VAF instruments OILCON MARK 6M User manual
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
1PREFACE ....................................................................................... 6
1.1General ...................................................................................................... 6
1.2Symbols ..................................................................................................... 7
1.3Copyright.................................................................................................... 7
2PRODUCT DESCRIPTION ............................................................. 8
2.1Principle of operation ................................................................................. 8
2.2Product configuration ................................................................................. 9
2.2.1Main Control Unit (MCU) ................................................................................ 9
2.2.2Electro Pneumatic Unit (EPU) ...................................................................... 10
2.2.2.1Intrinsically safe signal cable................................................................. 10
2.2.2.2Starter box............................................................................................. 10
2.2.3Skid assembly .............................................................................................. 11
2.2.4Pump/motor assembly.................................................................................. 11
2.2.5Flowmeter system ........................................................................................ 11
2.2.6Sample probe valve assembly...................................................................... 12
2.3Sampling system arrangements............................................................... 12
3TECHNICAL SPECIFICATION ..................................................... 14
3.1General .................................................................................................... 14
3.2Main Control Unit (MCU) .......................................................................... 14
3.3Electro Pneumatic Unit (EPU) .................................................................. 15
3.4Skid .......................................................................................................... 16
3.5Sample pump ........................................................................................... 16
3.6Reference table of products which may be measured ............................. 17
3.7Biofuel guidelines and definitions ............................................................. 18
4SAFETY INSTRUCTIONS ............................................................ 19
4.1Safety precautions ................................................................................... 19
5UNPACKING ................................................................................. 20
6INSTALLATION............................................................................. 22
6.1Introduction .............................................................................................. 22
6.2Utilities...................................................................................................... 22
6.2.1Fresh water supply ....................................................................................... 22
6.2.2Air supply...................................................................................................... 23
6.2.3Electrical supply............................................................................................ 23
6.3Pipework general ..................................................................................... 23
6.3.1Sample pump unit......................................................................................... 24
6.3.2Installation of the sample pump.................................................................... 24
6.3.3Electrical installation pump ........................................................................... 25
6.3.4First start....................................................................................................... 25
6.3.4.1Self priming ........................................................................................... 25
6.3.4.2Direction of rotation ............................................................................... 25
6.3.5Skid............................................................................................................... 26
6.3.6Sampling probes........................................................................................... 26
6.3.7Orifice plate .................................................................................................. 27
6.3.7.1General information............................................................................... 27
6.3.7.2Installation of flow sensor ...................................................................... 27
6.3.8dP/I transmitter ............................................................................................. 28
6.4Bulkhead penetrations general................................................................. 29
2
6.4.1Sample pump ............................................................................................... 29
6.4.2Air pipelines .................................................................................................. 29
6.4.3Intrinsically Safe signal cable ....................................................................... 30
6.5Electrical installation general.................................................................... 31
6.5.1Electro Pneumatic Unit (EPU) ...................................................................... 31
6.5.2Starter box .................................................................................................... 32
6.6Control room equipment – Main Control Unit (MCU)................................ 32
6.6.1Speed input .................................................................................................. 32
6.6.2Overboard valve control ............................................................................... 32
6.7Installation checklist ................................................................................. 33
6.7.1General installation checks........................................................................... 33
6.7.2Check of Flowmeter and automatic control .................................................. 33
6.7.3Starting interlock and/or overboard valve control ......................................... 34
6.7.4Pipework response time calculation ............................................................. 35
6.7.5Final check ................................................................................................... 36
6.8Overview installation check ...................................................................... 37
6.8.1Cable connection Main Control Unit ............................................................. 37
6.8.2Cable connection Electric Pneumatic Unit.................................................... 37
6.8.3Intrinsically safe ground points, measurement cell and EPU ....................... 38
6.8.4Power supply starter box and cable connection skid.................................... 39
6.8.5Multi Cable Transit (Bulkhead Penetration).................................................. 40
6.8.6Water and Airline connections Skid.............................................................. 41
6.8.7System settings. ........................................................................................... 42
7OPERATING INSTRUCTIONS ..................................................... 43
7.1Layout of the MCU ................................................................................... 43
7.1.1Control key switch ........................................................................................ 43
7.1.2USB connector ............................................................................................. 44
7.1.3Printer port.................................................................................................... 44
7.1.4Reset button ................................................................................................. 44
7.1.5Touch screen panel ...................................................................................... 44
7.2Operating the MCU and menu layout....................................................... 45
7.2.1Standby mode (menu 1) ............................................................................... 47
7.2.1.1Information mode (menu 1.1) ................................................................ 48
7.2.1.2Configuration mode (menu 1.2)............................................................. 49
7.2.1.3Data mode (menu 1.3) .......................................................................... 51
7.2.1.4Selftest mode (menu 1.4) ...................................................................... 52
7.2.1.5Setup mode (menu 1.5)......................................................................... 53
7.2.1.5.1Information mode (menu 1.5.1).......................................................... 53
7.2.1.5.2Setup mode (menu 1.5.2) .................................................................. 55
7.2.1.5.3Calibration flush mode (menu 1.5.3.0) ............................................... 57
7.2.1.5.4Idle mode (menu 1.5.3) ...................................................................... 58
7.2.1.5.4.1Information mode (menu 1.5.3.1) ................................................ 58
7.2.1.5.4.2Shutdown mode (menu 1.5.3.2) .................................................. 59
7.2.1.5.4.3Idle setup mode (menu 1.5.3.3)................................................... 60
7.2.1.5.4.4Self test mode (menu 1.5.3.4) ..................................................... 61
7.2.1.5.4.5Sample mode (menus 1.5.3.5) .................................................... 61
7.2.1.5.4.5.1Information mode (menu 1.5.3.5.1)....................................... 62
7.2.1.5.4.5.2Shutdown mode (menu 1.5.3.5.2)......................................... 62
7.2.1.5.4.5.3Manual flush mode (menu 1.5.3.5.3) .................................... 63
7.2.1.5.4.5.4Manual window wash mode (menu 1.5.3.5.4)....................... 63
7.2.1.5.4.5.5Self test mode (menu 1.5.3.5.5)............................................ 64
7.2.1.5.4.5.6Sample setup mode (menu 1.5.3.5.6)................................... 64
7.3Short reference guide for operating the MCU........................................... 65
3
7.3.1Discharging ballast water ............................................................................. 65
7.3.2Shutdown of discharging operations ............................................................ 67
7.4Miscellaneous .......................................................................................... 68
7.4.1Oil content reading higher than expected..................................................... 68
7.4.2Oil level alarm............................................................................................... 68
7.5Operational alarms................................................................................... 69
7.6System failures......................................................................................... 70
7.6.1Auto/manual operation ................................................................................. 70
7.6.1.1Flowmeter.............................................................................................. 71
7.6.1.2Ship’s speed indicator ........................................................................... 71
7.6.1.3Oilcon®Oil Discharge Monitoring and Control System.......................... 71
7.6.1.4Main Control Unit (MCU) ....................................................................... 71
7.7System overrides ..................................................................................... 72
7.7.1Transducer override ..................................................................................... 72
7.7.2Discharge control.......................................................................................... 72
7.7.3Discharge control answer-back .................................................................... 73
8MAINTENANCE ............................................................................ 74
8.1Maintenance general................................................................................ 74
8.2Routine maintenance ............................................................................... 75
8.2.1Sample pump/motor lubricator ..................................................................... 75
8.2.2Air regulators ................................................................................................ 76
8.2.3Cleaning the detector cell windows .............................................................. 76
8.2.4Window wash pump ..................................................................................... 76
8.2.5Skid shuttle valve.......................................................................................... 76
8.2.62-Way pneumatic valve(s) ............................................................................ 76
8.2.7Zero output check of the differential pressure transmitter ............................ 76
8.3Test and check-out procedure.................................................................. 77
9REPAIR OR REPLACEMENT....................................................... 84
9.1Detector cell ............................................................................................. 84
9.1.1Removing the detector cell ........................................................................... 84
9.1.2Reinstalling the detector cell......................................................................... 84
9.2Window wash pump ................................................................................. 85
9.2.1Disassembling the window wash pump........................................................ 85
9.2.2Air side maintenance .................................................................................... 85
9.2.3Water side maintenance............................................................................... 85
9.2.4Re-assembling the window wash pump ....................................................... 85
9.3Sample pump ........................................................................................... 86
9.3.1Disassembling the pump/motor .................................................................... 86
9.3.2Reassembling the pump/motor..................................................................... 87
9.4Differential pressure transmitter – FUJI.................................................... 88
9.4.1Zero adjustment of DPT – FUJI.................................................................... 88
9.4.2Span adjustment of DPT – FUJI................................................................... 88
9.5Differential pressure transmitter – ABB .................................................... 89
9.5.1Zero adjustment of DPT – ABB .................................................................... 89
9.5.2Span adjustment of DPT – ABB ................................................................... 89
10TAKE OUT OF SERVICE.............................................................. 90
11REMOVAL AND STORAGE OF EQUIPMENT ............................. 90
12MALFUNCTION AND SEND FOR REPAIR .................................. 90
13ENVIRONMENT............................................................................ 90
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14DISPOSAL .................................................................................... 90
15TROUBLE SHOOTING AND FAULT FINDING............................. 91
15.1Introduction fault finding guide .............................................................. 91
15.2Fault finding guide................................................................................. 92
15.3Calibration alarms ................................................................................. 94
15.3.1Zero error alarm............................................................................................ 94
15.3.2Path dirty alarm ............................................................................................ 95
15.4System alarms ...................................................................................... 96
15.4.1No air ............................................................................................................ 96
15.4.2No flow.......................................................................................................... 96
15.4.3Power failures............................................................................................... 96
15.4.4Communication failure.................................................................................. 96
15.4.5Led feedback error ....................................................................................... 96
15.4.6Flow overrange failure .................................................................................. 97
15.4.7Flow underrange failure................................................................................ 97
15.4.8Overboard arrangement failure .................................................................... 97
15.4.9Discharge rate failure ................................................................................... 98
15.4.10Total discharge oil limit alarm ................................................................... 98
15.5GPS problems ...................................................................................... 98
15.5.1No GPS signal visible ................................................................................... 98
15.6Power supply problems......................................................................... 99
15.6.1MCU Power failure ....................................................................................... 99
15.6.2Electro Pneumatic Unit power failure ........................................................... 99
15.7Air supply problems ............................................................................ 100
15.7.1Air supply failure ......................................................................................... 100
15.7.2Water found in the monitors of the air system ............................................ 100
15.8Solenoid valve problems..................................................................... 100
15.8.1Valve not working ....................................................................................... 100
15.9Pneumatic valve problems.................................................................. 101
15.9.1Valve not functioning .................................................................................. 101
15.9.2Valve gland leakage ................................................................................... 101
15.9.3Valve leakage ............................................................................................. 101
15.10Window wash pump problems ............................................................ 102
15.10.1Pump does not work ............................................................................... 102
15.10.2Pump cycles without pumping or does not stall ...................................... 102
15.10.3False cycle .............................................................................................. 102
15.10.4Fluid appears at muffler .......................................................................... 102
15.11Sample pump problems ...................................................................... 103
15.11.1Electrical problems.................................................................................. 103
15.11.1.1Pump runs but the green indicator on the starter box is off ................ 103
15.11.1.2Pump should be running but is off ...................................................... 103
15.11.2Pump related problems........................................................................... 103
15.11.2.1No flow................................................................................................ 104
15.12Differential pressure transmitter problems .......................................... 105
15.12.1No line current......................................................................................... 105
15.12.2Current of 21.0mA or 3.9mA ................................................................... 105
15.12.3Incorrect output ....................................................................................... 106
15.13Fault finding form ................................................................................ 106
16CERTIFICATES ...........................................................................110
16.1Certificates of Ex-proof ....................................................................... 110
16.2Certificates of type approval ............................................................... 125
5
17DRAWINGS..................................................................................126
18ABBREVIATIONS ........................................................................168
18.1Abbreviations ...................................................................................... 168
18.2Symbol list .......................................................................................... 168
19SPARE PARTS ............................................................................169
19.1Standard spares.................................................................................. 169
19.2Servicing spares ................................................................................. 169
20WARRANTY 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
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)
oI/S signal cable
oStarter 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
Discharge rate 0.0 l/nm segregated
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 discharge
Flow A 165 m3/h dirty
Skid Flow 0 l/h com: O
Speed A 10.0 kts pos: O
Discharge 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 mm2cable
Wire size output-connectors Min-max 0,2 – 2,5 mm2
Wire size input-connectors Min-max 0,2 – 2,5 mm2
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 Discharge-
dirty/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 mm2
Wire size output-connectors Min-max 0,2 – 2,5 mm2
Wire size input-connectors Min-max 0,5 – 4,0 mm2
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 mm2
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 mm2
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.
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