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Instruction Manual
TeamTec Incinerator
OG200C/OG200CS
TYPE: OG200C/OG200CS
25/9/2018
OG200C/OG200CS
2 OG200C
ADDENDUMS, CORRECTIONS AND NOTES
All TeamTec incinerators are made according to EC Type-Examination Certificate MED-B, and are
found to comply with the requirements in the following regulations/standards:
Annex A.1, item NO. A1/2.7 and Annex B, Module B in the Directive. Marpol 73/78 as amended, Annex
VI Regulation 16(2)(a), IMO Res. MEPC.76 (40).
Generally, for a design or type approval certificate, it is allowed to make minor modifications to the
equipment. Minor modifications are changes that will not affect the incinerators function or design. The
incinerator type is still the same, and all main functions are identical to the type approved unit and will be
covered by the certificates. The type stamped on the incinerator is the same as we have on the certificate,
but some of the drawings might have letter codes to describe the extra equipment (minor modification) on
your incinerator. All possible letter codes are:
OG200C 3
OG200C
4 OG200C
TABLE OF CONTENTS
Table of contents
ADDENDUMS, CORRECTIONS AND NOTES ....................................................................................... 3
GARBAGE MANAGEMENT.................................................................................................................... 17
INCINERATION OF SOLID AND LIQUID WASTE ............................................................................................... 17
SOLID AND LIQUID WASTE THAT IS PROHIBITED TO BE BURNED ................................................................... 17
SOLID WASTE HANDLING ............................................................................................................................ 18
BATCH LOADING ......................................................................................................................................... 18
SLUICE FEEDING .......................................................................................................................................... 18
SLUDGE CAPACITY ...................................................................................................................................... 18
INTRODUCTION ....................................................................................................................................... 19
INSTRUCTION MANUAL, PURPOSE AND SCOPE .............................................................................................. 19
SERVICE NETWORK FOR TEAMTEC (GOLAR) INCINERATORS. ...................................................................... 19
MAIN DATA ................................................................................................................................................ 21
PERFORMANCE DATA .................................................................................................................................. 21
Incinerator (combustion chamber). .......................................................................................................... 21
Burner (fixed on combustion chamber) .................................................................................................... 21
Diesel oil booster pump (optional) ........................................................................................................... 22
Flue gas fan (bulkhead mounted) ............................................................................................................. 22
Flue gas damper. ....................................................................................................................................... 22
Sludge tank ................................................................................................................................................ 23
Water tank (Optional) ............................................................................................................................... 23
Sludge circulating pump. (installed on sludge tank) ................................................................................ 23
Sludge filling pump (if dual sludge tank system)(Optional) .................................................................... 23
Sludge transfer pump (optional on dual sludge tank system)(Optional) ................................................. 23
Sludge dosing pump (fixed on combustion chamber) .............................................................................. 23
Water dosage pump (Optional)................................................................................................................. 24
Diesel oil preheater (fixed on combustion chamber) ............................................................................... 24
Electrical control panel incinerator ( fixed on combustion chamber) .................................................... 24
Frequency inverter for flue gas fan (Optional) ........................................................................................ 24
SHIPS SYSTEM INTERFACE REQUIREMENT. ................................................................................................... 25
Electrical. .................................................................................................................................................. 25
Diesel oil. ................................................................................................................................................... 25
Flue gas duct. ............................................................................................................................................ 25
Sludge and Steam or Air. .......................................................................................................................... 25
Water and Steam or Air. (Optional) ......................................................................................................... 25
Sludge tank. (1100 / 1700 / 2000 / 3000 l option) .................................................................................... 25
Water tank. (435 l) (Optional) .................................................................................................................. 26
GUARANTEE CERTIFICATE ........................................................................................................................... 27
TECHNICAL DESCRIPTION .................................................................................................................. 29
OVERALL SYSTEM FUNCTION DESCRIPTION ................................................................................................. 29
Water injection (Optional) ........................................................................................................................ 29
Combustion chamber ................................................................................................................................ 29
OG200C 5
LIST OF DRAWINGS
6 OG200C
TABLE OF CONTENTS
OG200C 7
LIST OF DRAWINGS
8 OG200C
TABLE OF CONTENTS
OG200C 9
LIST OF DRAWINGS
10 OG200C
LIST OF DRAWINGS
List of drawings
Project: «Project_No»
Incinerator
Dwg.no. Rev. Name of drawing.
2007801 Piping & Instrument Diagram OG200C/CS, Steam Heating
1009036 A Combustion Chamber Assy. OG200/400C
1009051 A Combustion Chamber Assy. OG200/400CS
1008973 A Combustion Chamber Mounting Drawing OG200/400C
1009047 Combustion Chamber Main Dimension. OG200/400C
1009049 Combustion Chamber Main Dimension. OG200/400CS
1009194 Oil Burner F-50-45-T, 220V With Analog Motor
1009107 Oil Burner F-50-45-T, 220V with Sludge Burner, Sub Assy.
1008970 A Refractory and Insulation OG200C
1009274 Sludge Oil Dosage Valve Assembly, OG200C.
1008974 A Garbage Door Assembly
1009038 A Door Assembly with Sluice
2008668 Steam Inlet Assembly Sludge
2008667 Sludge Inlet Assembly
3009328 B Sludge Oil Return Assembly
3008910 B Sludge Oil Discharge Assembly
Flue gas
Dwg. no. Rev. Name of drawing.
1006999 A Flue Gas Damper Assembly DN400/300
1006998 Flue Gas Damper, Sub. Assy DN400/300
1007005 Flue Gas Fan, Sub. Assy. DN 300 H2
4006930 A Main dimensions Flue Gas Fan DN 300 H2
AS300-5 Expansion Compensator DN 300
Sludge Tank
Dwg. no. Rev. Name of drawing.
1007011 E Sludge Tank Assembly 1100 L Net Steam Heating
1006026 D Main Dimension Sludge Tank 1100L Net Stem heating
4006522 B Level Transmitter
OG200C 11
LIST OF DRAWINGS
Electrical diagrams
Dwg. no. Rev. Name of drawing.
4008552 Cable Arrangement for OG200C
1009211 Control Panel 380/440V - 220V for OG200C
1009207 Mounting Plate with El.Components 380/440V-220V, OG200C
3010070 Electric Diagram 380/440V-220V Teamtec Incinerator OG200C
4007918 A Terminal Diagram Diesel Oil Burner F-50-45-T with Analog Motor
2006948 C Control Panel Sludge Tank w/Steam Heating
2006949 B Mounting Plate w/El.Components Sludge Tank w/Steam Heating
3007895 B Electric Diagram Sludge Tank w/Steam Heating
3006996 G Thermocouple with Transmitter for Flue Gas
12 OG200C
ACRONYMS AND TERMS”
Acronym/term Definition
Hysteresis The difference noted in a sensor's output as a
response to an increasing or decreasing
input signal of the same value
OG200C 13
ACRONYMS AND TERMS
14 OG200C
GARBAGE MANAGEMENT
Keep the incinerator chamber inlet outlet and burner parts clean. Inspect daily before start
in the morning, and clean as required.
Do never throttle the air/steam needle valve more than ¾ turn closed. If the pressure
increases above green area, clean the sludge burner nozzle.
Do never turn off the main power before the chamber temperature is down below 170°C.
If experiencing any problem with high temperature in combustion chamber, flue gas or
control of sludge dosing, replace the dosing pump stator.
Do not transfer sludge to the service tank during sludge burning in a single tank system
(can damage the refractory).
As a minimum, heat the sludge over night, without starting the circulating pump. Next
morning drain off the free water and start the sludge program.
Never load glass, lithium batteries or large quantities of spray cans in the incinerator –
nor large quantities of oily rags or filter cartridges. This may damage the flue gas fan.
Inspect the cooling jacket every 6 months (open the cover plates) and clean as required
with steam or hot water.
Read the instruction manual, and never change any settings unless instructed by
TeamTec, Norway
OG200C 15
GARBAGE MANAGEMENT
Garbage management
TeamTec recommend working out guidelines for an onboard garbage management plan.
Personnel responsible for operation of the incinerator shall be trained and capable of
implementing the guidance follows by the instruction manual.
Waste incineration on board sea going ships and offshore platforms is world wide regulated by
IMO MARPOL 73/78, RESOLUTION MEPC 76(40), STANDARD SPECIFICATION FOR
SHIPBOARD INCINERATORS, adopted on 25.september 1997, and IMO MARPOL ANNEX
VI REGULATION 16 and APPENDIX IV adopted on 26. September 1997.
MERCURY
LEAD
NICKEL
VANADIUM
ZINC
OG200C 17
GARBAGE MANAGEMENT
Class 2 refuse, consists of approximately even mixture of rubbish and garbage by weight. This
type of waste is common to passenger ships occupancy, consisting of up to 50% moisture, 7%
incombustible solids and has a heating value of about 10.000 kJ/kg as fired.
Be aware that plastics has high calorific value, about 36.000 kJ/kg and must only be incinerated
in small amounts at the same time.
Batch loading
Do not attempt to clean the combustion chamber without activating the slagging mode on the
touch screen display, to prevent injury to personnel due to insufficient ventilation.
Each morning, providing that the combustion chamber temperature is lower that 170°C, slag
and ashes should be removed. Partly burnt garbage shall remain in the chamber. This garbage
will be fully incinerated at the next sequence of incineration. The air inlet openings in the
bottom of the combustion chamber must be regularly cleaned. This is important in order to let
the combustion air come into the chamber.
Load the combustion chamber with garbage of type IMO class 2. If high calorific garbage is
loaded, a smaller quantity must be loaded per charge.
Sluice feeding
If sluice is installed, solid waste can be fed into the 55 litre sluice at temperatures between
700°C and 1050°. Fill the trash in a garbage paper bag, open the sluice lid/sluice door and put
the bag into the sluice. Do not jam the trash bag into the sluice or overfill it. Close the lid /
sluice door and rotate the sluice by the handle on the sluice. The recommended waiting time
between each time the sluice can be operated is 210 seconds. After the waiting time has elapsed,
the sluice is ready for a new load.
Sludge Capacity
The incinerator is certified according to MEPC 76(40) which determines the sludge to contain
20% water.
A high water content up to 50% water content will result in a higher capacity than what is
mentioned in the certificate. As an example, the sludge with 40% water content will have lower
calorific value than IMO sludge, hence higher hydraulic capacity.
A water content higher than 50% requires a pilot burner (support burner). This reduces the
available capacity for burning of sludge.
18 OG200C
INTRODUCTION
Introduction
Instruction manual, purpose and scope
This user manual is made according to guidelines in the Norwegian Standard NS 5820
The manual will guide the reader/user gradually to an understanding required for safe operation
and maintenance of the incinerator system.
It is important for the user to have a good understanding of the incinerator function, to avoid
malfunction caused by operational errors.
The guarantee will be invalid if problems and/or caused by operational errors or mistreatment.
Tel.: +(47) 37 19 98 00
Telefax: +(47) 37 19 98 90
E-mail: office@teamtec.no
Please note that our main strategy is to offer our customers the best service and quality
spare parts wherever and whenever they need them. To reach this goal we have
established a stock of spare parts and trained service personnel in major ports throughout
the world.
OG200C 19
MAIN DATA
20 OG200C
MAIN DATA
Main data
Performance data
Incinerator (combustion chamber).
Type: OG200C
Corresponding to: 70 kg/h IMO sludge oil (w. water injection) IMO sludge (20% water)
127 l/h Water consump. (w. water injection) From Bilge water tank
50 kg/h IMO sludge oil (without water IMO sludge (20% water)
injection) IMO class 02 waste
Solid waste max. 400 litre per charge or 55
l/charge continuous feeding
Electrical power, rated 15 kW (Flue gas fan included.) From ship distribution
consumption: system.
Weight (each): 30 kg
OG200C 21
MAIN DATA
Connections: 1/4"
Weight: 12 kg.
Weight: 326 kg
Size: DN 300/400
Weight: 68 kg
22 OG200C
MAIN DATA
Sludge tank
Volume: Net: 1,100/1,700 or 2,000/3,000 litres.
Flange rating: NP 16
Flange rating: NP 16
Weight: 424 Kg
OG200C 23
MAIN DATA
Enclosure rating IP 55
Weight: 56 kg
Weight: 22 kg.
24 OG200C
MAIN DATA
Diesel oil.
Diesel oil supply line Equipped with a closing valve.
Connection. DN 15 flange, max pressure
Recommended filter, mesh 1.5 bar
40µm
Max. suction lift 3500mm
Diesel oil return line Connection. DN 15 flange, max pressure
1.5 bar
OG200C 25
MAIN DATA
Detailed information regarding the system is found on the Piping & Instrument Diagram given in the
Drawings section.
26 OG200C
MAIN DATA
Guarantee certificate
We hereby confirm that the ordered equipment is guaranteed against faulty manufacturing for a
period of 12 months from approved start-up on board ship, but limited to 18 months from
shipment date of equipment.
Any faulty parts with proven manufacturing defects will be supplied free of charge, ex. works,
including packing, during the guarantee period. Possible travelling and accommodation
expenses for Service Engineer are not included.
The guarantee does not cover wear and tear parts. The guarantee is valid only if our operation-
safety- and maintenance instructions are properly followed, and start-up approved by signature
from ship owner's representative.
Tvedestrand,
OG200C 27
TECHNICAL DESCRIPTION
28 OG200C
TECHNICAL DESCRIPTION
Technical description
Overall system function description
The TeamTec Incinerator type OG200C is designed for on board incineration of ship's waste oil, solid refuse
and destruction of bilge water. The system consists of 5 main parts:
Combustion chamber with diesel oil burner, sludge burner, pilot fuel heater and electric control panel.
Flue gas fan with flue gas damper or frequency inverter (Optional).
Sludge service tank with circulating pump and heater.
Sludge settling tank with filling pump and heater (Optional).
Water injection (Optional).
When burning sludge with injected water, the sludge burning capacity increases, NOx in flue gas duct reduces
and it is an easy way to get rid of problem water. Dumping oily water directly into the sea can harm marine life,
and is illegal. Various ports are facing new local regulations on ship emissions, including discharges of ballast
water, gray water, bilge water, and deck runoff, among others. Disposal of the contaminated water in the
incinerator is an easy and effective solution to a complex problem.
Combustion chamber
The combustion chamber consists of a cylindrical chamber. The trash is ignited by burner in the chamber. The
combustion chamber is equipped with an inspection, which can be opened only while the incinerator is not
burning. The control system will prevent the door from being opened before the set temperature for cooling is
reached.
The flue gas outlet is located at the top of the left chamber for most efficient use of the flames. The flames
from the burners follow a corkscrew pattern towards the bottom and continue rotation upwards in the centre of
the combustion chamber. Remnants of particulate matters in the gas flow are neutralised by the burner, making
the combustion ecologically safe. As the fumes exits the chamber, cooling air drawn from the lower part of the
casing is mixed with the flue gas to bring the temperature down to approx. 330°C before it pulled out by the
flue gas fan and blown out the stack to atmosphere.
The burning process is monitored by the PLC and scanned by a photo resistor in the burner. The temperatures
are also monitored/regulated automatically by the PLC control system.
Two sight glasses are equipped, for the operator to be able to inspect the amount of trash in the chamber and the
function of the system.
The combustion chamber is of steel construction, lined with specially designed refractory blocks. Between the
steel and refraction there is a 50mm layer of insulation. The refractory material is made of a low cement/high
alumina quality being slag resistant and having very good thermal shock resistance. A double steel casing with
a cooling air jacket forms the outside of the combustion chamber.
The combustion chamber is equipped with a, three-stage diesel oil burner and a steam/air atomising nozzle for
sludge burning. Under the burner assembly, a bracket/drip tray for sludge burning equipment is mounted.
The Diesel Oil burner has 3 stages, automatically controlled by the PLC. In addition there are four stages for
sludge burning, using steam or compressed air for atomising. The sludge burner allows particles up to 4 mm to
pass through. The D.O. burner is monitored by the PLC and has a built in primary air fan and diesel oil pump.
The main electrical control panel is normally fitted on the incinerator and it contains circuit breakers, starters,
frequency inverters, PLC and operator panel. A separate frequency inverter for flue gas fan control is optional,
and are to be installed close to the fan. The electric panels are built according to international standards for
marine equipment. The operator panel, which is located at the side of the control panel, has a LCD display
touch screen for selecting burner program modes and for monitoring the burning process.
OG200C 29
TECHNICAL DESCRIPTION
Drain valves (sample points) are mounted on the tank to check the sludge level in the tank. A level transmitter
on the tank provides PLC to generate a animated tank level readout on operator panel (display on incinerator
control panel), and right amount of sludge burned.
A circulating pump is mounted on the tank. The pump transports the sludge to the incinerator and a return line
to the tank is provided, a god mixing of the sludge and water is guaranteed. A low level switch on the tank will
stop the incinerator, the circulating pump and heating when the level has reached a minimum. An indicating
light for heating is placed on the junction box on the tank.
A heater, controlled by a thermostat, will keep the sludge temperature around the set point (80 to 90°C). (With
temperatures above 60°C, regulations require tank to be insulated or guarded with metal screen).
Drain valves (sample points) are mounted on the tank to check the sludge level in the tank. The lowest one is
meant to use for draining off the water. A level transmitter on the tank provides PLC to generate a tank level
readout on operator panel (display on incinerator control panel).
A filling pump is mounted on the tank. The pump transports the sludge to the sludge service tank. A low level
switch on the tank will stop the filling pump and heating when the level has reached a minimum. It is not
possible to transfer sludge to the service tank during sludge burning
An indicating light for heating is placed on the junction box on the tank.
The water tank has filling, overflow and ventilation connection. The incinerator has frequency controlled water
dosing pump unit, with suction lift at 3500mm. The water is connected to the incinerator with DN 15 flange
connection.
The water tank has two level switches. A high level switch to stop the filling pump and a low level switch, with
dual contact set, to start the filling pump and to stop the water injection if switch is activated for more than two
minutes. This is to prevent the water dosage pump to run dry. A suitable tank is available from TeamTec.
30 OG200C
TECHNICAL DESCRIPTION
Sludge control
Introduction
The automatic sludge control logic is designed for burning a maximum amount of sludge, consuming a
minimum amount of diesel, and maintaining a combustion chamber temperature above 870°C (CCT stop burner
diesel oil), see operator panel - settings sludge program page 2/4. Sludge quality is an important factor for the
sludge burning process. The system is capable to handling sludge with a high content of water, but this might
however result in a higher consumption of diesel oil.
Temperature limits
680°C Start sludge burner.
640°C Temperature decrease to this level stop sludge burner and increase sludge quality
counter with 2.
660°C Temperature decrease to this level, after temperature have been above 690°C,
decrease the sludge dosage pump rpm with 50 and increase sludge quality counter
with 2.
690°C Temperature increase to this level increase the sludge dosage pump rpm with 70.
700°C Alarm level for low combustion chamber temperature, if combustion chamber
temperature has been above 850°C.
840°C Starts a diesel support burner in addition to the condition at 870°C and increase the
sludge quality counter with 2. Decrease the sludge dosage pump rpm with 140.
870°C Temperature allowing burning sludge alone. Temperature increase to this level the
increase the sludge dosage pump rpm with 140.
890°C Above this temperature the sludge quality counter will step down one every minute.
1000°C Temperature increase to this level and above, decrease the sludge dosage pump rpm
with 4 every 30 second if Sludge/Solid waste program is running.
1150°C Temperature increase to this level and above, decrease the sludge dosage pump rpm
with 4 every 30 second. Water injection control temperature. Water amount injected
to combustion chamber will increase if CCT is above this level, and decrease if CCT
below this level.
Burner stage
STAGE NO 3 Diesel oil nozzles no. 1 + 2.
OG200C 31
TECHNICAL DESCRIPTION
Control
At first start up a sludge burner program, the sludge burner start when combustion chamber temperature rise
above 680°C, the operator panel will indicate burner stage 5, the sludge dosage pump will be given start speed
190 rpm, and will run at this speed for 60 seconds. During the 60 seconds, burner step 5 will be fixed.
Assuming the sludge is of a good quality the temperature will start to rise. If the temperature raise is >=0°C
over 30 seconds, the sludge dosing pump increase 2 rpm. There will be a sampling of temperature each 30 sec.
and provided there is a temperature raise, a new step of 2 rpm will take place.
If the sludge quality is still good, the sludge dosing pump will be given a new step increase of 70 rpm when
temperature rises above 690°C. The burner stage will be 4. When temperature raise above 870°C the sludge
dosing pump will again be given a new step increase 60 rpm and the burner stage will be 7.
If the sludge contain too much water or chemicals, the temperature is likely to fall below 640°C and the sludge
dosing pump stop. Burner will change to stage 3, and the sludge quality counter will increase with 2 (after an
attempt to stage 5). When temperature rises above 680°C the sludge burner will start again. The burner stage
will then depend of sludge quality number. The sludge quality number is an indication of the quality of the
sludge. A high sludge quality number indicates a sludge with high water content, and burner will use more
diesel oil.
The low temperature alarm, 700°C, will first be activated if temperature has been above 870°C.
32 OG200C
OPERATOR PANEL
Operator Panel
General
The operator panel is a touch sensitive screen enabling the operator to enter information to the incinerator
control system. The screen is also displaying information from the control system to the operator. The panel is
connected to A PLC, controlling the combustion process. A description of the screens follows. The main
picture is displayed at start up and is possible to access by pressing “main” from most other screens. The screen
will display equipment according to scope of delivery from TeamTec AS
10
11
12
(The appearance of the screen may differ based on the choice of optional equipment)
OG200C 33
OPERATOR PANEL
Structure
Logic control system consists of an “Overview” screen and several sub-screens in the order as described below:
Main
Select/start
programs
Setup Burner
Sludge I/O
Solid waste
Information
The control system Pop-up
will activate these SW Sludge
screens. Service
Pop-up
Sludge and Water
Login
Restore
Factory
Burn-in Settings
Display backlight
Date time
Prog. info
Water tank
Hour
General: From all screens it is possible to stop the incinerator by pressing “Stop” It is also possible to access
“Main”, Setup” and “Alarm from all screens.
34 OG200C
OPERATOR PANEL
Information pop-up
An information pop-up gives information to the
user about irregularities between user actions and
incinerator status. Read the message and press
“Ack”.
The following messages may appear as
information messages:
Not possible to start sludge filling pump low level in sludge settling tank
Not possible to start sludge filling pump high level in sludge service tank
Not possible to start sludge filling pump when sludge program is running
OG200C 35
OPERATOR PANEL
Not possible to start sludge circulation pump low level in sludge service tank
Not possible to start sludge program - low level sludge service tank
Not possible to start sludge with water program - low level sludge service tank
Not possible to start solid waste - sludge program - low level sludge service tank
Not possible to start program - Door not closed - please close door
Burner
Display actual values and status on motors,
actuators and sensors. No adjustments or
settings on this screen – view only.
Setting tanks
Displays tanks physical attributes and sludge
mass for correct sludge consumption.
36 OG200C
OPERATOR PANEL
Hour counters
Display last run and total hours. Press “Next”
button to access screen “Hour counters 2”
Setup
Some functions require the operator to login in
order to access a screen or to alter a value in
the setup. This normally indicates that the
operator needs training in order to be aware of
the consequences of his actions.
Select the setup screen you want to access. If
not logged in as user “usr”, values on different
setup screens are “view only”.
OG200C 37
OPERATOR PANEL
Login
Pressing “Setup” will give access to “Login”.
Change values
Plot the value that should be changed. A numeric pop-up will appear:
The present value is displayed on the line. Type in a new value and press return to
accept, or press “ESC” to cancel.
38 OG200C
OPERATOR PANEL
Settings burner
If not logged in as user “usr”, values on different
setup screens are “view only”. Buttons “Prev.”
and “Next” is used in a circular shift function
between a number of setting screens.
Text Description
Burner damper burner Burner damper opening. Adjusts the amount of air supplied to the
step x combustion process by the burner motor fan.
Factor CCP burner Correction of burner damper opening related to combustion chamber
damper reg. pressure (CCP). Used internally in the control system.
Factor SDP burner Correction of burner damper opening in related to sludge dosage pump
damper reg. (SDP) speed. Used internally by the control system.
Settings alarms
If not logged in as user “usr”, values on
different setup screens are “view only”.
Text Description
Alarm low level Activate if alarm is needed when sludge service tank low level switch is
Sludge service tank1 activated.
Alarm sludge temp. The maximum temperature drop in sludge temperature. Related to “Min
low sludge temp run sludge”. See screen “Setting sludge (1/4).
OG200C 39
OPERATOR PANEL
Alarm sludge temp. The maximum temperature increase in sludge temperature. Related to “Min
high sludge temp run sludge”. See screen “Setting sludge (1/4).
Alarm max time The maximum time the dieselheater is activated the first time after start
dieselheater start incinerator. The dieselheater requires extra time at start-up.
Alarm max time The maximum time the dieselheater is activated during incinerating.
dieselheater run
Min. operating CCT Minimum combustion chamber temperature (CCT). Used as reference to
“Alarm CCT below min. oper.”
Alarm CCT below Maximum temperature drop combustion chamber temperature (CCT).
min. oper. Related to “Min. operating CCT”.
Text Description
Set burning time2 Set total burning time for sludge program
Sludge alone3 Yes - if sludge burning without diesel oil support burner is allowed
No - if sludge burning with diesel oil support burner is required
CCP start sludge Setpoint combustion chamber pressure (CCP) when starting a sludge
program
40 OG200C
OPERATOR PANEL
Max. CCP run sludge Maximum combustion chamber pressure (CCP). Used internally as a limit
in the control system
Min. CCP run sludge Minimum combustion chamber pressure (CCP). Used internally as a limit in
the control system
Min. sludge temp run Minimum sludge temperature before starting sludge program. This value is
sludge also calculating alarm sludge temperature. See alarm settings.
Min. CCT run sludge Minimum combustion chamber temperature (CCT) before starting sludge.
CCT low hysteresis – Maximum drop combustion chamber temperature (CCT) – stop sludge
stop sludge. dosage system.
Purging start sludge Time for purging sludge nozzle before opening sludge.
Purging stop sludge – Minimum combustion chamber temperature (CCT) for stop purging sludge
CCT below nozzle.
Text Description
Time start sludge Time after start sludge dosage pump (SDP) before making adjustments – to
before adjust ensure a stable process before adjusting sludge.
Time check CCT after Time between reading combustion chamber temperature (CCT) and making
adjust adjustments to the process
CCT inc between The minimum increase in combustion chamber temperature (CCT) needed
adjust – inc sludge at time check before making adjustment to process.
CCT inc sludge – dec Minimum combustion chamber temperature (CCT) before decreasing diesel
diesel oil oil and increasing sludge.
Hys dec sludge – inc Maximum drop combustion chamber temperature (CCT) before decreasing
diesel oil sludge and increasing diesel oil.
CCT stop burner Minimum combustion chamber temperature (CCT) before stop diesel oil
diesel oil and further increase sludge.
OG200C 41
OPERATOR PANEL
Hys burner restart Maximum drop combustion chamber temperature (CCT) before restart
diesel oil burner diesel oil and decrease sludge.
Max. CCT run sludge Maximum combustion chamber temperature (CCT) before reducing sludge.
– dec sludge
Hys max. CCT – stop Maximum drop combustion chamber temperature (CCT) before stop
dec sludge reducing sludge.
Set CCP running Step Set point for Combustion Chamber Pressure (CCP) is -12mmWC during
4&5 burner stage 4 & 5 as long as the Combustion Chamber Temperature is
below 800°C
Set min CCP for Minimum set point for Combustion Chamber Pressure (CCP) as long as the
temp.regulating Combustion Chamber Temperature is above 800°C
42 OG200C
OPERATOR PANEL
Text Description
Max. FGT – start Maximum flue gas temperature (FGT) before decreasing combustion
adjust CCP chamber pressure (CCP)
Hys max. FGT – stop Maximum drop flue gas temperature (FGT) before stop decreasing
adjust CCP combustion chamber pressure (CCP)
Time check FGT Time between check flue gas temperature (FGT) before making further
adjust CCP increase in combustion chamber pressure (CCP)
FGT max. inc. CCP Maximum flue gas temperature(FGT), increase combustion chamber
pressure(CCP).
Max. FGT – start Maximum flue gas temperature (FGT) decrease sludge dosage pump (SDP)
adjust SDP RPM RPM.
Hys FGT – stop adjust Minimum drop flue gas temperature (FGT) before stop decreasing sludge
SDP RPM dosage pump (SDP) RPM.
Min. CCT scale CCP Minimum combustion chamber temperature (CCT) in scaling range for
run sludge adjusting combustion chamber pressure (CCP)
Max. CCT scale CCP Maximum combustion chamber temperature (CCT) in scaling range for
run sludge adjusting combustion chamber pressure (CCP)
CCP running Combustion chamber pressure (CCP) when burning both diesel nozzles and
burnerstep 6 sludge nozzle.
SDP comp. decrease Increasing sludge when changing burner step from 5 to 4, or 6 to 5.
diesel oil
SDP comp. stop diesel Increasing sludge when changing burner step from 4 to 7.
oil
OG200C 43
OPERATOR PANEL
Text Description
SDP RPM decrease Decreasing SDP RPM every 30 second if combustion temperature CCT >
Max. CCT run sludge – dec sludge(1/4).
SDP RPM increase Increasing SDP RPM every 30 second if combustion temperature CCT
increases or equal.
44 OG200C
OPERATOR PANEL
Text Description
Set burning time4 On, makes it possible to program a fixed burning time
CCP start-up solid Minimum combustion chamber pressure (CCP) before start burner at start
waste program solid waste program
CCP max. solid waste Maximum combustion chamber pressure (CCP) when running solid waste
program
CCP min. solid waste Minimum combustion chamber pressure (CCP) when running solid waste
program
OG200C 45
OPERATOR PANEL
Text Description
Max. FGT start Maximum flue gas temperature (FGT) before start adjusting combustion
adjustment CCP chamber pressure (CCP).
Hysteresis FGT stop Minimum drop flus gas temperature (FGT) before stop adjusting
adjusting CCP combustion chamber pressure (CCP)
CCP inc when FGT Value for increasing combustion chamber pressure (CCP) when flue gas
above setpoint temperature (FGT) is above set point
CCP dec when FGT Value for decrease combustion chamber pressure (CCP) when flue gas
below setpoint temperature (FGT) is below set point
Time check FGT Time between reading flue gas temperature (FGT) before making
adjust CCP adjustments to combustion chamber pressure (CCP).
Max. FGT start adjust Maximum flue gas temperature (FGT) before start adjusting burner step.
burner step
Hysteresis FGT stop Minimum drop flue gas temperature (FGT) before stop adjusting burner
adjust burner step step.
Time check FGT Time between reading flue gas temperature (FGT) before making
adjust burner step adjustment to burner step.
46 OG200C
OPERATOR PANEL
Text Description
Max. CCT SW & Maximum combustion chamber temperature (CCT) – reduce sludge when
sludge running solid waste and sludge program.
Hysteresis max. CCT Minimum drop combustion chamber temperature (CCT) – stop reducing
SW & sludge sludge when running solid waste and sludge program.
OG200C 47
OPERATOR PANEL
Text Description
CCT enable Water Setpoint combustion chamber temperature for water injection to start.
injection
CCT max. for Water Maximum combustion chamber temperature when water injection is
injection enabled.
CCT min. for Water Minimum combustion chamber temperature when water injection is
injection enabled.
Increase RPM WDP Increase of Water dosage pump RPM every 60 second until “Max RPM
WDP” is reached
48 OG200C
OPERATOR PANEL
Text Description
CCP running cooling Set point for combustion chamber pressure (CCP) when running “Stop”
program (cooling).
FGF RPM when CCT Set point for flue gas fan (FGF) speed when running below “Stop”,
below stop5 combustion chamber temperature (CCT) – Loading/slagging speed.
Auto start of FGF after Off – After emergency stop the flue gas fan needs to be restarted by pushing
emergency stop6 “STOP” button on display.
OG200C 49
OPERATOR PANEL
Incinerator configuration
The button “Restore factory settings” can be
used to restore settings to factory
specifications.
Backlight
No user name and password required.
50 OG200C
OPERATOR PANEL
Program information
Values are view only. If assistance from
TeamTec is required, you might be asked for
the type and version listed on the screen.
Consumption
Display consumption for this run, last run and
total. Press “Setup consumption” to access
setup screen.
Consumption setup
If not logged in as user “usr”, values on
different setup screens are “view only”.
OG200C 51
OPERATOR PANEL
Alarm system
If the control system encounters any irregularities the system will give an alarm and shut down the incinerator.
When an alarm occurs, the internal audible alarm activates and the alarm signal is given to ships alarm system.
The "ALARM" screen will pop-up at the operator panel display and the most recent alarm(s) will be displayed
at the top of the list. The “ALARM” screen will display active alarms as well as the alarm history. A total of
128 alarms (active and history) can be displayed. When additional alarms occur, the oldest alarms will be
deleted from the alarm history list.
Symbol Status
! Active Not accepted
*! Active Accepted
* Not active Accepted
Buttons for handling alarm system.
52 OG200C
OPERATOR PANEL
Alarm List
The Alarm-list contains information about which alarms that are available. The reference refers to electrical
drawings.
Sludge temperature low 50°C Sl. prog. -U3 Sludge temperature low.
Sludge temperature high 95°C All time -U3 Sludge temperature high.
Sludge service tank temp. 110°C All time +3A.1-S1 Safety thermostat released.
high10 (require manual reset)
OG200C 53
OPERATOR PANEL
54 OG200C
OPERATOR PANEL
Setting list
Settings burner 50Hz 50Hz 60Hz 60Hz
Sluice Sluice
Burner damper burner step 1 18 % 18 % 18 % 15 %
Burner damper burner step 2 28 % 28 % 25 % 25 %
Burner damper burner step 3 37 % 37% 30 % 30 %
Burner damper burner step 4 28 % 28 % 25 % 25 %
Burner damper burner step 5 37 % 37 % 35 % 35 %
Burner damper burner step 6 100 % 100 % 100 % 100 %
Burner damper burner step 7 55 % 55 % 40 % 40 %
Factor CCP burner damper reg. 0.150
Factor SDP burner damper reg. 0.050
Settings alarms
Alarm low level Sludge service tank Off
Alarm sludge temp. low, below normal 30 °C
Alarm sludge temp. high, above normal 15 °C
Alarm max time dieselheater start 600 Sec.
Alarm max time dieselheater run 480 Sec.
Alarm max CCT 1200 °C
Min.operating CCT 850 °C
Alarm CCT below min. oper. 150 °C
Alarm max FGT 375 °C
Alarm min CCP (Draught failure) -5 mmWC
Settings sludge
Sludge alone Yes
CCP start sludge -28 mmWC
Max. CCP run sludge -28 mmWC
Min CCP run sludge -12 mmWC
Min. sludge temp run sludge 80 °C
Min. CCT for run sludge 680 °C
CCT low hysteresis – stop sludge 40 °C
Purging start sludge 5 Sec.
Purging stop sludge – CCT below 300 °C
Time start sludge before adjust 60 Sec.
Time check CCT after adjust 30 Sec.
CCT inc between adjust – inc sludge 0 °C
CCT inc. sludge – dec. diesel oil 690 °C
Hys dec sludge – inc diesel oil 30 °C
CCT stop burner diesel oil 870 °C
Hys restart burner diesel oil 30 °C
Max CCT run sludge – dec sludge 1150 °C
Hys max CCT – stop dec sludge 10 °C
Set CCP running step 4 & 5 -15 mmWC
Set min CCP for temperature regulation -15 mmWC
Max. FGT – start adjust CCP 330 °C
Hys max FGT – stop adjust CCP 0 °C
Time check FGT adjust CCP 30 Sec.
FGT max inc CCP -3 mmWC
Max FGT start adjust SDP RPM 340 °C
Hys FGT – stop adjust SDP RPM 1 °C
Min CCT scale CCP run sludge 800 °C
Max CCT scale CCP run sludge 1200 °C
CCP running burner step 6 -28 mmWC
SDP compensation – decrease diesel oil 60 rpm
SDP compensation – stop diesel oil 60 rpm
SDP RPM decrease 2 rpm
OG200C 55
OPERATOR PANEL
56 OG200C
OPERATOR PANEL
Settings
Tanks
TG5
Sludge
Max tank level Volume below low level Tank area density
435 L 500000 mm² 0.96 Kg/L
703 L 217,9 L. 750000 mm² 0.96 Kg/L
1107 L 219,5 L 1020703 mm² 0.96 Kg/L
1692 L 277,0 L 1517468 mm² 0.96 Kg/L
2071 L 277,0 L 1517468 mm² 0.96 Kg/L
2938 L 277,0 L 1517468 mm² 0.96 Kg/L
3812 L 622,0 L 1985565 mm² 0.96 Kg/L
4945 L 550,0 L 1985565 mm² 0.96 Kg/L
OG200C 57
OPERATOR PANEL
58 OG200C
OPERATOR PANEL
OG200C 59
OPERATOR PANEL
60 OG200C
OPERATOR PANEL
OG200C 61
PROGRAM DESCRIPTION
Program description
Overall program function description
The TeamTec Incinerator type OG200C is controlled by a Programmable logic controller (PLC) witch handles
both the operating functions and the alarm system. The Human Machine Interface (HMI) is a touch screen
operator terminal. The operator terminal allows the user to view and monitor the process and to give input to
the process by choosing appropriate program to the desired task.
The Incinerator has 5 programs to select from; “Sludge”, ”Sludge and Water15”, “Solid waste & Sludge”,
“Solid Waste” and “Slag”. Some functions are general and controlled in the same way regardless of choice of
program.
General
The diesel oil burner heats up the incinerator. The burner runs in different steps, each program calculates the
required burner step and the burner responds accordingly by controlling the diesel oil valves, the burner air
damper the burner motor and the ignition electrodes.
The airflow through the burner is adjusted by the burner damper to different air flow at different steps on the
burner. The damper opening is corrected for the actual pressure in the combustion chamber (CCP) and the
actual speed of the sludge dosing pump (SDP)
0 - Burner stopped.
1 – Nozzle 1
2 – Nozzle 2
3 – Nozzle 1 and 2
7 – Sludge only
62 OG200C
PROGRAM DESCRIPTION
Burner step 0 X X X X
Burner step 1 X X X X
Burner step 2 X X X X
Burner step 3 X X X X
The chosen program will call for different Combustion chamber pressure set points at different conditions and
stages of the program. The flue gas fan inverter uses a PID controller to determine the Flue gas fan speed
according to the given set point.
The incinerator starts heating up using the diesel oil burner. The diesel oil burner is controlled in different
steps. See description of burner for details.
After sludge program is started there is two criteria that needs to be fulfilled before incinerating starts; Sludge
temperature above 80°C and Diesel oil temperature above 60°C.
When the combustion chamber temperature (CCT) has reached set point “min CCT for run Sludge”(680°C), the
steam line will flush for 10 seconds to drain out condensate water before starting up the sludge burner. The
sludge dosage pump (SDP) starts. If the temperature increases after 60 seconds, the diesel oil burner reduces
“CCT inc sludge – dec diesel oil”(690°C). If temperature decreases below 640°C, sludge burning stops and
retries with a higher burnerstep at “min CCT for run Sludge”(680°C) if sludge quality counter is above the
OG200C 63
PROGRAM DESCRIPTION
initial value for increasing sludge burner step. At set point “CCT stop burner diesel oil” (870°C), the sludge
program requires burner step 7 from the burner program and runs sludge only if selected in the sludge settings.
Sludge dosage pump (SDP) will increase sludge dosing if combustion chamber temperature (CCT) is equal or
rising, until combustion chamber temperature (CCT) has reached set point ”Max CCT run Sludge” (1150°C) or
flue gas temperature (FGT) raises above “Max FGT – start adjust SDP RPM (350°C). The control system will
then adjust sludge dosage pump (SDP) to keep combustion temperature (CCT) and flue gas temperature below
maximum setpoints.
Low sludge tank will result in a normal stop of the program or alarm if it is selected in alarm settings. When
sludge burner stops, the sludge solenoid valve closes the sludge while the steam/air solenoid flushes the sludge
nozzle until the temperature in the combustion chamber is lower than 300°C in order to avoid building up of
coke on the burner tip.
The temperature and pressure in the combustion chamber is controlled by calculations in the control system.
By adjusting:
All checks of temperature are made in time intervals. After each change in state or function, further adjustments
are not made until time interval has elapsed.
At the end of each time interval (30sec), the change in combustion chamber temperature (CCT) is calculated.
Depending of temperature raise (or drop), adjustments are made, according to calculations, to components that
64 OG200C
PROGRAM DESCRIPTION
will influence the combustion chamber temperature (CCT), and the present combustion chamber temperature
(CCT) is stored.
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again.
The CCP set point is controlled by the combustion chamber temperature (CCT), flue gas temperature (FGT)
and burner step.
The control system will adjust the sludge dosage pump (SDP) to keep the combustion chamber temperature
(CCT) at “CCT max. for water injection”(1150°C). The maximum water dosage pump (WDP) RPM starts at
200/600 rpm and increases by “Increase RPM WDP” (5 rpm) every 60 second, until “Max. RPM WDP”
(600/1200) RPM is reached. Water dosage pump (WDP) RPM is controlled as a function of the combustion
chamber temperature (CCT), see illustration.
If combustion chamber temperature (CCT) drops below “CCT min. for water injection”(840°C), the water
dosage pump (WDP) stops.
WDP[RPM]
1200
1000
800
WDP[RPM]
600 WDP[RPM]
400
200
0
840 860 880 900 920 940 960 980 1000 1020 1040 1060 1080 1100 1120 1140 1150
CCT[°C]
OG200C 65
PROGRAM DESCRIPTION
Note: All references to settings and values are for explanation only. The values on your incinerator or
application may be different.
The program assumes a batch load of waste in the incinerator and will have initial speed and pressure set points
to facilitate enough combustion air to handle this (CCP=28 mmWC, burnerstep 1).
All checks of temperature are made in time interval. After each change in state or function, further adjustments
are not made until time interval has elapsed.
At the end of each time interval (40 sec), the change in combustion chamber temperature (CCT) is calculated.
Depending of temperature raise (or drop), adjustments are made, according to calculations, to components that
will influence the combustion chamber temperature (CCT), and the present combustion chamber temperature
(CCT) is stored.
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again according to tabular below.
Delta CCT Delta step 1 Delta Delta Delta step Delta step
step 2 step 3 4 5
CCT < -1C°
STEP CCT -1 to + 3 to +10 to > +17C°
+3C° +10C° +17C°
> 1000C° P +1 0 -2 -4 -5
4 B 0 -1 -1 -1 -2
900 - 1000C° P +2 +1 0 -2 -2
3 B +1 0 -1 -1 -1
700 – 900C° P +4 +3 +2 0 -2
2 B +1 +1 +1 0 0
< 700C° P +8 +6 +4 +2 -1
1 B +1 +1 +1 +1 0
P = Combustion chamber pressure (-mmWC)
B = Burnerstep
The diesel oil burner heats up the incinerator. The burner starts and runs in 3 steps (burner step 1-3). Change in
burner steps are made in time intervals as described above.
When combustion chamber temperature (CCT) reaches set point 1000 °C, the diesel oil burner reduces one
step, and further increase in combustion chamber temperature (CCT), reduces burner to step 1.
At the end of time interval (see description above), corrections are made to combustion chamber pressure
(CCP), according to calculations involving a combination of actual temperature in combustion chamber (CCT)
and the temperature raise (or drop) since last correction.
Combustion chamber pressure is also controlled by the flue gas temperature (FGT). At flue gas temperature
(FGT) above set point (330 °C), the control system overrides calculations made in time interval (as described
above).
66 OG200C
PROGRAM DESCRIPTION
OG200C 67
MAINTENANCE INSTRUCTION
Maintenance instruction
Preventive maintenance
Preventive maintenance periods are defined in the
control system apart from the daily checks. The
control system counts the running hours of the diesel
oil burner. Each group is connected to a list of service
points required to perform. The preventive
maintenance is divided into four groups: Weekly,
monthly, 6 monthly and yearly. Based on experience
the intervals correspond to respectively 100h, 400h,
2500h and 5000h programmed with a service interval
“Hours service”. When the actual running hours since
last performed maintenance exceeds the service
interval the control system calls for service by a pop
up screen.
6 months and yearly service banner will appear, regardless of running hours, when 180/365 days has elapsed.
It is then required to follow the appropriate procedure. When the maintenance has been carried out press
“Done” and “Hours since last service” is reset. If not logged in as user “usr”, values on different setup screens
are “view only”. Also the “Done” buttons are only visible if user “usr” has logged in.
Service hours:
When “Hours since last service” is above
setting “Hours service”, a red banner is
activated in line for the item. By pressing
“Done”, the hour counter “Hours since
last service” is reset to 0 and the red
banner is turned off.
Daily
1. Inspect the combustion chamber. Remove all ash and slag before loading and starting the incinerator.
2. NOTE: The combustion chamber air inlets in the bottom must always be cleaned.
2. Check that combustion air inlets and cooling air inlets on the incinerator casing are free from
obstructions. Clean if necessary.
3. Visually inspect the flue gas outlet for deposits, clean if necessary.
68 OG200C
MAINTENANCE INSTRUCTION
2. Check refractory condition. Check for pieces falling out or big cracks.
3. Clean diesel oil burner, blast tube flame scrod and ignition electrodes.
2. Replace the rubber stator on sludge oil dosage pump and check the rotor for wear. It should have a
smooth polished surface.
6. Lubricate the sluice bearings (if incinerator has sluice). See Sluice Assembly drawing.
7. Lubricate door hinges and check the door gaskets for proper sealing. Use chalk on the edges of the
door opening. Close the door. Open and check that the door gasket had contact with the edge all the
way around the opening. If not adjust the door.
8. Open the inspection hatches on the lower side of the incinerator cooling panel. Clean as required with
steam or hot water.
2. Check the control and alarm system according to "Test of function and safety devices"
4. Check all valves, pumps and solenoid valves for leakage. Repair if necessary
OG200C 69
MAINTENANCE INSTRUCTION
Inspection
ITEM ACTION
Combustion chamber: Monthly check: Check visually the refractory inside the combustion
chamber. If pieces of refractory have fallen out so the insulation or steel is
visible, then use of the incinerator must be discontinued until a repair has
been carried out. Pay attention to residue on the walls. If this is over 20 mm
thick, remove this by means of a wire brush and a paint-scraper. Do not use
a hammer!
Diesel oil pump: Daily check: Check visually for leakage. The pressure is to be checked
daily. If pressure drops below 16 bar and cannot be adjusted by means of
the adjustment screw, clean the filter. (Ref. Appendix D )
To clean the filters, proceed as follows:
Close the valves on supply and return line to D.O. pump. Remove all 8 bolts
at the end the pump opposite the drive-side. Remove the end cover and the
cover gasket.
The filter is now visible and can be pulled out without the use of tools. Clean
the filter in diesel oil and blow dry with compressed air. Reassemble and
adjust the pressure to 16 bar.
Flue gas fan: Monthly check: Check the fan belts for sufficient tightness. Correct
deflection is 10 mm using a force of approx. 3 kg. weight load.
Sludge dosage pump: Weekly check: Check visually for leakage. Turn the shaft by hand to check
it is moving freely.
Water dosage pump19: Weekly check: Check visually for leakage. Turn the shaft by hand to check
it is moving freely.
70 OG200C
MAINTENANCE INSTRUCTION
Photo resistor: The photo resistor should be cleaned by means of a damp cloth every week.
Diesel oil burner: Caution: The main switch must be in OFF position whenever working with
the burner.
For dismantling and re-assembly, see Appendix C. The blast tube, flame
scrod and diesel nozzle should be cleaned every month. This can be
cleaned with Kerosene, White Spirit or Marine Diesel Oil and a brush. The
electrodes should be wiped off with a cloth dipped in one of the above
mentioned agents.
Diesel oil pump: The filter must be cleaned every 6 month. For dismantling and re-assembly,
see Appendix D.
Flue gas fan: The grease in the bearings must be changed every six months. Make sure
the bearings are clean before they are re-greased. Pay special attention to
reinstalling of the top half of the housing to its respective base after re-
greasing. The top halves must not be mixed, each top half is made unique to
the base.
Also check the tension of the V-belts.
Door hinges: Door hinges to be greased every six months. Use ordinary ball bearing
grease.
Sluice: The sluice bearings must be lubricated every month. Use a graphite grease
type Esso Beacon Q2 or equal.
Unscrew the blinding plug and lubricate the nipple. Replace the plug. Also
lubricate the bearing on the opposite side by lubricating the nipple through
the expanded metal.
Pusher: Lubricate the bearings for the pusher with a grease gun every 6-month. Use
heat resistant type (Esso Beacon EP2 or equal).
Sludge burner: The sludge burner should be cleaned every month, if necessary.
For dismantling and re-assembly, see Appendix.
Water injection20: The water injection nozzle should be cleaned every month, if necessary.
For dismantling and re-assembly, see Appendix.
OG200C 71
MAINTENANCE INSTRUCTION
Repair
It is not advisable to repair an impeller unless one has access to balancing equipment.
Replacement
No special procedure is required except for cleaning the shaft and the hub before the hub is
placed on the shaft.
Reassembly
Proceed as for disassembly, in opposite manner.
72 OG200C
MAINTENANCE INSTRUCTION
Performance verification
1. Run the fan in cold and hot condition and listen for noise.
2. Inspect that the fan is able to provide at least 100 mm WC negative pressure in the
combustion chamber. (Cold gas.)
The mounting torque for the various hubs shall be as shown in this table:
Bushing type Set screw type Torque in NM Allen wrench Fan type
type
For re-lubrication of the bearings, the caps must be demounted. The housing base and cap are
matched during manufacture and are not interchangeable. To prevent mixing, the same
consecutive number is marked on the cap and base of each individual housing.
The bearings are mounted with an adaptor sleeve. The bearings have a small internal clearance
and an accurate mounting is very important. When the bearing is properly mounted, the outer
ring can be easily turned, but there should be a slight resistance when the ring is swivelled out.
When mounting a new bearing to the fan’s shaft, the following procedure should be followed:
Before mounting the threads of the nut and the side face of the nut witch is about the bearing
should be greased and the outside diameter of the sleeve should be lightly oiled. The bearing is
then pushed on to the sleeve and the nut screwed on by hand. Check that the bearing is correctly
located on the shaft. Use a hook spanner and turn the nut an angle of 90°. By turning the nut
through this given angle of 90° the bearing will be pressed up on the tapered seating of the
sleeve. Re-position the hook spanner and apply a light hammer blow to the spanner. The bearing
will straighten up on its seating and is correctly fastened to the shaft. Lock the nut but bending
down one of the tabs on the locking washer. The residual clearance of the bearing should be
checked.
OG200C 73
MAINTENANCE INSTRUCTION
74 OG200C
SPARE PARTS
Spare parts
Recommended minimum spare parts
Name / Minimum Spare Parts, OG200/400C/CI, TG5 / Art.No.
Article 17910/17916
Article /
Name (Alle)
OG200C 75
SPARE PARTS
76 OG200C
SPARE PARTS
OG200C 77
SPARE PARTS
78 OG200C
SPARE PARTS
OG200C 79
SPARE PARTS
80 OG200C
SPARE PARTS
OG200C 81
OPERATION INSTRUCTION
For long time storage, TeamTec recommend to place Silica Gel inside the Control Panels.
Once a month, check visually that the Control Panels are not damaged. Special attention must be paid to the
silica gel inside the panels. If there has been humidity in the panel, the Silica Gel must be replaced.
Check that the coating of the steel work is OK. If the coating is damage and the steel is exposed to the
atmosphere, it must be touched up with new paint according to paint spec.
The equipment is delivered with plastic sheet, the plastic sheeting does not offer protection against hot work.
If the incinerator is exposed to high humidity for a period of time, silica gel must be placed inside the control
panel.
Turn the electrical motors for fan, pumps and burner slightly.
If possible, the power should be switched on to the control panel in order to keep the panel dry.
82 OG200C
OPERATION INSTRUCTIONS
Pre-commissioning
Mechanical completion check list.
Prior to function testing at first start up, the following mechanical completion must be checked.
1. Check that the foundation support and the deck strength are adequate for the incinerator unit. (5. ton)
2. Check that flue gas fan foundation is of a sturdy design for fan to run without vibration.
3. Check that the air inlet to the incinerator room has sufficient capacity.
4. Check that the necessary drainpipe are installed and connected.
5. Check that the incinerator door can be fully opened and locked in the installed locking mechanism.
6. Check that the insulation, flue gas duct and flue gas fan is installed and fixed.
7. Check that the flue gas duct is not welded direct into painted wall penetration. (fire hazard)
8. Check that the refractory brickwork has been dried out with a portable heater for 48 hours at
approximately 100°C.
9. Check the diesel oil line for correct hook up, and make sure that no valve is closed on the return line.
(A blocked return line will result in a leak in the diesel oil pump shaft seal)
10. Check the electrical power supply for correct rated protection at the ship distribution board.
11. Check that all pipes (sludge, steam and water) ducts and cables hooked up have been correctly
completed according to arrangement drawings.
12. Check that the “Burn In” program has been run for 10 hours. The “Burn In” program starts with an
combustion chamber temperature at 100°C and increase the temperature 1°C every minute until the
combustion chamber temperature reach 800°C. The Burn In Program is available from the set up
menu in the operator panel when logged in as factory user.
1. Start the flue gas fan and check for correct rotation direction.
2. Start the diesel oil burner and check for correct rotation direction, and that normal diesel oil pressure
is reached.
3. Check that the operator control panel is live, and indicating normal.
4. Make sure that sludge is filled in the sludge tank to a level above the low level switch before starting
the pump. Start the sludge pump and check for correct rotation direction, and normal pressure
indication.
5. Make sure that water is filled in the water tank to a level above the low level switch.
After having checked out the above items, a function test according to this manual can take place
OG200C 83
OPERATION INSTRUCTION
2. FLUE GAS TEMP. HIGH At flue gas temperature above alarm set point,
Adjust alarm set point the alarm will activate and the burner stops.
[Alarm max. FGT]
Flue gas temp. high
below operating temp.
5. MOTOR OVERLOAD The motor stops, the alarm will activate and the
Activate test button at front of burner stops.
the motor circuit breaker.
Thermal failure - motor overload
84 OG200C
OPERATION INSTRUCTIONS
8. DIESEL OIL TEMP HIGH At release of safety thermostat-S3 the alarm will
Start a burner program. activate and the burner stops
Adjust down the safety
thermostat -S3 to below set
Diesel oil temp. high
point for working thermostat -
S4. The safety thermostat require manual reset.
9. DIESEL OIL TEMP LOW At start of heating the alarm activates and the
Adjust alarm set point burner stops.
[Alarm max. time dieselheater
start]
Diesel oil temp. low
to "0".
Start a burner program.
10. DIESEL OIL PRESSURE At pressure switch +2-S1 set point, the alarm
LOW activates and the burner stops.
Start a burner program.
Reduce the fuel oil pressure
by adjusting the pump. Diesel oil press. low
OG200C 85
OPERATION INSTRUCTION
13. STEAM/AIR PRESSURE After 10 sec. alarm activates and the burner
SLUDGE HIGH stops.
Adjust the steam/air pressure
high sludge alarm switch to
Steam/air press. - sludge high
4.5 bar.
14. SLUDGE PRESSURE LOW After 10 sec. alarm activates and the burner
Adjust the sludge pressure stops.
low alarm switch to 0.1 bar.
Sludge pressure low
Start a sludge program.
Close the sludge supply.
15. SLUDGE TEMP LOW Alarm activates and the burner stops.
Start a sludge program.
Adjust set point
[Min. sludge temp run sludge] Sludge temperature low
above actual temperature and
adjust [Alarm sludge temp
low] to 0.
86 OG200C
OPERATION INSTRUCTIONS
16. SLUDGE TEMP HIGH Alarm activates and the burner stops.
Start a sludge program.
Adjust set point
Sludge temperature
[Min. sludge temp run sludge] high
below actual temperature and
adjust [Alarm sludge temp
high] to 0.
17. STEAM/AIR PRESSURE After 15 sec. alarm activates and the burner
WATER LOW/HIGH50 stops.
Adjust the steam/air water
pressure low alarm switch to
1,5 bar. Steam/air press. - Water
high/low
Start sludge with water.
Close steam/air supply.
18. FREQUENCY INVERTER After 10 second delay, alarm activates and the
FAILURE SDP burner stops.
19. FREQUENCY INVERTER After 10 second delay, alarm activates and the
FAILURE WDP51 burner stops.
OG200C 87
OPERATION INSTRUCTION
22. LOW LEVEL SLUDGE After 5 sec. delay the Alarm/Warning activates
SERVICE TANK and burner stops
23. CIRCUIT FAILURE FGT Alarm activates and the burner stops.
Disconnect wire terminal
Circuit failure FGT
+1–X1-114
24. CIRCUIT FAILURE CCT Alarm activates and the burner stops.
Disconnect wire from U2
Circuit failure CCT
terminal 4
25. CIRCUIT FAILURE SDP Alarm activates and the burner stops.
TEMP
Disconnect wire from U3
Circuit failure SDP Temp
terminal 4
88 OG200C
OPERATION INSTRUCTIONS
OG200C 89
OPERATION INSTRUCTION
5. SL. CIRC PUMP (SCP) Pressure gauge should read approx. 0.2 bar. Not possible to
Check sludge tank level. start sludge
If low level on sludge tank :
Start circulation pump by circulation pump
pushing the motor low level in sludge
symbol for SCP in main service tank
menu display.
6. SL. TRANSFER PUMP Start the sludge transfer pump by pump by Not possible to start
(STP) pushing the motor symbol for STP in main menu sludge transfer pump
display. high level in sludge
If applicable settling tank
If high level sludge settling tank:
90 OG200C
OPERATION INSTRUCTIONS
9. SLUDGE a) If not started manually, the sludge circulation Waiting for correct
Check that level in pump and sludge heater will start. Pressure sludge temperature
sludge tank is above low indicator for sludge pressure should read
level. Push the key approx. 0.2 bar and the sludge temperature
"Sludge" from the start must be above start temp. 80°C (Min. sludge
menu display. temp. run sludge)
b) Diesel oil heater will operate 2-5 min. until the Damper closing…
oil temperature has reached normal level.
c) Flue gas fan starts, and after app. 30 sec. the CCP start sludge
burner starts, visualized indicated in main -28mmWg
menu. Burner stage 3
OG200C 91
OPERATION INSTRUCTION
92 OG200C
OPERATION INSTRUCTIONS
OG200C 93
OPERATION INSTRUCTION
14 ALARM IN SYSTEM Start a program when there is incinerator is in Not possible to start
Alarm state. program – Alarm is
active – please check
Alarms
94 OG200C
OPERATION INSTRUCTIONS
Operation instructions
Prior to start
1. Main switch on the control panel is switched to position "ON" .The operator panel is
energised and the Process picture will show in the display.
Slagging
1. Check that there are no flames in the incinerator.
2. Push the "SLAG" key, the flue gas fan will run at a fixed speed when the temperature is
below 170°C (+50 hysteresis).
3. Open the ash door and remove ashes and slag, partly burned cans, can remain. These will
burn out eventually.
NOTE! Combustion air inlet openings at "floor" level must be cleaned.
This is important for a free airflow to the combustion chamber.
Solid Waste
1. Fill the combustion chamber half full with waste (max 400l)
NOTE: The Solid waste program start up sequence assumes a batch load. If the incinerator
is to be heated up without a batch load, choose the sludge program.
2. Close the door.
3. Push the key "START" and choose "SOLID WASTE" from the menu. The flue gas fan will
start and automatically control the pressure in the chamber. If there are conditions not met
required for starting the incinerator, the operator panel will display a message explaining
the condition.
4. When the key "STOP" is pushed, the burner will stop, and the cooling down sequence
starts.
5. When the temperature in the combustion chamber has decreased to 170°C, the flue gas fan
will stop and door locks energized.
Sludge
1. Fill up the sludge tank and activate the heater. This is done by the pressing the heater
symbol on the operator panel. Choose start heater and the heater symbol will change colour
to indicate that the heater is on and the temperature is controlled locally by the thermostat
2. Drain off water from the settling tank. (The sludge should be settled overnight before water
is drained off) . Remember, longer settling time, better settling!
3. Start the filling pump by pressing the pump symbol and choose start pump. The symbol will
change colour to green to indicate that the pump is running. The pump will stop
automatically if the service tank level is high or the settling tank level is low.
4. Start the service tank circulation pump by pressing the pump symbol and choose start pump.
The symbol will change colour to green to indicate that the pump is running. Check the
sludge pressure on the pressure indicator to be in the range of 0.2 bar, adjust if required,
using the by pass valve. Run the circulation pump for at least 1 hour prior to burning
sludge!
OG200C 95
OPERATION INSTRUCTION
5. Check the atomising -air /-steam supply pressure to be 6 - 8 bar. If steam is used, the
condensate must be drained off by use of the valve located at sludge equipment drip tray.
6. Push the key "START" and choose "SLUDGE" from the menu. The flue gas fan will start
and automatically control the pressure in the chamber. If there are conditions not met
required for starting the incinerator, the operator panel will display a message explaining
the condition.
7. The manual regulating valve for air / steam atomising located at sludge equipment drip tray
should be from ¾ to 1 turn open. The pressure should be shown in the upper half of the
green area (3.3 bar or 48 PSI) when the sludge burner/nozzle is clean. If pressure rises, do
NOT adjust the valve, but clean the sludge burner.
8. When the low level in sludge tank, or the key "STOP" is pushed, the burner will stop, and
the cooling down sequence starts.
9. When the temperature in the combustion chamber has decreased to 170°C the flue gas fan
will stop and door locks will be energized.
96 OG200C
OPERATION INSTRUCTIONS
Emergency stop
In the incinerator room.
Turn the main switch at the control panel "OFF".
OG200C 97
OPERATION INSTRUCTION
Trouble shooting
Symptom Probable cause Checkout procedure
1. OPERATOR PANEL 1. Faulty main power supply. Check main switch -Q1
DEAD. Check power supply from main
switchboard.
2. Emergency stop switch Check switch -S1.
open.
3. Faulty fuse for pilot Check fuses –F11 and –F12
transformer.
4. Faulty fuse -F13. Check fuse.
Change stator.
3. Damaged sludge dosing
pump stator.
Adjust to correct setting.
4. Sludge pressure to high. (0.2 bar)
5. Temperature raising 1. Loaded too much waste Stop loading, and tray to block
"uncontrolled" with high calorific value. lower four corner ventilation
slots.
2. Damaged sludge dosing Change stator.
pump stator.
3. Sludge speed control not Check sludge speed.
working.
4. Leaking diesel oil solenoid Change the valve.
valve.
98 OG200C
OPERATION INSTRUCTIONS
OG200C 99
OPERATION INSTRUCTION
10. DRAUGHT FAILURE 1. Leaking sensor tube. Check sensor tube for damage
(low under pressure) and fixing.
12. LOW CAPACITY 1. Blocked air cooling inlet. Clean inlet. (Bottom grating)
100 OG200C
APPENDIX A
102 PLC
APPENDIX A
Appendix A: PLC
General
The Standard PLC contain of 4 units. See Figure 11 and 12.
1 2 3 4
Figure 11
PLC 103
APPENDIX A
Base Unit
Figure 12
104 PLC
APPENDIX A
2. Align the connector on the memory module with the connector pins on the controller.
PLC 105
APPENDIX A
106 PLC
APPENDIX A
Dimension:
A – 90mm (3.5 in.)
B – 27.5mm (1.08 in.)
C – 27.5mm (1.08 in.)
PLC 107
APPENDIX A
Diagnostics
108 PLC
APPENDIX A
PLC 109
APPENDIX A
Error Conditions
110 PLC
APPENDIX B
Touch screen
Figure 14.
See also chapter Operator Panel, page 21, for user functions.
Technical data
COMM and
FAULT LEDs
The operator panel is a RS-232 only display with 1 USB port, and consist of a colour
(320X240) graphics display. Colour terminals support a fixed palette of 32 standard EGA
colours. All colours in an application is defined when the application is created, and not
selectable at the terminal.
The compact flash slot is used to program the display. Normally this will be done by TeamTec
personnel.
The operator panel is connected to the PLC with RS-232 serial communication.
The terminal requires 24VDC.
Reset Button resets the terminal.
Display temperature should be less than 55°C. The CPU temperature should be less than 95°C.
The terminal has two LED indicators isolate operating problems:
COMM indicator (green) for communications
FAULT indicatior (red) for hardware faults
Red LED Green LED Indication
Blinking Off Last firmware download failed. Reload firmware.
Blinking Blinking Boot loader firmware failed or is missing. Reload firmware.
Blinking On Windows CE OS firmware failed or is missing. Reload
firmware.
On Off Fatal hardware error occurred. Contact TeamTec to replace
terminal
On Blinking Fatal hardware error occurred in Display. Contact TeamTec to
replace terminal
Product certification compliance with European Union Directives. EMC tests satisfies EN
50081-1-2:1993 and EN 61000-6-2:1999
Dismantling DO pump
DO pressure gauge
2
5
1. Pull out the photo cell.
3
2. Remove the cover on top of the burner .
Air adjustment.
The Burner damper motor is analogue, and will open the damper proportionally to the control voltage applied
by the control system. The only two checks necessary is Closed position and that it operates freely.
To check that the damper is closed make sure that the damper blade is vertical to the opening when the control
system shows 0% opening (after power up, flue gas fan not running).
To check that the damper operates freely, wind up the actuator by using a 4mm hex key on the top of the
damper motor, then release and observe that the damper closed by the spring action.
DO nozzles
Standard nozzle
Incinerator Nozzle 1 Nozzle 2 Std. pressure DO temp.
OG 200C 2.5 GPH 60 4.5 GPH 45 16 bar 50°C
OG 400C 2.5 GPH 60 4.5 GPH 45 16 bar 50°C
GS 500C 3.5 GPH 60 5.5 GPH 45 16 bar 50°C
GS1000C 4.5 GPH 45° 6.5 GPH 45° 16 bar 50 °C
For special cases other nozzles can be used.
Maintenance
Burner nozzle cannot be repaired.
Capacities
Oil burner nozzle capacities in l/h at various pressures.55
Rated flow 56 Pressure in bar
G.P.H. l/h 10 11 12 13 14 15 16
1,50 5,68 6,82 7,12 7,41 7,71 8,00 8,24 8,47
1,65 6,25 7,41 7,82 8,24 8,53 8,82 9,29 9,76
1,75 6,62 7,88 8,29 8,71 9,06 9,41 9,71 10,00
2,00 7,57 9,06 9,47 9,88 10,29 10,71 11,06 11,41
2,25 8,52 10,24 10,71 11,18 11,59 12,00 12,41 12,82
2,50 9,46 11,29 11,82 12,35 12,88 13,41 13,88 14,35
3,00 11,36 13,53 14,18 14,82 15,47 16,12 16,65 17,18
3,50 13,25 15,88 16,65 17,41 18,06 18,71 19,35 20,00
4,00 15,14 18,12 19,00 19,88 20,65 21,41 22,18 22,94
4,50 17,03 20,35 21,35 22,35 23,24 24,12 24,94 25,76
5,00 18,93 22,59 23,71 24,82 25,82 26,82 27,71 28,59
5,50 20,82 24,82 26,06 27,29 28,35 29,41 30,47 31,53
6,00 22,71 27,18 28,47 29,76 30,94 32,12 33,24 34,35
6,50 24,61 29,41 30,59 31,76 33,53 35,29 36,47 37,65
7,00 26,50 31,76 33,53 35,29 36,47 37,65 38,82 40,00
7,50 28,39 34,12 35,88 37,65 38,82 40,00 41,76 43,53
8,00 30,28 36,47 38,24 40,00 41,18 42,35 44,12 45,88
55
Sp gr 0,85 @ 25C and viscosity 1,3E @ 20°C
56
Pressure = 100 P.S.I.
Applications
Light and medium oil
Nozzle flow up to 110 l/h (2850 rpm, 5 cSt, 10 bar)
Normally associated with in-line solenoid valve.
One or two-pipe system
Bleed
Two pipe operation
During starting period when the gear-set speed is increasing, all the oil passes through a
special flat on the piston, back to the return.
Once the speed reaches a certain value and the flow can no longer pass through this flat,
then the pressure increases rapidly overcoming the valve spring force and opens the valve
Cut-off:
During the stop sequence, the gear-set speed slows down and the valve closes when the gear-set capacity is
lower than the flow.
The cut -on and cut-off speed depends on the set pressure.
Figure 3
Technical data
General
Mounting Flange according to DIN 24220
Connection:
Inlet 1/4" NPTF
Return 1/4 " NPTF
Nozzle outlet 1/8" NPTF
Pressure gauge port 1/8" NPSF
Vacuum gauge port ¼" NPTF
Valve function Pressure regulating cut-off.
Strainer 45 cm² open area 120 opening size.
Shaft 11 mm according to DIN 24220
By-pass plug Inserted for 2 pipe system. To be removed with
3/16" allen key for 1 pipe system.
Weight 4 kg
Rotation Anti-clockwise rotation. Left hand nozzle.
(seen from shaft end).
Hydraulic data
Nozzle pressure range. 10 to 21 bar.
Delivery pressure setting. 16 bar
Viscosity range. 2.8 to 200 cSt
Inlet and return pressure. 1.5 bar max.
Suction height. 0.45 bar max. vacuum to prevent air separation
from oil.
Rated speed. 3600 rpm max.
Oil temperature. Max. 90°C in the pump.
Starting torque. 0.4 N.m
Figure 4 Figure 5
Pump dimensions
Pipe dimensions
The tables below give the maximum length (in meters) of suction line as function of 3 variables:
Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 12 27 51 90
1 14 30 57 99
2 17 36 68 118
3 20 42 79 136
4 22 48 90 155
Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 9 21 41 71
1 8 18 35 61
2 5 12 24 42
3 2 6 13 24
4 0 0 2 5
Installation
The pump is ready for use with 2 pipe systems (i.e. with by-
Figure 6 pass plug fitted, in the return port.)
The inlet and return pressures must not exceed 1.5 bar.
The vacuum must not be more than 0.45 bar to prevent air separation from oil.
It is recommended to use a separate filter upstream of the pump.
The pump is to be used with cylindrical fitting or conical fittings as appropriate and sealing washers. Other
sealants are not recommended.
Start up
Check that the sense of rotation for pump and motor are the same (an arrow is stamped on the pump body).
In order to purge pumps used on 1 pipe systems, loosen one of the high pressure connections. On 2 pipe
systems, purging is automatic.
Pressure regulation
Remove end cap nut from pump for access to pressure stetting screw. Turning the regulator screw clockwise
increases the pressure.
Systematic maintenance
1. Check the stop valve and in line filters.
2. Check the pump filter.
This filter should be cleaned with a soft brush and fuel oil.
Each time, the cover gasket should be changed.
3. Check the tightness of all couplings and unused plugs.
4. Check the shaft coupling.
5. Check the pump pressure.
Fit a pressure gauge in the fitting provided and run the pump in normal manner.
If the pressure required cannot be obtained, check that the pump is completely purged. If
air bubbles are found in the fuel, check all connections for tightness.
6. Check the pump vacuum.
Fit a vacuum gauge in fitting provided and run the pump in the normal manner, making sure
to fully purge the pump.
The vacuum should not exceed 0.45 bar. If this is the case, check condition of all
components (non return valve, stop valves, filters....).
If the pump does not suck correctly, check for any leaks in the line by retightening all
fittings.
Figure 7
Parts list
Pos. no. Description Article no.
Technical characteristics
Degree of protection IP 20 without protective vent cover. IP31 other areas.
Vibration and shock 1 gn from 13 to 150 Hz, 15 g for 11 ms
resistance
(EN60068)
Degree of pollution Degree 2 according to UL840. Protect the drive against dust,
corrosive gases, and falling liquid.
Relative maximum 96% without condensation or dripping water (if there is a risk
humidity of condensation provide a heating system).
Ambient air temp. in Operating: -10°C to +60°C (with vent cover removed)
acc. with EN50178 Storage: -25°C to +70°C
Maximum operating 1000 m. without derating. Above this, derate the current by
altitude 1% for each additional 100 m.
Control
terminals
Power
terminals
Figure 31
Power Terminals
The power terminals must be connected before connecting the control terminals!
Figure 32
Control Terminals
Figure 33
Programming
The Assignment of the “Fast stop” or “Freewheel stop” functions will prevent the drive from starting
if the corresponding logic inputs are nor powered up. The ATV12 then displays “nSt” in freewheeel
stop mode and “FSt” in stop mode. This is normal since these functions are active at zero so that the
drive will be stopped safely if there is a wire break.
Check that the run command input(s) have been actuated in accordance with the chosen control mode
(tCC parameter in the I-O menu).
If an input is assigned to the limit switch function and this input is zero, the drive can only be started
up by sending a command for the opposite direction, see ATV 12 programming manual.
If the LED on the DC bus is lit and nothing appears on the display, check that there is no short-circuit
on the 24 V power supply.
If the drive displays “rdY” and refuses to start, check that there is not short circuit on the 24 V power
supply and check the wiring of input AI1 and LI1.
Weight 22 kg
Figure 34
Technical characteristics
Degree of protection IP 54 / UL Type 12
Maximum operating 1000 m. without derating. Above this, derate the current by 1% for each
altitude additional 100 m.
Breaking torque 30% of the nominal motor torque without braking resistor (typical value)
Up to 130 % with braking resistor installed as an option,
Speed controller - Galvanic isolation between power and control circuits (inputs,
protection and safety outputs, supplies)
Thermal protection:
- against overheating and of the power stage
Protection against:
- short-circuits between motor phases and input phase breaks
- overcurrents between output phases and earth
- overvoltages on the DC bus
- a break on the control circuit
- exceeding the limit speed
Safety function for:
- line supply overvoltage and undervoltage and input phase loss, in 3-
phase
Motor protection Thermal protection integrated in drive via continuous calculation of I2t
taking speed
into account:
b The motor thermal state is saved when the drive is powered down.
b Function can be modified via operator dialogue terminals, depending
on the type
of motor (force-cooled or self-cooled).
Protection against motor phase breaks
Power cable
A standard power cable, 3 x 1,5 + E, from control panel to frequency inverter flue gas fan, ATV61, yard
supply. TeamTec recommend a cable type LM-HF 0,6/1 kV or similar type.
To access the power terminal on frequency inverter for flue gas fan, unlock the power part access flap and
remove it as shown below:
Motor cable
From U/T1, V/T2 and W/T3 on frequency inverter flue gas fan to motor for flue gas fan, you must use a
shielded motor cable, yard supply. TeamTec recommend a cable type LSM-HF 0,6/1kV or similar type.
Shielded cable for motor connection with shielding connected to ground at both end. The shielding must be
continuous and intermediate terminals must be in EMC shielded metal boxes. Connect the shield to ground at
each end by using EMC Cable Gland. The frequency inverter cabinet is delivered with two EMC cable glands
with nut. M40 is to be used for motor cable. The shield is to be grounded on the EMC cable gland.
If using conduit, do not lay the motor, power supply and control cables in the same conduit. Keep the metal
conduits containing the power supply cables at least 8 cm (3 in.) away from the metal conduit containing the
control cables. Keep the non-metal conduits or cable ducts containing the power supply cables at least 30 cm
(12 in.) away from the metal conduits containing the control cables. If necessary for control and power cables
to cross each other, be sure they cross at right angles.
NOTE: EMC-filter, on frequency inverter flue gas fan, is not dimensioned for motor cable length over 15
meters. Depending on the cable lengths it may be necessary to use an output filter.
Figure 31
Power Terminals
Maximum connection
AWG 14 – 2,5 mm2
capacity:
Tightening torque: 3.0 Nm
Figure 32
Control Terminals
Figure 33
Programming:
Faults that can be reset with the automatic restart function, after cause has
disappeared
These faults can also be reset by turning on and off or by means of a logic input or control bit ({Fault reset]
(rSF) parameter). APF, SnF, COF, EPF1, EPF2, FCF2, LFF2, LFF3, LFF4, nFF, ObF, OHF, OLC, OLF,
OPF1, OPF2, OSF, OtF1|, OtF2, OtFL, PHF, PtF1, PtF2, PtFL, SLF1, SLF2, SLF3, SPIF, SSF, tJF and ULF
faults can be inhibited and cleared remotely by means of a logic input or control bit ({Fault inhibit assign.]
(InH) parameter.
Faults that can be reset with the automatic restart function, after the cause has
disappeared (continued)
Loosen setscrews (A), and nut (B) and pull out the external pipe (C).
Clean the external (C) and internal (D) pipes.
After cleaning, re-assemble the sludge burner in reverse order.
Check that internal pipe (D) is centred (concentric) in the external pipe (C), adjust with set-
screw (A) according to the adjustment procedure below.
Dimension
Weight:19,5 kg
Figure 34
Figure 35
Figure 35
Installation
Installation and Safety Recommendations
In common with other items of process plant a pump must be installed correctly to ensure satisfactory and safe
operation. The pump must also be maintained to a suitable standard. Following these recommendations will
ensure that the safety of personnel and satisfactory operation of the pump is achieved.
General
When handling harmful or objectionable materials, adequate ventilation must be provided in order to disperse
dangerous concentrations of vapours. It is recommended that wherever possible pumps should be installed with
provision for adequate lighting, thus ensuring that effective maintenance can be carried out in satisfactory
conditions. With certain product materials, a hosing down facility with adequate draining will simplify
maintenance and prolong the life of pump components.
Storage
Short-term storage
Where a pump has to be stored for 6 months or less then the following steps are advised:
1. Store pump inside wherever possible or if this is not feasible then provide protective covering. Do not
allow moisture to collect around the pump.
2. Remove the drain plug, if fitted. Any inspection plates fitted should also be removed to ensure that the
suction housing could drain and dry completely.
3. Loosen the packing gland and inject sufficient grease into the stuffing box. Tighten the gland nut
hand tight. If a water flush system is to be used do not grease, a small amount of light oil is
recommended for these.
Long-term storage
If the pump is to be kept in storage for more than six months then in addition to the above the following
procedures should be carried out regularly (every 2 - 3 weeks if possible):
1. If practicable rotate the pump at least three quarters of one revolution to avoid the rotor setting in the
stator.
2. Note, however, that the pump is not to be rotated for more than two revolutions each time because
damage could be caused to the rotor/stator elements.
Electrical
Electrical connection should only be made using equipment suitable for both rating and environment. Where
any doubts exist regarding the suitability of equipment, supplier should be consulted before proceeding.
Normally the pump should be installed with starting equipment arranged to give direct on line starting.
Earthing points will be provided on electric drives (if supplied) and it is essential that these are correctly
connected. When the motor is being wired and checked for rotation, the start/stop sequence must be
instantaneous to prevent dry running or pressurising upstream equipment. (Check direction arrow on pump
nameplate). The electrical installation should include appropriate isolating equipment to ensure that the pump
unit is safe to work on.
Important
The pump must never run against a closed inlet or outlet valve, as this could result in mechanical failure.
General safety
Great care must be taken to protect all electrical equipment from splashing when hosing down.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness before operation.
To eliminate vibration, the pump must be correctly aligned with the drive unit, and all guards must be securely
flexed in position. When commissioning the plant, all joints in the system must be checked thoroughly for
leakage.
If, when starting, the pump does not appear to operate correctly, the plant must be shut down immediately and
the cause of the malfunction established before operations are recommenced. It is recommended that
depending upon plant system operation, either a combined vacuum and pressure gauge, or a vacuum gauge only
be fitted to the pump inlet port, and a pressure gauge fitted to the outlet port, these will then continuously
monitor the pump operating conditions.
Start-up procedure
Pumps must be filled with liquid before starting. The initial filling is not for priming purposes, but to provide
the necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid
will normally be trapped in the rotor/stator assembly to provide lubrication upon re-starting.
If, however, the pump has been left standing for an appreciable time, moved to a new location, or has been
dismantled and re-assembled, it must be refilled with liquid and given a few turns before starting. The pump is
normally somewhat stiff to turn by hand owing to the dose rotor/stator fit. However, this stiffness disappears
when the pump is running normally against pressure.
Dryrunning
Never run the pump in a dry condition even for a few revolutions, the stator will be damaged
immediately. Continual dry running could produce some harmful or damaging effects.
Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the pump.
Warning/control device
Prior to operating the pump, if any warning or control devices are fitted these must be set in accordance with
their specific instructions.
When pump performance has reduced to an unacceptable level one or possibly both items will need replacing.
Diagnostic chart
SYMPTOMS POSSIBLE CAUSES
1 NO DISCHARGE 1.2.3.7.26.28.29.
2 LOSS OF CAPACTY 3.4.5.6.7. &: 9.10. 11.13. 16.17.21.22.23.29.
3 IRREGULAR DISCHARGE 3.4.5.6.7.8.13.15.29.
4 PRIMING LOST AFTER START 3.4.5.6.7.8.13.15.
5 PUMP STALLS AT START UP 8.11.24.
6 PUMP OVERHEATS 8.9.11.12.18.20.
7 MOTOR OVERHEATS 8.11.12.15.18.20.
8 EXCESSIVE POWER ABSORBED BY PUMP 8.11.12.15.18.20.
9 NOISE AND VIBRATION 3.4.5.6.7.8.9.11.13.15. 18.s~19. 20.22.23.27.
10 PUMP ELEMENT WEAR 9.11..
11 EXCESSIVE GLAND OR SEAL WEAR 12.14.25.30.
12 GLAND LEAKAGE 13.14.
13 SEIZURE 9. 11.12.20.
Figure 37
Valve
Valve housing Brass
Repair kit for sludge valve article no. 12806 consist of:
Figure 38
Model 40WYXH-6-20
Marine Sludge Oil Circulation Pump
Operation Instruction
1.General information
Model 40WYXH-6-20 marine sludge oil circulation pump is a motor-
driven horizontal sludge oil pump (Reference to as residual oil pump
hereinafter).
Pumps of this series are suitable for delivering heavy oil and sludge oil
with temperature up to 90℃. This is a piece of equipment optimal for
completion of incinerator in water treatment plant.
1.1Type designation
40 WY XH ─ 6 ─ 20
Pressure at rated flow0.20Mpa
Rated flow 6m3/h
Circulation pump
Sludge oil(residual oil)
Inlet and outlet dia40mm
2.Structure and Features
2.1Structure (See fig.)
A. Pump of this series is composed of casing, impeller, locking bolts,
sealing device, motor and etc.
B. Pump of this series is a horizontal pump with the motor at rear and
pump in front coupled together. The pump uses semi-open impeller
which is directly connected to motor output shaft.
C. Inlet and outlet of the pump shall be connected to external with
standard four-step four-hole flanges.
2.2 Features
Pumps of this series feature high discharge power, good sealing
performance, thermal resistance, high efficiency and energy saving.
3.Selection of Main Part and Component Materials
a. Pump casing, rear pump casing and impeller are made of ductile cast
iron.
b. Metal bellow mechanical sealing ring is used as shaft seal。
Packing list
Inspection:____________ Packing:____________Date:____________
Dimension
Weight:19,5 kg
Figure 39
Figure 40
Figure 35
Figure 41
Installation
Installation and Safety Recommendations
In common with other items of process plant a pump must be installed correctly to ensure satisfactory and safe
operation. The pump must also be maintained to a suitable standard. Following these recommendations will ensure that
the safety of personnel and satisfactory operation of the pump is achieved.
General
When handling harmful or objectionable materials, adequate ventilation must be provided in order to disperse
dangerous concentrations of vapours. It is recommended that wherever possible pumps should be installed with
provision for adequate lighting, thus ensuring that effective maintenance can be carried out in satisfactory conditions.
With certain product materials, a hosing down facility with adequate draining will simplify maintenance and prolong
the life of pump components.
Storage
Short-term storage
Where a pump has to be stored for 6 months or less then the following steps are advised:
1. Store pump inside wherever possible or if this is not feasible then provide protective covering. Do not allow
moisture to collect around the pump.
2. Remove the drain plug, if fitted. Any inspection plates fitted should also be removed to ensure that the
suction housing could drain and dry completely.
3. Loosen the packing gland and inject sufficient grease into the stuffing box. Tighten the gland nut hand tight.
If a water flush system is to be used do not grease, a small amount of light oil is recommended for these.
Long-term storage
If the pump is to be kept in storage for more than six months then in addition to the above the following procedures
should be carried out regularly (every 2 - 3 weeks if possible):
1. If practicable rotate the pump at least three quarters of one revolution to avoid the rotor setting in the stator.
2. Note, however, that the pump is not to be rotated for more than two revolutions each time because damage
could be caused to the rotor/stator elements.
Electrical
Electrical connection should only be made using equipment suitable for both rating and environment. Where any
doubts exist regarding the suitability of equipment, supplier should be consulted before proceeding. Normally the
pump should be installed with starting equipment arranged to give direct on line starting.
Earthing points will be provided on electric drives (if supplied) and it is essential that these are correctly connected.
When the motor is being wired and checked for rotation, the start/stop sequence must be instantaneous to prevent dry
running or pressurising upstream equipment. (Check direction arrow on pump nameplate). The electrical installation
should include appropriate isolating equipment to ensure that the pump unit is safe to work on.
Important
The pump must never run against a closed inlet or outlet valve, as this could result in mechanical failure.
General safety
Great care must be taken to protect all electrical equipment from splashing when hosing down.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness before operation. To
eliminate vibration, the pump must be correctly aligned with the drive unit, and all guards must be securely flexed in
position. When commissioning the plant, all joints in the system must be checked thoroughly for leakage.
If, when starting, the pump does not appear to operate correctly, the plant must be shut down immediately and the
cause of the malfunction established before operations are recommenced. It is recommended that depending upon
plant system operation, either a combined vacuum and pressure gauge, or a vacuum gauge only be fitted to the pump
inlet port, and a pressure gauge fitted to the outlet port, these will then continuously monitor the pump operating
conditions.
Start-up procedure
Pumps must be filled with liquid before starting. The initial filling is not for priming purposes, but to provide the
necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid will
normally be trapped in the rotor/stator assembly to provide lubrication upon re-starting.
If, however, the pump has been left standing for an appreciable time, moved to a new location, or has been dismantled
and re-assembled, it must be refilled with liquid and given a few turns before starting. The pump is normally
somewhat stiff to turn by hand owing to the dose rotor/stator fit. However, this stiffness disappears when the pump is
running normally against pressure.
Dry running
Never run the pump in a dry condition even for a few revolutions, the stator will be damaged immediately.
Continual dry running could produce some harmful or damaging effects.
Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the pump.
Warning/control device
Prior to operating the pump, if any warning or control devices are fitted these must be set in accordance with their
specific instructions.
When pump performance has reduced to an unacceptable level one or possibly both items will need replacing.
Diagnostic chart
SYMPTOMS POSSIBLE CAUSES
1 NO DISCHARGE 1.2.3.7.26.28.29.
2 LOSS OF CAPACITY 3.4.5.6.7. &: 9.10. 11.13. 16.17.21.22.23.29.
3 IRREGULAR DISCHARGE 3.4.5.6.7.8.13.15.29.
4 PRIMING LOST AFTER START 3.4.5.6.7.8.13.15.
5 PUMP STALLS AT START UP 8.11.24.
6 PUMP OVERHEATS 8.9.11.12.18.20.
7 MOTOR OVERHEATS 8.11.12.15.18.20.
8 EXCESSIVE POWER ABSORBED BY PUMP 8.11.12.15.18.20.
9 NOISE AND VIBRATION 3.4.5.6.7.8.9.11.13.15. 18.s~19. 20.22.23.27.
10 PUMP ELEMENT WEAR 9.11..
11 EXCESSIVE GLAND OR SEAL WEAR 12.14.25.30.
12 GLAND LEAKAGE 13.14.
13 SEIZURE 9. 11.12.20.
DRAWINGS
184 DRAWINGS