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OPERATION MANUAL
FOR
15ppm BILGE SEPARATOR
Dec. 2011
6
12-06-04
H E I S H I N P U M P W O R K S C O . , LT D
0Q
OPERATION MANUAL
FOR
HFM-MODEL 15PPM BILGE SEPARATOR
CONTENTS
1.
2.
3.
Operation
4.
Suspension of operation
5.
6.
Maintenance
7.
Trouble Shooting
13
8.
16
9.
19
1-1
1st stage
Rough separation of oil form bilge water in the 1st stage is dependent upon the specific
gravity (relative density) of the oil being separated. The separation is achieved by using
multiple parallel plates which are housed in the separating compartment in two layers.
Therefore, they are capable of dealing with bilge water mixed with high density fuel oils
and particles of oil which are larger then 60 microns in size.
1-2
2nd stage
The 2nd stage is filled with hard type of emulsion breaker. Not only the emulsion is broken
but also foreign matter in the bilge is filtered by the breaker and coalescers in 3rd and 4th
stages is protected from clogging by the foreign matter.
1-3
3rd stage
The 3rd stage contains a coalescer which allows small particles of oil to coagulate and
become bigger in size and thereby float to the surface.
Heishins coalescers are made of 18-8 stainless steel and heat/corrosion resistant glass
fiber and are capable of separating oil of 15-20 microns particles. If maintained properly, it
is not necessary to replace these coalescers as often as compared with other types of
15ppm Bilge Separator which use fine filter elements. Moreover, if contaminated, they can
be easily restored by washing with steam or hot water.
1-4
4th stage
The 4th stage contains a coalescer which coagulates small particles of oil that can not be
separated in the 3rd stage and become bigger in size and thereby float to the surface.
1-5
1-6
1-7
Motor-driven valve
Air or oil
On
open
Water
Off
close
Off
close
Flicker (1 sec.)On
Probe
Air
or
Oil
Water
Oil
Oil
Oil
Water
Water
Water
2-1
Bilge pump
The 15ppm Bilge Separator bilge pump has a very important function, and has a strong
influence on the separators performance.
Reciprocating and screw pumps are normally used for 15ppm Bilge Separators, because
of their excellent self priming ability and pumping capacities without agitation. The water
passes through these pumps at a very low speed thereby reducing the possibility of
emulsification.
If properly maintained, the reciprocating pump gives stable operation for a long period of
service without affecting the performance of the 15ppm Bilge Separator.
The eccentric screw pump (a single screw type of pump) is suitable for the 15ppm Bilge
Separator as if can transfer bilge water containing high viscosity oil without agitation. It is
necessary to take care not to run the eccentric screw pump in a dry condition where the
rubber made starter will be easily damaged.
-3-
OPERATION
3-1
2.
3.
4.
5.
6.
3-2
Piping for the 15ppm Bilge Separator is laid down in accordance with the
manufactures piping arrangement, and the specification of ship owner/shipyard if
provided.
The electric wiring of power supply and alarm signal for 15ppm Bilge Separator is
correctly made.
For cleaning inside the pipe from the suction line to the inlet of 15ppm Bilge Separator,
flush with seawater by running bilge pump. (In this step, seawater is not to be supplied
to 15ppm Bilge Separator)
After elimination of sludge, mud and dirt in the pipe, confirm that there is no leakage
from the pipe and the system.
15ppm Bilge Separator is filled up with seawater by bilge pump
No leakage should be observed from the pipe before the 15ppm Bilge Separator.
Operation
Procedures for daily service of 15ppm Bilge Separator:
1.
2.
Open all the valves fitted to the bilge discharge pipe line and start the bilge pump.
Caution
Where the 15ppm Bilge Separator has been unused for more than one week, flush
the 15ppm Bilge Separator with seawater using bilge pump for 15 - 20 minutes prior to
handling the bilge. This is because oil, suspended solids (SS), sediment and bacteria
staying in the 15ppm Bilge Separator may have changed into containments by
biochemical reaction and affect the 15ppm Bilge Separators performance.
3.
During the operation of the 15ppm Bilge Separator, oil is separated from bilge water
and accumulates at the upper part of each stage, and eventually this separated oil
should be discharged into the waste oil tank.
The separated oil in the 1st stage is discharged automatically by an automatic oil
discharge device. Oil in the 2nd, 3rd and 4th stages, however, must be discharged
manually at any time when considered necessary upon checking by the test cock
fitted to the stage. The recommended time for oil discharge is 2 - 3 minutes.
SUSPENSION OF OPERATION
In finishing the operation,
1.
2.
3.
Flush the 15ppm Bilge Separator with seawater for about 15 minutes.
Stop the bilge pump, and switch off the electric power supply.
Ensure that the 15ppm Bilge Separator is kept full of water and should not be emptied
whilst it is unused.
-4-
5-1
MAINTENANCE
In order to keep the performance and function of the 15ppm Bilge Separator in good
condition, proper maintenance is always required considering the bilge water contains a
variety of contaminants including waste oil, sludge, suspended solids (SS), chemical
substance, bacteria, etc. all in different forms.
6-1
Routine check
1.
(1)
(2)
(3)
(4)
(1) Check the pressure difference between the 1st and 3rd stage. When the pressure
difference is more than 0.07 0.1 MPa;
(a) Clean up the T-shape strainer.
(b) For cleaning, turn the handle by hand 4 - 5 times and drain the sludge form the
bottom of the strainer using the ball valve during the operation.
(c) If the pressure difference does not decrease, wash the coalescer of the 3rd stage
in accordance with 6 - 2.
(2) Check if there is no leakage from the separator body.
(3) Check the function of the automatic oil discharge device.
-5-
6-2
Washing
HFM-model 15ppm Bilge Separator is provided with a washing port fitted on the front
cover of the 1st stage and at the inlet pipe of the 3rd stage. The 15ppm Bilge Separator
should be washed with steam (or hot water) periodically once a month or whenever
considered necessary. Washing can done for both stages either at one time or one stage
at a time.
Washing process:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Run the bilge pump for a short time to discharge separated oil from one by one stage.
Supply live steam (or hot water) in order to heat up water in the 15ppm Bilge Separator
up to 70 - 80. When the temperature rises, stop the supply of steam and keep the
15ppm Bilge Separator in this condition for 2 hours.
Run the bilge pump for 2 - 3 minutes to discharge the remaining oil.
Drain the water of only the 1st stage to the bilge well from the bottom of the stage.
When draining the water out of the 2nd, 3rd and 4th stages, ensure that separated oil
has been completely discharged out of the stage.
Close all valves but open the valves on the pipe for bilge treatment if closed.
Start the operation of the 15ppm Bilge Separator for bilge.
Caution
The 15ppm Bilge Separator should be filled with seawater prior to the switch over to
bilge. Washing is completed when seawater is fed into the system.
Important note !!
1. When the 15ppm Bilge Separator is first used, the pressure loss in the coalescer in
the 3rd stage is about 0.01 MPa.
2. When the pressure difference becomes more than 0.07 0.1 MPa, washing should
be carried out. There should be no problem if the pressure loss in the coalescer is
over 0.01 MPa even after washing unless it is more than 0.05 MPa.
3. Direct and thorough cleaning by complete dismantle and overhauling of the
coalescer should be done provided the pressure loss is over 0.05 MPa after steam
or hot water washing.
4. It is necessary to replace the existing coalescer in the 3rd stage with a new one if;
(1) the pressure loss still remains over 0.05 MPa after cleaning by overhaul, or
(2) any damage to the coalescer is observed.
-6-
6-3
2nd stage
The 2nd stage contains hard type of emulsion breaker. Filled quantity is checked once per
6 months and the breaker is supplemented with the following procedure if necessary.
(1) Open the oil discharge valve on the 2nd stage and run the bilge pump for a short time
to discharge separated oil from 2nd stage.
(2) Remove the top cover and discharge the inside water from drain port of the 2nd stage.
(3) When the emulsion breaker is seen, stop the discharge from the drain port.
(4) Supplement the emulsion breaker up to *0 high when filling height of the breaker is *1
high as shown below.
Amount of spare emulsion breaker is considered by the average of consumption rates for 1 year to 2 years.
Consumption rates depends on operating condition.
Sales unit of the emulsion breaker is 15kg / 1unit.
-7-
6-4
1st stage
(1)
(2)
(3)
(4)
Disconnect the influence inlet pipe fitted to the body of the stages.
Unbolt the right body to remove it from the main body.
Unbolt the inner cover for the parallel plates section and remove it.
After removing the front cover, pull out all the parallel.
At the centre of each parallel plates, there is a hole with which the plate can be
pulled out.
(5) Zinc anodes fitted inside the front cover should have an visual inspection at least
once every 6 months.
Please replace with new ones if heavily corroded.
2.
2nd stage
(1) Unbolt the manhole cover and emulsion breaker can be pull out.
(2) Remove the top cover in order to check inside condition of the stage.
3.
3rd stage
(1) Unbolt flange on the body flange of right side to pull out the coalescer complete.
(2) Zinc anodes fitted inside the front cover should have an visual inspection at least
once every 6 months.
Please replace with new ones if heavily corroded.
4.
4th stage
Remove the top cover to pull out the coalescer element.
5.
Clean each component and inside the wall of the stage by wiping off or washing with
light oil if necessary. Special attention should be given to check if corrosion has
occurred.
6.
7.
Re-assemble the 15ppm Bilge Separator exactly in the reveres order to the
disassembly.
8.
-8-
6-5
External wiring
7
6
Motor-driven valve
3 (N) common
2 (N)
Power source (AC 100 - 230V)
1 (P)
-9-
2.
Sensitivity adjustment
(1) Sensitivity level is adjusted with dip1 to 4 of SW1 according to table shown below.
(2) Sensitivity level has been set to 7 at our workshop.
(3) If water content in the separated oil is very high, i.e., eclectic conductivity is as
high as that of water, the level is adjusted to more high number, i.e., level 8
10.
Note: More than level 4: motor-driven valve is opened if the probe detects heavy or
light oil.
More than level 12: motor-driven valve is opened if the probe detects sea or
fresh water.
Sensitivity level
D4
D3
D2
D1
10
11
12
13
14
15
- 10 -
3.
Time adjustment
(1) Time is adjusted with dip1 to 4 of SW2 according to table shown below.
(2) Time has been set to 2 seconds at our workshop.
Time (sec.)
D4
D3
D2
D1
10
12
14
16
18
20
22
24
26
28
30
4.
Confirmation of operation
A: Detecting function of oil
(1) Check that the wiring is correct.
(2) Check that 1st stage is filled up with seawater.
(3) Turn off all switches of SW1 and SW2. Operation indicate LED (R) goes off and
motor-driven valve is closed.
(4) Turn on all switches of SW1. (sensitivity level: 15)
Operation indicate LED flickers for 1 second and motor-driven valve is opened
after 1 second.
(5) Return to pre-set value of SW1 and SW2 after above check.
Sensitivity adjusting switch : level 7
Time adjusting switch
: 2 seconds
Note: Motor-driven valve is opened when test switch is set to TEST.
At normal operation, the test switch should be set to RUN.
- 11 -
6-6
- 12 -
7 TROUBLE SHOOTING
If any troubles occur to 15ppm Bilge Separator, find the cause immediately for a proper
countermeasure in accordance with the following table.
TROUBLE
Poor performance
of 15ppm Bilge
Separator (high oil
content in the
effluent)
CAUSE
COUNTERMEASURE
- 13 -
TROUBLE
CAUSE
COUNTERMEASURE
- 14 -
TROUBLE
CAUSE
COUNTERMEASURE
Pressure of
15ppm Bilge
Separator rises
too much.
Coalescer is clogged.
- 15 -
TROUBLE
CAUSE
COUNTERMEASURE
- Repair it.
Motor-driven
valve is kept open
too long or
motor-driven
valve opens and
shuts too often.
Bilge pump
cannot run.
- 16 -
8-1
Periodical inspection
1.
Cleaning
Periodical checks if bilge water is contaminated by detergent and cleaning by system
(or hot water) from time to time is one of the most important maintenance duties for
ships crew.
2.
Discharge of sludge
Bilge water entering the 15ppm Bilge Separator contains oily sludge including sand,
mud, iron rust, carbon, etc. This oily sludge settles and accumulates in the 15ppm
Bilge Separator and causes clogging resulting in deterioration of separation efficiency.
In particular, F.O. and L.O. sludge create strong corrosion making holes through the
wall of the 15ppm Bilge Separator.
Therefore, it is necessary to remove sludge periodically by either steam washing or
overhaul cleaning and touch up the coating whenever the inner coating is damaged.
3.
8-2
Bilge characteristics
As stated before, bilge water has complex characteristics, and one of the main reasons is
presumably due to chemical and biochemical reaction between oils, water, detergent,
chemical agent and bacteria.
Different chemical agents are added to not only lubricating oil but also to fuel oil, and these
chemicals and detergents are certainly the main cause of emulsified oil in bilge water.
1.
Detergents
Simply for cleaning purposes detergent is made to dissolve oil and oily substances as
a form of emulsion by chemical reaction. To emulsify oil efficiently, different surface
active agents are added to petroleum or plant and animal oil, and therefore the
detergent is in most cases regarded as an oil itself if chemically analysed.
In general the following group of detergents are in current use on board ships
depending upon the purpose of the detergent. Type are:
) those which dissolve in water but not in oil,
) those which dissolve in oil but not in water, and
) those which dissolve in both water and oil.
- 17 -
Without exception, all detergents in the market react against oil to make it chemically
emulsified when mixed with water. The size of an oil particle in a chemical emulsion is
far less than 1 micron and will not float at all. For the above reason, in general
detergent has a substantial influence on the 15ppm Bilge Separator.
Physical separation method based on the gravitational difference between oil and
water is not capable of separating particles of oil of less than 20 microns in size for
light oil and 10 microns for heavy oil. Chemically emulsified oil makes maintenance
term of coalescer in the 3rd and 4th stage shorten due to burden enlargement of the
coalescers for emulsion separation.
Therefore, it is very important to avoid mixing any detergent into bilge as less
as possible.
2.
3.
Compressor drain
Although drain fluid discharged from air compressors is very small in quantity, this
drain fluid is in most cases emulsified which may cause a negative effect on the
15ppm Bilge Separator.
Attention should be paid to the quantity of compressor drain fluid and proper
countermeasures are necessary if the quantity increases for any reason.
4.
Sludge
Sludge is equally as bad a factor on 15ppm Bilge Separator performance as detergent
when it enters the 15ppm Bilge Separator in any great amount. In any case, it is
strongly recommended that mixing sludge into bilge water should be minimised.
- 18 -
9-1
9-2
Kind of oil
Regardless of the conditions, a 15ppm Bilge Separator must separate oil from bilge water
to a level of where the oil content becomes less than 15 ppm in the effluent. Therefore,
15ppm Bilge Separator should play an important role to reduce oil pollution. Our 15ppm
Bilge Separator has been designed and constructed to handle bilge water without any
problems based on our long experience.
In general the separation performance varies depending upon the type of oil in the bilge
water. The lighter the oil becomes, the more difficult becomes the separation of oil from
water.
In other words, oil of a small relative density and low viscosity is difficult for the 15ppm
Bilge Separator to handle. Also the higher the pressure of the bilge pump becomes, the
greater the quantity of smaller oil particles resulting in poor separation efficiency.
*
* *
- 19 -
CLEANING OF COALESCER
Under the condition where an oily water separator is used for a long time, a coalescer installed in the 3rd
chamber (stage) is gradually getting dirty to make separation performance less by clogging the coalescer.
The clog of the coalescer mainly happens when the separator is supplied the bilge containing much sludge
and/or suspended solid, and big amount of oil floating the surface of the bilge. In case that the coalescer is
clogged, differential pressure between 2nd and 3rd chambers (stages) becomes bigger and bigger.
In general, it is recommended to clean the coalescer with steam or hot water when the differential pressure
goes up to 0.07-0.1 MPa except the differential pressure comes from clog of a T-shape strainer fitted on the
connection pipe between 2nd and 3rd chambers (stages). If the strainer is clogged, the strainer is cleaned by
handle fitted on top of the strainer. In either case, cleaning work is carried on in accordance with operation
manual.
In condition where the coalescer is heavily clogged (the differential pressure goes up to about 0.1 MPa.), it is
requested to take out the coalscer from the separator in the following manner for cleaning purpose.
1.
The coalescer is taken out from the separator, and immerses the coalscer element into light oil for a half
day to dissolve sludge therein.
2.
The coalescer element is taken out from the light oil, and the wire for forming is cut. Then, spread the
element sheets on an iron plate or equivalent plate.
3. The element is washed by sea or fresh water which pressure should be less than 0.1 MPa.
Caution:
1.
To avoid damage of glass fiber of the coalescer element, attention shall be taken;
a) not to spray fresh or sea water to the element with pressure of more than 0.1 MPa.
b) not to spray the fresh or sea water to the element in condition where the element sheets are not
spread on the flat plate.
c) not to shake the element sheets in water very hard.
2. It is not necessary to remove color of iron rust on the element. If the element is strongly washed to
remove the color, glass fiber of the element is damaged.
3.
Cleaning detergent is not allowed for washing the element. If the detergent is remained in the element
after cleaning work, separation performance is adversely affected as oil is emulsified in the coalescer
element.
Caution of the cleaning
1.
Wire for
2.
forming
Coalescer complete
Coalescer element
element.
3.
Coalescer element
Flat plate
Oil Outlet
1st Stage
Oily-Water
Inlet
2nd Stage
Emulsion Breaker
Filled quantity is to be checked
once per 6 months and supplement
the breaker if necessary. No need
to replace.
Emulsion breaking: Oil is de-emulsified as preparation
for oil/water separation by the 3rd stage coalescer
Patented Material
Slow consumption rate
No clogging
Easy Maintenance
Head OfficeFactory
675-0146
1-5-30
Tel. 079-436-3018
Tel. +81-79-436-3018
Fax. 079-436-4501
Fax. +81-79-436-4501
Sales Agent