introduction, general information (continued)
A-1.3 Indexing and pagination system
The operating manual is divided into parts A (Alpha) through J (Juliet). Each part is divided into
chapters; each chapter is divided into sections and subsections. This structure allows smaller
amendments when necessary without the need to replace the entire chapter or the operating
manual completely.
The pages of the operating manual have a heading showing the plant type, the factory number of
the oily water separator, contents, volume, index, page number, date of issue and date of change
(as far as necessary).
If necessary, the operating manual is divided into several volumes. I/I - volume I on one volume, I/II
- volume I of two volumes, II/II - volume II of two volumes
The index is made up by part, chapter, section and subsection.
Example: C-TOC - part C, table of contents (short designation: TOC)
Example: C-1.3.5 - part C, chapter 1, section 3, subsection 5.
Some parts of the operating manual are separated into a mechanical part (short designation: MECH)
and an electrical part (short designation: ELEC).
Example: Part C: Commissioning, operation (MECH)
Document changes are marked on each page. The exact date of the change is documented in the
revision index A-2 or in the preliminary revision index A-3.
Example: REV 01 - change 1 of 99 possible changes.
Plant type Contents Volume Index Page number
Factory number (optional) Year and moth of issue
Fig. 900000
Empty pages are not numbered. Empty pages will be marked with the text “This page has been
left blank intentionally.” This means that empty pages will be integrated into the operating manual
without giving the impression of a misprint.
A-1.4 Change system
Changes to this operating manual will be issued as considered necessary. Changed parts of this
operating manual will be provided to you as a customer and/or operating company, either as a print-
out or electronically. If you are not also the operating company of the oily water separator, you must
inform the operating company of the oily water separator of the changes.
Changes to the chapters, parts, sections and subsections are marked with a vertical black line.
| Example: This line has been marked as a change at the left side of this page.
| This change is further documented in the change index A-2.
(continued)

OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
Introduction, general information
I/I A-1 5
JUL 15
A-1 Introduction, general information (continued)
A-1.4 Change system (continued)
Changes will not be marked with a vertical line if entire parts and chapters have been changed. As a
customer and/or the operating company of the oily water separator you additionally have the
possibility of documenting changes in the preliminary change index A-3 by hand at the request of
the manufacturer. Your handwritten entry is valid until the operating manual is amended by the
manufacturer. As a customer or operating entity you must insert the changed pages provided by the
manufacturer into the operating manual immediately.
After having inserted the changed pages you must delete (cross out) the hand-written entries in the
preliminary change index.
A-1.5 Contents and structure volume I/I
Part A Introduction, general information
This part explains how the operating manual is structured and how the change system is organised.
It explains how graphic symbols and signal words are used to warn you about hazards which might
cause death, severe injuries or diseases. It explains how graphic symbols and signal words are used
to warn you against actions which might result in the destruction of or damage to the oily water
separator, or in an impairment of the functioning of the oily water separator. It explains the graphic
symbol for useful hints.
Part B: Storage, transport, installation
This part explains how the oily water separator must be handled during transport. It explains how
the oily water separator must be stored. It provides advice about the environmental conditions at the
installation site and the required connections. You will receive instructions for correct installation so
that the oily water separator can be commissioned safely. This part also provides a note with
respect to the intended use of the oily water separator.
Part C: Commissioning, operation (MECH)
This part explains how to perform a safe commissioning of the mechanical components of the oily
water separator. It includes information about the safe operation of the mechanical components. It
also includes a note with respect to the intended use of the oily water separator. The commissioning
of the mechanical components is always performed along with the commissioning of the electrical
components (part D).
Part D: Commissioning, operation (ELEC)
This part explains how to perform a safe commissioning of the electrical components of the oily
water separator. It includes information about the safe operation of the electrical components. It
also includes a note with respect to the intended use of the oily water separator. The
commissioning of the electrical components is always performed along with the commissioning of
the mechanical components (part C).
Part E: Maintenance
This part explains how to perform the maintenance of the components. It includes information about
how to keep the oily water separator alive and how to restore functions of it.
(continued)

OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
Introduction, general information
I/I A-1 6
JUL 15
A-1 Introduction, general information (continued)
A-1.5 Contents and structure volume I/I (continued)
Part F: Trouble Shooting
This part shows faults and their remedy to get the oily water separator working again in case of
trouble or malfunction.
Part G: Spare Parts
In this part the different spare parts for the oily water separator are listed. For the different products
sizes the part numbers are shown, which should be mentioned in case or request.
Part A to part G: Appendix APX
The appendix (short designation: APX) includes additional documents; it will be added as necessary.
A-1.6 Abbreviations and initials
JAN
January
AUG
August
REV
Revision
FEB
February
SEP
September
APX
Appendix
MAR
March
OCT
October
VOL
Volume
APR
April
NOV
November
MECH
Mechanical
MAY
May
DEC
December
ELEC
Electrical
JUN
June
OM
Operating Manual
DE
German
JUL
July
TOC
Table of contents
EN
English

OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
Change index I/I
I/I A-2 7
JUL 15
A-2 Change index I/I
The change index includes the following information:
Consecutive number and date of the change, name of the person who entered the changes and the
date of the insertion of the change.
Nr.
Change date Inserted on / by
Nr. Change date
Inserted on / by
1 41
2 42
3 43
4 44
5 45
6 46
7 47
8 48
9 49
10 50
11 51
12 52
13 53
14 54
15 55
16 56
17 57
18 58
19 59
20 60
21 61
22 62
23 63
24 64
25 65
26 66
27 67
28 68
29 69
30 70
31 71
32 72
33 73
34 74
35 75
36 76
37 77
38 78
39 79
40 80

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FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
Preliminary Change Index I/I
I/I A-3 9
JUL 15
A-3 Preliminary Change Index I/I
The Preliminary Change Index includes the following information:
Consecutive number and date of the change, page and index, name of the person who entered the
changes and the date of the insertion of the change.
No. Date
Page / index Inserted on / by
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

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DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
List of valid pages
I/I A-4 11
JUL 15
A-4 List of valid pages
Page / index Date / change Page / index Date / change Page / index Date / change
1 / A-TOC JUL 15 7 / C-1 JUL 15 27 / E-2 JUL 15
Empty page
8 / C-1 JUL 15 28 / E-2 JUL 15
3 / A-1 JUL 15 9 / C-2 JUL 15 28 / E-2 JUL 15
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6 / A-1 JUL 15 Empty page 31 / E-2 JUL 15
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JUL 15 4 / D-1 JUL 15 35 / E-2 JUL 15
11 / A-4 JUL 15 5 / D-1 JUL 15 36 / E-2 JUL 15
12 / A-4 JUL 15 Empty page 37 / E-2 JUL 15
13 / A-4 JUL 15 7 / D-2 JUL 15 38 / E-2 JUL 15
14 / A-4 JUL 15 8 / D-2 JUL 15 39 / E-2 JUL 15
1 / B-TOC JUL 15 9 / D-2 JUL 15 40 / E-2 JUL 15
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19 / B-APX1 JUL 15 15 / E-1 JUL 15 58 / E-2 JUL 15
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1 / C-TOC JUL 15 21 / E-1 JUL 15 64 / E-2 JUL 15
2 / C-TOC JUL 15 Empty page 65 / E-2 JUL 15
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6 / C-1 JUL 15 26 / E-2 JUL 15 69 / E-2 JUL 15

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FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
List of valid pages
I/I A-4 12
JUL 15
A-4 List of valid pages (continued)
Page / index Date / change Page / index Date / change Page / index Date / change
70 / E-2 JUL 15
71 / E-2 JUL 15
Empty page
1 / F-TOC JUL 15
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3 / F-1 JUL 15
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10 / G-1 JUL 15

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FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
List of valid pages
I/I A-4 13
JUL 15
A-4 List of valid pages (continued)
Page / index Date / change Page / index Date / change Page / index Date / change

OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
®
“
Operating Manual
Part A: Introduction, general information
List of valid pages
I/I A-4 14
JUL 15
A-4 List of valid pages (continued)
Page / index Date / change Page / index Date / change Page / index Date / change

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FSU-„OILCHIEF
®
“
Operating Manual
Part B: Storage, transport, installation
Table of contents
I/I B-TOC 1
JUL 15
B-TOC Table of contents ....................................................................................................................... 1-2
B-1 Important notes ............................................................................................................................. 3
B-1.1 Intended use ................................................................................................................................. 3
B-1.2 Safety note .................................................................................................................................... 3
B-1.3 Caution.......................................................................................................................................... 3
B-1.4 Note .............................................................................................................................................. 3
B-1.5 Caution.......................................................................................................................................... 3
B-2 Storage ......................................................................................................................................... 5
B-2.1 Environment conditions ................................................................................................................. 5
B-2.2 Secondary packaging .................................................................................................................... 5
B-3 Transport ...................................................................................................................................... 7
B-3.1 Oily Water Separator with secondary packaging ............................................................................ 7
B-3.2 Oily Water Separator without secondary packaging ....................................................................... 7
B-3.3 Note .............................................................................................................................................. 7
B-4 Installation..................................................................................................................................... 9
B-4.1 Explanations .................................................................................................................................. 9
B-4.2 System description ........................................................................................................................ 9
B-4.2.1 Oily Water Separator with Eco-Pack (optional) ............................................................................. 10
B-4.2.2 Oily Water Separator with certified By-Pass (optional) .................................................................. 10
B-4.2.3 Oily Water Separator with electric operated valves (optional) ....................................................... 10
B-4.2.4 Oily Water Separator with Heating Device (optional) ..................................................................... 10
B-4.3 Technical data ............................................................................................................................. 11
B-4.3.1 Power .......................................................................................................................................... 11
B-4.3.2 Dimensions and weights ............................................................................................................. 11
B-4.3.3 Electric connections .................................................................................................................... 11
B-4.3.4 Pneumatic connection ................................................................................................................. 11
B-4.3.5 Mechanic connection: Flanges and Threaded spouts / threaded sleeves ...................................... 12
B-4.3.6 Standard tubing and instrument flow diagram (P&ID flow diagrams) ............................................ 13
B-4.3.6.1 150 FSU -1000 FSU..................................................................................................................... 13
B-4.3.6.2 2500 FSU – 10000 FSU ............................................................................................................... 14
B-4.4 Erection of the oily water separator ............................................................................................. 15
B-4.4.1 Caution........................................................................................................................................ 15
B-4.4.2 Note ............................................................................................................................................ 15
B-4.4.3 Fixing points ................................................................................................................................ 16
B-4.4.4 Connection dimensions ............................................................................................................... 16
B-4.4.5 Connecting the connections......................................................................................................... 16

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FSU-„OILCHIEF
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Operating Manual
Part B: Storage, transport, installation
Table of contents
I/I B-TOC 2
JUL 15
B-4.4.5.1 Pipe connections .......................................................................................................................... 16
B-4.4.5.2 Alarm Monitor .............................................................................................................................. 17
B-4.5 Glossary ....................................................................................................................................... 18
B-APX1 Assembly drawing documentation ................................................................................................ 19
B-APX2 P&ID flow diagram documentation ............................................................................................... 21
B-APX3 Certificate of Type Approval for Oily Water Separator .................................................................... 23

OM_20170508NBM_DVZ-FSU-OILCHIEF-FSUOC001_EN - Technische Änderungen vorbehalten
DVZ-SERVICES GmbH | Boschstra e 9 | D-28857 Syke | Germany | FON [phone] | FAX [phone] | WEB www.dvz-services.de | MAIL [e-mail]
FSU-„OILCHIEF
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Operating Manual
Part B: Storage, transport, installation
Important notes
I/I B-1 3
JUL 15
B-1 Important notes
B-1.1 Intended use
The oily water separator DVZ-FSU-„OILCHIEF
®
“ is solely suitable for the separation of oily-water-
mixtures according to IMO MEPC.107(49) on e.g. seagoing vessels, riverboats, yachts, naval vessels
and offshore constructions.
The Equipment conforms to the requirements of “Technical Regulations on the Safety of Sea
Transport Items” (it is approved as the resolution of the Government of the Russian Federation of
August 12, 2010 No. 620). All-Production Classification Code of Products 64 1600. The product is
labelled with conformity mark (RF Government Order No.696 dated 19.11.2003).
The oily water separator plant must not be operated with sea water, brackish water or condensate.
The rating of the DVZ-FSU “OILCHIEF
®
” oily water separator is prescribed by HELCOM.
B-1.2 Safety note
The oily water separator may only be stored, transported, assembled, operated, maintained and
disposed of by qualified specialist staff. Qualified specialist staff are persons who have a
qualification reflecting their activity, e.g.:
1. Training or instruction as a skilled worker in the areas of ship engine technology, shipboard
electrical systems or oily water separator for vessels and offshore constructions.
2. Training or instruction with respect to the use of personal protection equipment according to
the acknowledged rules of safety engineering.
3. Training and instruction with respect to work and health protection as well as with respect to the
Accident Prevention Regulations and the Accident Prevention Regulations for Enterprises
engaged in Seafaring.
4. Training and instruction according to the IMO International Safety Management Code (ISM code).
B-1.3 Caution
The oily water separator has special sling points for transport purposes. If lifting accessories are
fixed to other points than the provided sling points, the oily water separator or individual parts of
the oily water separator will be seriously damaged or become inoperable. The oily water separator
may only be lifted and transported using the sling points provided for this purpose and with
appropriate lifting accessories. The weights of the different installation types are stated in the
Technical Data.
B-1.4 ote
We recommend round using slings according to EN 1492-2 or round sling harnesses to lift the oily
water separator. We recommend that the round slings or round sling harnesses be attached to an
appropriate spreader and that this be used to move the oily water separator to the storage or
installation site.
B-1.5 Caution
All flange and threaded connections of the oily water separator are fitted with plugs and caps in
order to protect against contamination and foreign objects.
If the plugs or caps are removed during storage or transport, contamination and foreign objects may
penetrate the oily water separator. The oily water separator will thereby get damaged or
unserviceable. Only remove plugs and caps from flanges and threaded connections during
installation.

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