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
1PREFACE ....................................................................................... 6
1.1General ...................................................................................................... 6
1.2Symbols ..................................................................................................... 7
1.3Copyright.................................................................................................... 7
2PRODUCT DESCRIPTION ............................................................. 8
2.1Principle of operation ................................................................................. 8
2.2Product configuration ................................................................................. 9
2.2.1Main Control Unit (MCU) ................................................................................ 9
2.2.2Electro Pneumatic Unit (EPU) ...................................................................... 10
2.2.2.1Intrinsically safe signal cable................................................................. 10
2.2.2.2Starter box............................................................................................. 10
2.2.3Skid assembly .............................................................................................. 11
2.2.4Pump/motor assembly.................................................................................. 11
2.2.5Flowmeter system ........................................................................................ 11
2.2.6Sample probe valve assembly...................................................................... 12
2.3Sampling system arrangements............................................................... 12
3TECHNICAL SPECIFICATION ..................................................... 14
3.1General .................................................................................................... 14
3.2Main Control Unit (MCU) .......................................................................... 14
3.3Electro Pneumatic Unit (EPU) .................................................................. 15
3.4Skid .......................................................................................................... 16
3.5Sample pump ........................................................................................... 16
3.6Reference table of products which may be measured ............................. 17
3.7Biofuel guidelines and definitions ............................................................. 18
4SAFETY INSTRUCTIONS ............................................................ 19
4.1Safety precautions ................................................................................... 19
5UNPACKING ................................................................................. 20
6INSTALLATION............................................................................. 22
6.1Introduction .............................................................................................. 22
6.2Utilities...................................................................................................... 22
6.2.1Fresh water supply ....................................................................................... 22
6.2.2Air supply...................................................................................................... 23
6.2.3Electrical supply............................................................................................ 23
6.3Pipework general ..................................................................................... 23
6.3.1Sample pump unit......................................................................................... 24
6.3.2Installation of the sample pump.................................................................... 24
6.3.3Electrical installation pump ........................................................................... 25
6.3.4First start....................................................................................................... 25
6.3.4.1Self priming ........................................................................................... 25
6.3.4.2Direction of rotation ............................................................................... 25
6.3.5Skid............................................................................................................... 26
6.3.6Sampling probes........................................................................................... 26
6.3.7Orifice plate .................................................................................................. 27
6.3.7.1General information............................................................................... 27
6.3.7.2Installation of flow sensor ...................................................................... 27
6.3.8dP/I transmitter ............................................................................................. 28
6.4Bulkhead penetrations general................................................................. 29

2
6.4.1Sample pump ............................................................................................... 29
6.4.2Air pipelines .................................................................................................. 29
6.4.3Intrinsically Safe signal cable ....................................................................... 30
6.5Electrical installation general.................................................................... 31
6.5.1Electro Pneumatic Unit (EPU) ...................................................................... 31
6.5.2Starter box .................................................................................................... 32
6.6Control room equipment – Main Control Unit (MCU)................................ 32
6.6.1Speed input .................................................................................................. 32
6.6.2Overboard valve control ............................................................................... 32
6.7Installation checklist ................................................................................. 33
6.7.1General installation checks........................................................................... 33
6.7.2Check of Flowmeter and automatic control .................................................. 33
6.7.3Starting interlock and/or overboard valve control ......................................... 34
6.7.4Pipework response time calculation ............................................................. 35
6.7.5Final check ................................................................................................... 36
6.8Overview installation check ...................................................................... 37
6.8.1Cable connection Main Control Unit ............................................................. 37
6.8.2Cable connection Electric Pneumatic Unit.................................................... 37
6.8.3Intrinsically safe ground points, measurement cell and EPU ....................... 38
6.8.4Power supply starter box and cable connection skid.................................... 39
6.8.5Multi Cable Transit (Bulkhead Penetration).................................................. 40
6.8.6Water and Airline connections Skid.............................................................. 41
6.8.7System settings. ........................................................................................... 42
7OPERATING INSTRUCTIONS ..................................................... 43
7.1Layout of the MCU ................................................................................... 43
7.1.1Control key switch ........................................................................................ 43
7.1.2USB connector ............................................................................................. 44
7.1.3Printer port.................................................................................................... 44
7.1.4Reset button ................................................................................................. 44
7.1.5Touch screen panel ...................................................................................... 44
7.2Operating the MCU and menu layout....................................................... 45
7.2.1Standby mode (menu 1) ............................................................................... 47
7.2.1.1Information mode (menu 1.1) ................................................................ 48
7.2.1.2Configuration mode (menu 1.2)............................................................. 49
7.2.1.3Data mode (menu 1.3) .......................................................................... 51
7.2.1.4Selftest mode (menu 1.4) ...................................................................... 52
7.2.1.5Setup mode (menu 1.5)......................................................................... 53
7.2.1.5.1Information mode (menu 1.5.1).......................................................... 53
7.2.1.5.2Setup mode (menu 1.5.2) .................................................................. 55
7.2.1.5.3Calibration flush mode (menu 1.5.3.0) ............................................... 57
7.2.1.5.4Idle mode (menu 1.5.3) ...................................................................... 58
7.2.1.5.4.1Information mode (menu 1.5.3.1) ................................................ 58
7.2.1.5.4.2Shutdown mode (menu 1.5.3.2) .................................................. 59
7.2.1.5.4.3Idle setup mode (menu 1.5.3.3)................................................... 60
7.2.1.5.4.4Self test mode (menu 1.5.3.4) ..................................................... 61
7.2.1.5.4.5Sample mode (menus 1.5.3.5) .................................................... 61
7.2.1.5.4.5.1Information mode (menu 1.5.3.5.1)....................................... 62
7.2.1.5.4.5.2Shutdown mode (menu 1.5.3.5.2)......................................... 62
7.2.1.5.4.5.3Manual flush mode (menu 1.5.3.5.3) .................................... 63
7.2.1.5.4.5.4Manual window wash mode (menu 1.5.3.5.4)....................... 63
7.2.1.5.4.5.5Self test mode (menu 1.5.3.5.5)............................................ 64
7.2.1.5.4.5.6Sample setup mode (menu 1.5.3.5.6)................................... 64
7.3Short reference guide for operating the MCU........................................... 65

3
7.3.1Discharging ballast water ............................................................................. 65
7.3.2Shutdown of discharging operations ............................................................ 67
7.4Miscellaneous .......................................................................................... 68
7.4.1Oil content reading higher than expected..................................................... 68
7.4.2Oil level alarm............................................................................................... 68
7.5Operational alarms................................................................................... 69
7.6System failures......................................................................................... 70
7.6.1Auto/manual operation ................................................................................. 70
7.6.1.1Flowmeter.............................................................................................. 71
7.6.1.2Ship’s speed indicator ........................................................................... 71
7.6.1.3Oilcon®Oil Discharge Monitoring and Control System.......................... 71
7.6.1.4Main Control Unit (MCU) ....................................................................... 71
7.7System overrides ..................................................................................... 72
7.7.1Transducer override ..................................................................................... 72
7.7.2Discharge control.......................................................................................... 72
7.7.3Discharge control answer-back .................................................................... 73
8MAINTENANCE ............................................................................ 74
8.1Maintenance general................................................................................ 74
8.2Routine maintenance ............................................................................... 75
8.2.1Sample pump/motor lubricator ..................................................................... 75
8.2.2Air regulators ................................................................................................ 76
8.2.3Cleaning the detector cell windows .............................................................. 76
8.2.4Window wash pump ..................................................................................... 76
8.2.5Skid shuttle valve.......................................................................................... 76
8.2.62-Way pneumatic valve(s) ............................................................................ 76
8.2.7Zero output check of the differential pressure transmitter ............................ 76
8.3Test and check-out procedure.................................................................. 77
9REPAIR OR REPLACEMENT....................................................... 84
9.1Detector cell ............................................................................................. 84
9.1.1Removing the detector cell ........................................................................... 84
9.1.2Reinstalling the detector cell......................................................................... 84
9.2Window wash pump ................................................................................. 85
9.2.1Disassembling the window wash pump........................................................ 85
9.2.2Air side maintenance .................................................................................... 85
9.2.3Water side maintenance............................................................................... 85
9.2.4Re-assembling the window wash pump ....................................................... 85
9.3Sample pump ........................................................................................... 86
9.3.1Disassembling the pump/motor .................................................................... 86
9.3.2Reassembling the pump/motor..................................................................... 87
9.4Differential pressure transmitter – FUJI.................................................... 88
9.4.1Zero adjustment of DPT – FUJI.................................................................... 88
9.4.2Span adjustment of DPT – FUJI................................................................... 88
9.5Differential pressure transmitter – ABB .................................................... 89
9.5.1Zero adjustment of DPT – ABB .................................................................... 89
9.5.2Span adjustment of DPT – ABB ................................................................... 89
10TAKE OUT OF SERVICE.............................................................. 90
11REMOVAL AND STORAGE OF EQUIPMENT ............................. 90
12MALFUNCTION AND SEND FOR REPAIR .................................. 90
13ENVIRONMENT............................................................................ 90

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14DISPOSAL .................................................................................... 90
15TROUBLE SHOOTING AND FAULT FINDING............................. 91
15.1Introduction fault finding guide .............................................................. 91
15.2Fault finding guide................................................................................. 92
15.3Calibration alarms ................................................................................. 94
15.3.1Zero error alarm............................................................................................ 94
15.3.2Path dirty alarm ............................................................................................ 95
15.4System alarms ...................................................................................... 96
15.4.1No air ............................................................................................................ 96
15.4.2No flow.......................................................................................................... 96
15.4.3Power failures............................................................................................... 96
15.4.4Communication failure.................................................................................. 96
15.4.5Led feedback error ....................................................................................... 96
15.4.6Flow overrange failure .................................................................................. 97
15.4.7Flow underrange failure................................................................................ 97
15.4.8Overboard arrangement failure .................................................................... 97
15.4.9Discharge rate failure ................................................................................... 98
15.4.10Total discharge oil limit alarm ................................................................... 98
15.5GPS problems ...................................................................................... 98
15.5.1No GPS signal visible ................................................................................... 98
15.6Power supply problems......................................................................... 99
15.6.1MCU Power failure ....................................................................................... 99
15.6.2Electro Pneumatic Unit power failure ........................................................... 99
15.7Air supply problems ............................................................................ 100
15.7.1Air supply failure ......................................................................................... 100
15.7.2Water found in the monitors of the air system ............................................ 100
15.8Solenoid valve problems..................................................................... 100
15.8.1Valve not working ....................................................................................... 100
15.9Pneumatic valve problems.................................................................. 101
15.9.1Valve not functioning .................................................................................. 101
15.9.2Valve gland leakage ................................................................................... 101
15.9.3Valve leakage ............................................................................................. 101
15.10Window wash pump problems ............................................................ 102
15.10.1Pump does not work ............................................................................... 102
15.10.2Pump cycles without pumping or does not stall ...................................... 102
15.10.3False cycle .............................................................................................. 102
15.10.4Fluid appears at muffler .......................................................................... 102
15.11Sample pump problems ...................................................................... 103
15.11.1Electrical problems.................................................................................. 103
15.11.1.1Pump runs but the green indicator on the starter box is off ................ 103
15.11.1.2Pump should be running but is off ...................................................... 103
15.11.2Pump related problems........................................................................... 103
15.11.2.1No flow................................................................................................ 104
15.12Differential pressure transmitter problems .......................................... 105
15.12.1No line current......................................................................................... 105
15.12.2Current of 21.0mA or 3.9mA ................................................................... 105
15.12.3Incorrect output ....................................................................................... 106
15.13Fault finding form ................................................................................ 106
16CERTIFICATES ...........................................................................110
16.1Certificates of Ex-proof ....................................................................... 110
16.2Certificates of type approval ............................................................... 125

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17DRAWINGS..................................................................................126
18ABBREVIATIONS ........................................................................168
18.1Abbreviations ...................................................................................... 168
18.2Symbol list .......................................................................................... 168
19SPARE PARTS ............................................................................169
19.1Standard spares.................................................................................. 169
19.2Servicing spares ................................................................................. 169
20WARRANTY CONDITIONS .........................................................171

6
1 PREFACE
1.1 GENERAL
The Oilcon®Oil Discharge Monitoring and Control System is used for monitoring and controlling the
discharge of ballast water overboard. The system comprises the following main components:
Oilcon®Oil Discharge Monitor
Flowmeter system
The purpose of the Oilcon®Oil Discharge Monitor is to calculate and record:
the instantaneous rate of discharge of oil, in litres per nautical mile
the total quantity of oil discharge into the sea on each voyage
and also to control the ship’s overboard discharge system as necessary to reduce the
possibility of discharging excessively oily water
Oil content discharge
This manual contains instructions for installation, operation and maintenance (IOM) of the
Oilcon®Oil Discharge Monitor and Control System.
For IOM information of associated equipment supplied by VAF Instruments, refer to the separate
manual supplied with those products.
This manual contains important information for the installer, the operator and for your maintenance
department.
NEVER USE THE EQUIPMENT OUTSIDE ITS SPECIFICATIONS OR BEYOND
COMMON ENGINEERING PRACTICE NOR USE THE EQUIPMENT FOR OTHER
APPLICATIONS OR MAKE CONNECTIONS TO OTHER EQUIPMENT THAN
EXPLICITLY DESCRIBED IN THE ORDER ACKNOWLEDGEMENT AND/OR
TECHNICAL MANUALS OF VAF INSTRUMENTS.
CAUTION:
TO ENSURE SAFE AND CORRECT INSTALLATION AND HANDELING, OPERATION
AND MAINTAINING, READ THIS MANUAL COMPLETELY BEFORE INSTALLING
THE EQUIPMENT AND STARTING OPERATIONS.
For any additional information contact:
VAF Instruments B.V. Tel. [phone]
Vierlinghstraat 24, 3316 EL Dordrecht Fax [phone]
P.O. Box 40, NL-3300 AA Dordrecht E-mail: [email protected]
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