OPEC Oil Mop Skimmers Operator’s Manual
TABLE OF CONTENTS SECTION
TITLE
PAGE NO.
SECTION 1 – EQUIPMENT DESCRIPTION 1.0 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6
EQUIPMENT DESCRIPTION NOTES FOR OPERATORS INTRODUCTION TYPES OF MACHINE E-SERIES LAC TYPE-III E-SERIES B TYPE-III OM TYPE HV TYPE ANCILLARY ITEMS KEY PARAMETERS DIMENSIONS WEIGHTS POWER REQUIREMENT SPECIFICATIONS MATERIALS OF CONSTRUCTION MOP SELECTION
3 4 4 5 5 5 6 6 6 9 9 9 9 10 10 10
SECTION 1 – DRAWING AND CHART REFERENCES 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
VISCOSITY RECOVERY CHART ANCILLARY EQUIPMENT: FP31C ANCILLARY EQUIPMENT: STORAGE TANK ANCILLARY EQUIPMENT: MOUNTING FRAMES ANCILLARY EQUIPMENT: ORA – OUTRIGGER ARMS ANCILLARY EQUIPMENT: VFR – VERTICAL GUIDE ROLLER TYPICAL E-SERIES SCHEMATIC - 14.01.09.117 E-SERIES TYPICAL SET UP 1 E-SERIES TYPICAL SET UP 2 E-SERIES TYPICAL SET UP 3 HV C/W DEPLOYMENT FRAME – 2” TANK CLAMP FOR HV – GA HV DESCRIPTION HV TYPICAL SET UP 1 – 08.05.09.179
11 12 13 14 15 16 17 18 19 20 21 22 23 24
SECTION 2 – INSTALLATION AND MAINTENANCE 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.6.2 2.7 2.8 2.9 2.10 2.10.1 2.10.2 2.11
INSTALLATION AND MAINTENANCE SAFETY NOTICE SPECIAL CONDITIONS OF SAFE USE IN AN EXPLOSIVE ATMOSPHERE POWER POISITIONING PRIMING THE SEPARATOR INSTALLATION AND FITTING THE MOP E-SERIES HV JOINING THE MOP – METHOD 1 JOINING THE MOP – METHOD 2 JOINING THE MOP – METHOD 3 MAINTENANCE REMOVAL OF THE SAFETY COVER INSPECTION SPARES
25 26 26 27 27 27 27 27 28 29 29 29 30 30 30 33
SECTION 2 – DRAWING AND CHART REFERENCES 2.0 2.0 2.0 2.0 2.0 2.0
FITTING THE MOP TO THE E-SERIES FITTING THE MOP TO THE HV MOP INLET ANGLES MOP JOINING METHOD 1 MOP JOINING METHOD 2 MOP JOINING METHOD 3
36 37 38 39 40 41
SECTION 3 – TECHNICAL INFORMATION 3.0 3.1 3.2
TECHNICAL INFORMATION SERVICE ENQUIRIES TROUBLESHOOTING
42 43 44
SECTION 3 – DRAWING AND CHART REFERENCES 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0
GA – E-SERIES LAC MKII – 212.05.10.09.001 GA – E-SERIES LAC C/W ST5 – 210.05.10.09.001 GA – E-SERIES LAC C/W ST25 – 211.05.10.09.001 E-SERIES MAIN PLATE ASSEMBLY LAC – 23.10.08.95 E-SERIES UPPER ROLLER ASSEMBLY LAC – 23.10.08.094 E-SERIES LOWER ROLLER ASSEMBLY LAC – 23.10.08.093 GA – HV C/W ST5 GA – HV HV ASSEMBLY
45 46 47 48 49 50 51 52 53
SECTION 4 – SPECIFIC DATA 4.0 4.1 4.2
SPECIFIC DATA MOTOR/GEARBOX/MISC CERTIFICATES/DECLARATIONS/WARRANTY
54 55 58
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3
1.0 EQUIPMENT DESCRIPTION 1.1 NOTES FOR OPERATORS Prior to first start up, please read all the Chapters thoroughly and fully acquaint yourselves with all the details of this manual. Damages caused by incorrect operation cannot be claimed for under warranty repair or replacement. When ordering spare parts, please always advise: •
• • •
Type and serial number (located on the metal plate attached to the back plate, the number is made up of 7 digits, e.g. 0401408. The first 2 refer to the year of manufacture, the second 2 to the month of manufacture and the last digits refer to the individual machine’s number). Description of required accessory part. Spare part number. (See Spares Lists) Where applicable the drawing number.
1.2 INTRODUCTION The basic element of the OPEC method of recovering oil from the surface of water is a specially manufactured fibrillated polypropylene yarn which is woven and sewn into flat section continuous lengths which form the OPEC Oil Mop. This latest type of mop is the result of research and development by the Company since the 1970’s. The application of the mop principle is mainly used for recovering oil from the surface of water in a multitude of industrial and emergency situations. The principle of the hydrophobic/oleophillic properties of polypropylene is now an established fact and these properties have been exploited to the full in the latest developments from the OPEC stable. The ‘E’ Series oil recovery systems utilise a third generation mop drive/oil extraction unit combined with the latest developments in continuous oil mops coupled with exclusive well developed accessories all of which contribute to providing a safe, efficient, reliable and cost effective installation.
The CONTINUOUS MOP is constructed from woven packs of polypropylene fibres continuously sewn on to a central load carrying polypropylene tape. The fibre packs are produced by a weaving and slitting process which results in a mop with single ended fibres which eliminates the problems of debris becoming caught up or snagging during operation. The manufacturing process locks in the fibres which ensure that they cannot be pulled out during operation, except with extreme difficulty. There are different sizes and grades of mop to suit different duties and types of oil. One of the features of the CMF type mops is the ease of joining the lengths into a continuous loop of any desired length.
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Vertical GUIDE ROLLERS or FLOATING PULLEYS may be used to direct the mop where desired on the surface of the water depending on the type of installation, in some cases it may not be necessary or practical to use pulleys or rollers in which case the mop is allowed to fall vertically on to the water surface. In common with all the latest OPEC Equipment the
4
The MOP DRIVE/OIL EXTRACTOR units perform two functions, one is to propel the continuous loop of mop along the water surface at the most efficient speed to enable it to absorb oil efficiently, and secondly the drive rollers are coated with an elastomer which squeezes the mop sufficiently to extract the absorbed oil without causing wear or damage to the mop fibres. The units are designed for ease of operation and maintenance and the loops of mop can be fitted to the machine in the ready joined condition.
mops can be fitted to the rollers and pulleys in the ready joined condition. The ‘HV’ unit is designed to operate with the mop deployed vertically without the use of guides or pulleys etc. However these may be used in exceptional cases should conditions or circumstances so dictate. The ‘E’ Series and HV mop drive/oil extraction units have been designed with SIMPLICITY in mind. They are: • • •
Simple to use. Simple to install. Simple to maintain.
They will give many hours trouble free service but in return require a basic amount of maintenance which amounts to no more than cleaning and checking. We strongly recommend that the procedures laid out in this operator’s manual are closely followed and this will ensure the systems operate trouble free. 1.3 TYPES OF MACHINE 1.3.1 E-SERIES LAC TYPE-III The equipment is a mop drive/oil extraction unit which comprises of a main unit which incorporates a continuously revolving mop. It is built around 3x 6mm stainless steel (304) plates which act as the structure to which all other components are assembled. There is a speed reduction gearbox which is assembled on the outside of the main plate and which is driven directly by an electric motor. The main shaft is fitted into the gearbox sleeve and a project into the inside of the main frame, this shaft carries a drive gear and the upper main roller. The lower main roller is carried in two self lubricating bearings which are integral with the modified carrying arms, these are in turn carried in mating sockets attached to a pivoting shaft allowing the lower roller to move relative to the upper one. This carrier shaft is tensioned against the upper roller buy a bonded ‘rubber in compression’ unit which may be released by a toggle lever when the rollers need parting for inspection or threading the mops. The pressure applied may be adjusted within limits by a threaded rod on the toggle lever. The lower roller shaft is carried in simple replaceable nylon bushes. There is a large diameter, shaped, plastic guide roller carried on a stainless steel shaft which is positioned at the upper front of the main machine and this guides the mop on to the rollers in the correct position, also carried on the shaft is a drip tray which prevents oil and debris which may fall from the incoming mop onto the outgoing run of the mop. The complete machine is protected from the weather by an all-over stainless steel cover which pivots from the rear plate and is attached with two toggle fasteners.
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1.3.2 E-SERIES B TYPE-III Is as above but utilizes a drive pulley and belt arrangement to enable the unit to be powered by a Diesel Engine. This model is commonly used for the rapid response mobile units which
5
The CMF mop is of a flat configuration with the working strands of fibrillated polypropylene running transversely from a centre load bearing tape of close woven polypropylene thread which gives a very dense narrow fabric that is highly resistant to aggressive fluids, has high tensile strength with very low stretch, and has a specific gravity of around 0.9 which gives it positive buoyancy. (See Drawing. 14.01.09.117-Schematic)
are trailer mounted. The benefit been that they can be powered anywhere without the need for an electricity supply. 1.3.3 OM TYPES These systems are intended to be suspended from deck cranes or similar and use virtually standard E-series units mounted to specially designed sumps which carry 2,4,6, or 8 units in a basically square configuration. 1.3.4 HV TYPE The basic unit is built around a folded steel chassis plate which forms the backbone of the unit and all other components are assembled on to this frame. There is the speed reduction gearbox which is mounted on the outside of the main plate and the drive motor is flange mounted directly coupled to the gearbox. The main shaft is fitted onto the gearbox sleeve and projects into the inside of the main frame through a heavy duty ball journal bearing. The lower drive roller is overhung on the main shaft and is secured to it by a long through bolt screwed into the inner end of the main shaft stub. Drive is transmitted to the roller via a dowel key which engages with a slot in the end of the roller sleeve. Because this roller is overhung the mop may be installed even when it has been pre-joined into a continuous loop. The upper squeeze roller is identical to the lower one and is carried on two heavy duty self aligning ball journal bearings. The two bearings are bolted to the upper part of the main plate. The rollers are fixed and the squeeze pressure is set when the machines are assembled. There are two adjustable arms fitted with tube rollers which guide the mop into and out of the main squeeze rollers, these arms may be positioned to give the most favourable spread of mop, there are two sets of hole positions depending on whether a wide or narrow spread of mop is required. A steel sump with drain stub is bolted to the bottom of the main frame. An overall stainless steel safety cover is provided for general protection which has to be positioned after the mop has been installed on to the rollers, the cover is secured with two plastic hand knobs. The cover also guides the mo onto the rollers when in operation. 1.3.5 ANCILLARY ITEMS GENERAL OPEC provides a range of accessories to enhance the performance and assist in the configuration of the mop skimmer systems. These accessories allow the mop to be positioned accurately as well as aid in the collection of the recovered oil. FLOATING PULLEYS Used to determine the flow pattern of the mop in emergency spill operations for horizontal deployment of the mop. The pulley wheel is polypropylene. (See Drawing. 204.08.10.09.001)
GUIDE ROLLERS There are two types of OPEC Guide Rollers:
6
•
Are for use in emergency deployment installations Minimise abrasion of the mop material Ensure maximum efficiency of the equipment installed Suitable for creating bund around on-site working equipment which can stand inside the bund if required Allow the mop configurations to be altered easily by the lengthening or shortening of tension ropes
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• • • •
GR - A fixed rotational float which moves the mop in a desired configuration, and be designed and constructed meet individual installation requirements. See Info sheet.
VFR (Variable Floating Roller) - A float which encompasses a special frame that allows the roller to float on the interface of the water and oil regardless of the level of water present. This type of guide roller is used where the water level fluctuates so that the mop is always positioned correctly in the water. See Info sheet.
Guide Rollers: • • • • •
Are for fixed installations Are produced with a variety of mounting arrangements Are bespoke to the requirements of the installation Minimise abrasion of the mop Maximise efficiency of the mop skimmer systems
OUTRIGGER ARMS The outrigger arms are used for both fixed installations and emergency response to allow the mop to be vertically deployed. The main reason for this is to create a further 1 metre (approximately) of mop on the oil/water surface thus allowing for further adsorption of the floating oils or chemicals. This increases the efficiency and effectiveness of vertically deployed permanent mop skimmer installations. Outrigger arms can be single or double roller and are usually 1 metre in length but can be made bespoke to your requirements. (See Drawing. 14.01.09.117-Schematic & Typical set up Drawings) WIND CANOPIES: • • • • •
Prevents oil from being blown outside of the polluted area Can be easily removed for maintenance of the machine Improves efficiency of oil retention of the mop Is an added safety feature especially in hazardous environments (See Drawing. 14.01.09.117-Schematic & Typical set up Drawings)
MOUNTING FRAMES Mounting Frames are exclusively for permanent installations to position the skimmer directly over the oil/water surface. The mounting frame’s main purpose is safety in maintenance. The ST Tanks are fitted with nylon wheels which allow the skimmer to be retracted from its deployment position via the mounting frame channels for general maintenance. (See Drawing. 14.01.09.117-Schematic) RECOVERED OIL STORAGE TANKS These tanks are for use in permanent installations. Unlike the OPEC range of Flexitanks and Pillow Tanks which are for emergency response situations.
Page
They are designed to be incorporated below the mop skimmer machine so that the storage tank which can then be either pumped into road tankers or piped to another destination for the next stage of the recovery process.
7
Tanks can be fabricated in mild steel, stainless or GRP and are made to order depending on the installation requirements.
HV STANDARD DEPLOYMENT FRAME Is designed to provide a means of supporting the ‘HV’ unit for use in a multitude of different situations. It may be used with horizontal legs facing forward for situations where the legs are long enough or wide enough to straddle the aperture through which the mop is deployed, these could include channels, drains, manholes, interceptor covers, etc. The angled support arm has been fixed at a height which allows for a recovered oil storage container up to the size of a standard 225 litre oil drum to be placed underneath the rear drain opening. It may also be deployed with the legs facing rearward and the machine cantilevered over a tank, interceptor, steam, separator, etc. In this case it is imperative that counterbalance weights are used either in the form of recovered oil container placed on a platform or pallet on the legs, or custom made weights which locate in holes in the ends of the legs. Whichever method is used it is ESSENTIAL that the counterweights, in whichever form is chosen, are placed on the stand legs BEFORE attaching the ‘HV’ unit. The ‘HV’ unit is attached to the stand by inserting the drain stub into the upper end of the angled cross pipe, there is a hole drilled in the top of the drain stub which mates with a locating bolt in the end of the cross pipe. Ensure that the bolt is screwed fully home so that it will prevent the unit from rotating. The cross pipe, which is also the oil drain, is mounted with a horizontal pivot and an adjusting screw, this enables the mop machine to be levelled up when the stand has been finally positioned. It is necessary to set the roller level so that when the machine is in operation the mop runs in the centre of the cover aperture. The stand may be used without horizontal legs by clamping the vertical member to horizontal pipes etc. such as standard handrails; this enables the mop to be deployed into interceptors, tanks, separators, which are normally guarded by handrails. HV Counterbalance Weights Are available which can be located at the ends of the horizontal legs which enable the machine to be cantilevered out on the opposite side to the legs. HV Pipe Clamps May be used to secure the vertical member of the deployment stand to horizontal rails such as those normally found around interceptors, pits, deep drains, separators, etc. This enables the unit to be used overhanging the water without using counterbalance weights and with the unit fully secured to fixed secured to fixed rails.
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8
HV Deployment Shafts Are available for deploying the ‘HV’ unit into underground interceptors or drains, either for permanent or temporary use, where wind or security etc., could be a problem. The shaft can be totally enclosed with the drain pipe existing through the side of the shaft into a suitable storage tank.
1.4 KEY PARAMETERS 1.4.1 DIMENSIONS (mm) E-SERIES (UNIT ONLY)
308 WIDE x 530 LONG x 450 HIGH
ST5
610 WIDE x 750 LONG x 435 HIGH
ST25
750 WIDE x 1230 LONG x 435 HIGH
HV (UNIT ONLY)
200 WIDE x 425 LONG x 340 HIGH
1.4.2 WEIGHTS E-SERIES (UNIT ONLY)
49 KG
E-SERIES – STD MOTOR
5.5 KG
E-SERIES – ATEX MOTOR
19 KG
E-SERIES – AIR MOTOR
5.5 KG
E-SERIES – HYDRAULIC
2 KG
ST5 TANK
43 KG
ST25 TANK
52KG
HV (UNIT ONLY)
21 KG
HV – STD MOTOR
3-12 KG
HV – AIR MOTOR
4.5 KG
HV – HYDRAULIC
2 KG
1.4.3 POWER REQUIREMENT (E SERIES) • • • •
ELECTRIC DIESEL HYDRAULIC AIR
0.37 kW 3.5 kW 15 LITRES/ FLOW @ 125 BAR. 800 LITRES/FLOW @ 4.2 BAR.
1.4.3 POWER REQUIREMENT (HV) • • •
ELECTRIC HYDRAULIC AIR
1.4.4 SPECIFICATIONS E-SERIES RECOVERY RATE (MAX) (SINGLE MOP)
0.18 kW 15 LITRES/ @ 125 BAR. 800 LITRES/MIN FLOW @ 4.2 BAR.
4” (100mm) – 2000 l/hr 6” (150mm) – 4000 l/hr 9” (230mm) – 6000 l/hr
MOP SPEED (NOM FIXED)
16M/MIN
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Maximum capacities are given. Capacity can only be achieved when recovering light oils with OPEC‘CMFSTD’ Mop with a constant oil layer thickness of 15mm in ambient temperate climate conditions.
9
Recovery rates are based on a normal fixed rotating mop speed of 16m/min.
MOP LENGTH (MAX)
100METERS
ST5 TANK CAPACITY
155 L
ST5 OIL RETENTION
30 L
ST25 TANK CAPACITY
320 L
ST25 OIL RETENTION
120 L
1.4.4 SPECIFICATIONS (HV) RECOVERY RATE (MAX)
4” (100mm) – 600 l/hr
(SINGLE MOP) Recovery rates are based on a normal fixed rotating mop speed of 16m/min.
1.4.5 MATERIALS OF CONSTRUCTION (E SERIES & HV) MAJOR COMPONENTS 304 STAINLESS STEEL MAIN ROLLERS
POLYURETHANE COATED MILD STEEL
ST5 TANK
304 STAINLESS STEEL
ST25 TANK
304 STAINLESS STEEL
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10
1.4.6 MOP SELECTION In most cases the mops are supplied already factory joined into continuous loops, if for any reason the customer wishes to or is required to join a mop the following methods are preferable. Mops are supplied in 2 formats, the first is CMF STANDARD, and this mop is recommended to recover less viscous oils. The second is CMF XD, this mop is recommended to recover more viscous oils. (Refer to the chart on following page)
5000
STD
XD
PERCENT OF MAX RECOVERY RATES FOR OPEC MOPS IN RELATION TO OIL VISCOSITY (cSt)
Heavy Fuel Oil
Beatrice Crude
Fuel Oil Emulsion
Medium Fuel Oil
Venezuelan Heavy Crude
Light Fuel Oils
Lube Oils
0
20
40
60
100
80
PERCEN NT OF RECOVERY RATE
120
Light Petroleum
Ancillary FP 31C FLOATING PULLEY
The photograph below shows to good effect the simplicity and straight forward design of the FP 31C Floating Pulley. The frame is made of 2 polypropylene plates, the centre guide roller is also polypropylene, and the 4 floats are closed cell polyethylene foam, held in place with stainless steel shafts.There are many hundreds of these in service and they are particularly useful for deployment of mops in emergency situations.
FP31C Floating Pulleys:
Are for use in emergency deployment installations. Minimise abrasion of the mop material.
Ensure maximum efficiency of the equipment installed.
Suitable for creating bund around on-site working equipment which can stand inside the bund if required.
Allow the mop configurations to be altered easily by the lengthening or shortening of tension ropes
Technical drawing of FP 31C
Ancillary Storage Tanks
OPEC can build bespoke waste oil storage tanks to order depending on application and customers requirements. Tanks can be made from stainless steel, mild steel painted or GRP. Tanks can be self bunded. Tank sizes range from 1400 litres to 10000 litres. Features can include but not limited to: lifting eyes, skid frames, forklift box sections, site glass, inspection hatch, level gauges, drain port and vent.
In most cases storage tanks can be used as the frame to mount the E-Series or HV mop skimmer systems in position so all recovered oil is gravity fed without the need for any pumps or additional pipe runs. The above illustrates the use of a storage tank as a mounting point for the system control panel for an oil recovery process.
OPEC Ltd - 1 Nab Lane - Birstall - Batley - West Yorkshire - WF17 9NG - UK Tel: +44 (0) 1924 442701 - Fax: +44 (0) 1924 471925 www.opec.co.uk
Ancillary Mounting Frames
Mounting Frames are exclusively for permanent installations to position the skimmer directly over the oil/water surface. The mounting frame’s main purpose is safety in maintenance. The ST Tanks can be fitted with nylon wheels which allow the skimmer to be retracted from its deployment position via the mounting frame channels for general maintenance.
Stainless Steel Constructed
Fixing Pads
Mounting Frame Method 1
Mounting Frame Method 2
Ancillary Outrigger Arms
The outrigger arms are used for both fixed installations and emergency response to allow the mop to be vertically deployed. The main reason for this is to create a further 1 metre (approximately) of mop on the oil/water surface thus allowing for further adsorption of the floating oils or chemicals. This increases the efficiency and effectiveness of vertically deployed permanent mop skimmer installations. Outrigger arms can be single or double roller and are usually 1 metre in length.
Conecting Bar
Stainless Steel Frame
Double Outrigger Arm - OR2
Single Outrigger Arm - OR1
Polypropylene Rotational Moulded Wheel
Double Outrigger Arm - OR2
Ancillary VFR Vertical Guide Roller
The guide roller is a tool that is used to create greater mop coverage across the surface of water to maximise oil recovery.
VFR - A float which encompasses a special frame that allows the roller to float on the interface of the water and oil regardless of the level of water present. This type of guide roller is used where the water level fluctuates so that the mop is always positioned correctly in the water.
Guide Rollers: • Are used in installations to maximise area covered by the mop. • Are for fixed installations • Are produced with a variety of mounting arrangements • Are bespoke to the requirements of the installation • Minimise abrasion of the mop • Maximise efficiency of the mop skimmer systems
Mounting bracket and fixing pads are Bespoke to customer requirements.
Maximum Water Level
1 to 2.5m Max
Minimum Water Level
The photograph (Fig.1) shows a VFR 10 vertical Guide roller mounted on a cross bar set up for use in a stream which has rapid changes of water level. VFR 10 has a maximum level of change of 1 metre. These guide rollers are produced with a variety of mounting arrangements.
The photograph (fig.2) show a VFR 10 Vertical Guide Roller in a deep interceptor with a frame designed for top of wall mounting so that the installation can take place without having to drain or enter the pit.
Fig.1
Fig.2
A
TENSIONER UNIT IS FACTORY SET TO GIVE THE CORRECT 'SQUEEZE' ON THE MOP
OVERFLOW OUTLET 2" BSP
TOGGLE LEVER. TO RELEASE THE LOWER ROLLER.
REAR OUTLET (NOT SHOWN) 2.5" BSP
B SLUDGE OUTLET 2"BSP
CMF6XD MOP SITS ON WATER SURFACE
TYPICAL MOUNTING FRAME. BOLT HOLES ARE PROVIDED TO ENSURE THE UNIT CAN BE SECURED TO A LEVEL BASE.
FREE WATER RETURN OUTRIGGER (OPTIONAL). GIVES A INCREASED SURFACE AREA COVERAGE FOR THE MOP.
DRIVE GEARS
A
B
M12
DRIVE ROLLER MUST ROTATE CLOCKWISE
SAFETY COVER NOT SHOWN FOR ILLUSTRATION PURPOSES ONLY
304 S/S FINISH: BEADBLAST
NA CUSTOMER: NA
MATERIAL:
W/O REF:
Designed by
Checked by
Approved by
DRIP TRAY CATCHES ANY EXCESS DRIPS
ADJUSTABLE LOWER ROLLER IS RELEASED TO INSTALL NEW MOPS
www.opec.co.uk
XXXX
Date
05/10/2009
A.PECKSTON INLET ROLLER
Date
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
TYPICAL E SERIES SCHEMATIC 14.01.09.117-SCHEMATIC
Edition
Sheet
1/1
ISOMETRIC VIEW
FRONT VIEW 1
2
3
NOTES: 1- THE HEIGHT OF THE MOUNTING FRAME ENABLES THE RECOVERED OIL TO GRAVITY FEED INTO A HOLDING TANK. AS SUCH A SEPERATE PUMP IS NOT REQUIRED. 2- BESPOKE HOLDING TANKS CAN BE SUPPLIED.
WINDCANOPYS PREVENT OIL FROM BEING BLOWN OUTSIDE THE POLLUTED AREA.
8
1500,00
MOUNTING FRAMES CAN BE MADE TO ANY HEIGHT
ITEM
QTY
1
1
PART NUMBER E150-LAC-MKIII-ST5-1500
DESCRIPTION E SERIES SKIMMER MOUNTED ON A
Designed by
1000L Tank
IBC
3
1
OUTLET
GRAVITY FEED TO IBC
4
1
OVERFLOW
OVERFLOW RETURN PIPE
5
1
SLUDGE OUTLET
SLUDGE OUTLET PIPE
6
1
WINDCANOPY BASE
CAN BE MADE TO ANY LENGTH,
SECTION
COMPLETE WITH INTERNAL ROLLERS
BALL-VALVE - 2IN
NA
CUSTOMER: NA
1
1
W/O REF:
ST5 SEPARATION TANK 2
8
5
6
PARTS LIST
4
MATERIAL: NA FINISH: Checked by
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
NA
Approved by
Date
Date
09/10/2009
A.PECKSTON
www.opec.co.uk
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
TYPICAL SETUP 1 E150-LAC-MKIII-ST5-1500-MOP-IBC
Edition
Sheet 1/1
2
5
6 11
8
4
12
1
ISOMETRIC VIEW
TANK WAS DESIGNED TO 'FIT' OVER THE SUMP WALL
7
3
9
PARTS LIST IT 1
PART NUMBER 07.07.08.050-TANK
DESCRIPTION
PLAN VIEW
BESPOKE TANKS CAN BE MANUFACTURED INDIVIDUALLY TO SUIT CUSTOMER NEEDS OR STANDARD SIZES CAN BE SUPPLIED.
2
LEVEL SENSOR FLANGE
LEVEL SENSORS SWITCHES CAN BE FITTED
DETAIL -STUDS 3
TANK FIXING PAD
ENSURE THE UNIT IS FIRMLY SECURED IN PLACE
4
MANWAY COMP-500X500
GIVES ACCESS TO THE INSIDE OF THE TANK
5
E150-LAC-MKIII-ST5-2
E SERIES SKIMMER HEAD MOUNTED ON A ST5 SEPARATION UNIT (SEE
WHEEL OUTRIGGER
INDIVIDUAL DRGS FOR DETAILS)
OVERFLOW OUTLET
ENSURES THE UNIT TANK WILL NEVER OVERFLOW. ANY OVERFLOW OIL WILL
6
BE RECYCLED BACK INTO THE SUMP AREA 7
AIR VENT
8
07.07.08.051
SUMP WALL
9
BALL-VALVES - 2IN
SLUDGE OUTLET
10
2 WHEELED OUTRIGGER
INCREASES THE SURFACE AREA COVERAGE OF THE MOP AND THEREFORE INCREASES EFFICIENCY
11
OIL OUTLET
GRAVITY FEED TO STORAGE TANK
W/O REF:
NA
MATERIAL:
NA
CUSTOMER:
NA
FINISH:
NA
Designed by
Checked by
Approved by
Date
Date
09/10/2009
A.PECKSTON
www.opec.co.uk
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
TYPICAL SET UP 2 Edition
E150-LAC-MKIII-ST5-OR2-MOP-TANK
Sheet 1/1
STORAGE TANK
OPEC SKIMMER UNIT
CMF MOP NOTES: 1- SHOWS A TYPICAL SET UP OF A OPEC E SERIES OIL SKIMMER USING FLOATING PULLEYS. 2- THE SKIMMING AREA CAN BE ALMOST ANY SHAPE AND SIZE. SUMPS, LAGOONS, CLARIFIERS, SETTLEMENT PONDS ETC AND THE VERSITILITY OF THE MOP SKIMMER ENSURES THAT THE WHOLE AREA CAN BE SKIMMED, THIS IS BENIFICIAL OVER THE TRADITIONAL TYPES OF SKIMMERS WHICH ONLY COVER A SMALL LOCALISED AREA AND REQUIRE CONSTANT RELOCATION AROUND THE SKIMMING SURFACE. 3- FLOATING PULLEYS ARE HELD IN PLACE WITH ROPE. THEY CAN BE POSITIONED INTO ALMOST ANY CONFIGURATION TO ENSURE THAT THE MAXIMUM SURFACE AREA IS COVERED BY THE MOP. FLUTUATIONS IN THE WATER LEVEL CAN BE OVERCOME BY LEAVING AN APPROPIATE EXCESS ON THE SECURING ROPE.
FLOATING PULLEYS
W/O REF:
NA
MATERIAL: NA
CUSTOMER:
NA
FINISH:
Designed by
Checked by
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
NA
Approved by
Date
Date
09/10/2009
A.PECKSTON
www.opec.co.uk
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
TYPICAL SETUP 3 204.08.10.09.001
Edition
Sheet
1/1
6
5 782
4
3
2
1
2
D
D
Standard Deployment Frame Is designed to provide a means of supporting the ‘HV’ unit for use in a multitude of different situations. It may be used with horizontal legs facing forward for situations where the legs are long enough or wide enough to straddle the aperture through which the mop is deployed, these could include channels, drains, manholes, interceptor covers, etc. The angled support arm has been fixed at a height which allows for a recovered oil storage container up to the size of a standard 225 litre oil drum to be placed underneath the rear drain opening.
ADJUSTABLE HINGE TO ALTER SKIMMER OPERATING ANGLE.
CROSS PIPE/ OIL DRAIN
1745
It may also be deployed with the legs facing rearward and the machine cantilevered over a tank, interceptor, steam, separator, etc. In this case it is imperative that counterbalance weights are used either in the form of recovered oil container placed on a platform or pallet on the legs, or custom made weights which locate in holes in the ends of the legs. The cross pipe, which is also the oil drain, is mounted with a horizontal pivot and an adjusting screw, this enables the mop machine to be levelled up when the stand has been finally positioned. It is necessary to set the roller level so that when the machine is in operation the mop runs in the centre of the cover aperture.
1239
C
1
C 3 WAY ELBOW (NOT SHOWN) HORIZONTAL LEGS
1135
n13
100,00
1664
B
,00 T H RU
The stand may be used without horizontal legs by clamping the vertical member to horizontal pipes etc. such as standard handrails; this enables the mop to be deployed into interceptors, tanks, separators, which are normally guarded by handrails.
B
1110,00
860,00
810,00
ALL FRAME COMPONENTS 304 S/S
A
ITEM 1
QTY 1
2
1
Designed by
Checked by
Parts List PART NUMBER MCHO21-DEPLOYMENT FRAME-2" SUMP HV Approved by
Date
6
5
OPEC LTD 4
3
A
Date
25/09/2007
A PECKSTON
1067
DESCRIPTION SEE INDIVIDUAL DRG. MCH021 SEE INDIVIDUAL DRAWING
HV C/W DEPLOYMENT FRAME 2" HV - MCH021 2
Edition
1
Sheet
1/1
6
5
4
3
2
1
562 2 D
520
D
1
C
C
150,00 OPEC CMF MOP: MADE TO SIZE
B
OPEC LTD HV SKIMMER & TANK CLAMP
A
B
ITEM 1 2 Designed by
5
4
1 Checked by
HV-MOP Approved by
Date
OPEC LTD 3
DESCRIPTION SEE INDIVIDUAL DRAWING MCH030 SEE HV-GA A
Date
26/11/2007
A PECKSTON
CLAMPS CAN BE MADE BESPOKE TO FIT ALMOST ANY SUITABLE ONSITE STRUCTURE. 6
QTY 1
Parts List PART NUMBER TANK CLAMP FOR HV
TANK CLAMP FOR HV- GA MCH030-GA 2
Edition
1
Sheet
1/1
15
13
3
1
10
4 8
11 12 14
7 6 OIL OUTLET
5 OUT
PARTS LIST ITEM
QTY
PART NUMBER
1
1
MCH001- MAIN FRAME CHASSIS
2
1
MCH014-SUMP
3
2
MCH013- UPPER BEARING
4
1
MCH010- MAIN SHAFT BEARING
5
2
MCH007-MAIN ROLLER
6
1
MCH009- MAIN ROLLER END PLATE
7
2
MCH012- STUB SHAFT
8
2
MCH015- ROLLER ARM
9
1
MCH017- WEATHER COVER
10
1
MCE151- LABEL PLATE
11
2
MCH016-ROLLER ARM TUBE-40
12
4
MCH016-ROLLER ARM TUBE
13
1
HV-GEARBOX AND 3PH MOTOR
14
4
MCH033-INLET ROLLER SPACER
15
1
M10
16
1
MOP-001
DESCRIPTION
16
2
INLET MOP IN
NOT SHOWN
W/O REF:
MATERIAL:
CUSTOMER:
FINISH:
Designed by
Checked by
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
Date
Approved by
23/11/2009
A.PECKSTON oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
Lifting Eyebolt
Date
HV EQUIPMENT DESCRIPTION
www.opec.co.uk THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
Edition HV-A-02
Sheet 1/1
INITIAL REPRESENTATIONAL DRAWING OF OPEC LTD RECOMMENDED OIL SKIMMER INSTALLATION:
A
EQUIPMENT: SKIMMER -OPEC HV SEPARATION TANK- OPEC ST5 MOUNTING FRAMES. HOLDING TANK NOT SHOWN ON DRAWING
5
2
MATERIAL:304 S/S UNLESS SPECIFICALLY REQUESTED OTHERWISE
4
1 3 ISOMETRIC VIEW
A
6
7 PARTS LIST ITEM 1 2 3 4 5 6 7
QTY 1 1 1 1 1 1 1
PART NUMBER ST5 MOUNTING FRAME ST5 MOUNTING FRAME-HEIGHT TBC MCH019-TANK BRACKET-REV01 HV-SKIMMER UNIT 08.05.09.179_MOP 08.05.09.179_SITE
EQUIPMENT TO REMOVE THE FLOATING OIL FROM THE SUMP. THE SEPERATED OIL CAN THEN BE GRAVITY FED TO A HOLDING. ADDITIONAL IMAGES AVAILABLE ON REQUEST. SEE INDIVIDUAL COMPONENT DRAWINGS FOR SPECIFICATIONS
Designed by
Checked by
Approved by
Date
Date
06/05/2009
A.PECKSTON
TYPICAL SET UP 1 08.05.09.179
Edition
Sheet
1/1
Page
25
2.0 INSTALLATION AND MAINTENANCE 2.1 SAFETY NOTICE All machines can be dangerous.
Consequently the following can cause serious harm: • • •
Removal of protection (e.g. safety covers) Lack of inspection and maintenance In proper use
The personnel must be informed of any danger caused by contact with: • • •
Rotating parts. Live parts (see motor manufactures handbook for more details). Hot surfaces. Check normal working conditions of the specific motor in the manufacturers’ handbook.
The safety manager must ensure and guarantee that the machine is moved, installed, put into service, inspected, maintained and repaired only by qualified personnel, who should have: • • • •
Specific technical training and experience. Knowledge of technical standards and applicable laws. Knowledge of general safety regulations as well as national, local and installation regulations. Ability to recognise and avoid all possible dangers.
Work on the machine should be carried out upon authorization of the safety manager after having ensured that: • • •
The motor has been disconnected from the power supply and that no parts of the motor including auxiliary parts are live. Discharge of the capacitor has been done for single phase motors. The machine has completely stopped and there is no danger of accidental restarting.
If the machine is operating in a zoned environment, the unit, including the motor must be removed before maintenance work is carried out. When moving the machine the correct site health and safety procedures should be followed. Under no circumstances should the machine be moved by personnel unaware of personal lifting procedures. 2.2 SPECIAL CONDITIONS OF SAFE USE IN A EXPLOSIVE ATMOSPHERE
Page
When equipment is supplied with an electric motor a path to earth is created in the normal way through wiring from the motor to the control box and on to earth. In the case that a hydraulic or air powered unit is supplied a path to earth is created by fitting a earthing strip to the supplied earth terminal (which should be located on the motor side of the safety cover fitting bolt) and then connecting to earth. All installation work should be carried out be trained operatives.
26
If the unit is to be installed in a zoned area then the mop must firstly be saturated with water. This can be done simply be placing the mop in a bucket or container of water and then installing the mop directly from the water onto the machine, thus ensuring it is saturated.
2.3 POWER The machine is provided with a prime mover but, except for special cases, the control gear for electric motors, for instance, is the responsibility of the user. IMPORTANT INSTALLATION NOTICE These systems are designed to operated unattended for unlimited periods of time, it is therefore essential that they are provided with some form of overload protection, i.e. thermal overload in the case of a unit driven by an electric motor. Should the mop become tangled in an obstruction or get trapped for some reason then the overload protection device will prevent damage to the mop or main rollers. The setting of any overload device should be just above the normal system operating condition and not necessarily at full load condition of the prime mover. (for machines operating within a potentially explosive atmosphere the overload device and an emergency cut of switch fitted must be ATEX approved to operate within the specific zone).
ANY WARRANTY IS NULL AND VOID IF SUITABLE OVERLOAD PROTECTION HAS NOT BEEN FITTED AND PROPERLY SET AT THE TIME OF INSTALLATION. 2.4 POSITIONING The unit should be set up on a level foundation whether it is supplied as an independent unit or mounted on an OPEC oil water separation tank. The ancillaries such as guide pulleys, or guide rollers, or outrigger arms, should be assembled and fixed where required as shown in any installation drawings which may be provided. 2.5 PRIMING THE SEPARATOR (ONLY FOR UNITS INCLUDING ST5, ST25 & ST40) If the unit is supplied with an OPEC oil water separation tank it is necessary to set this up. Firstly, prime the front compartment with water up to a minimum depth of 150mm (to ensure the oil trap is sealed). Secondly, put the unit into operation until the oil level reaches and passes over the weir. Then stop the unit and it will be possible to determine the level of water in the front compartment, this should be approximately 5mm below the level of the water at the top of the weir, this water level can then be adjusted by means of the screwed adjustable collar fitted to the drain water pipe. 2.6 INSTALLATION & FITTING THE MOP 2.6.1 E SERIES To fit the mop into the ‘E’ Series mop drive/oil extraction unit when it is joined it is necessary to remove the safety cover (this is done by unfastening the toggle clips and hinging the cover towards the rear of the machine), open the main squeeze rollers by moving the tensioning toggle lever from the upright position until roller pressure is released. This opens up a gap which allows the mop to be positioned between the rollers. The mop should pass over the shaped inlet guide roller to the upper main roller, then around and between the rollers finally passing out from the machine back to the water surface. The debris/drip tray which pivots on the inlet guide roller shaft should rest on its bracket to prevent it from touching the lower roller.
Page
The mop may enter the machine over the inlet guide roller at any angle from horizontal to vertical fore and aft and up to approximately 30 either side of the longitudinal axis but this may be increased in certain conditions if required. (See Drawing Below Ref: mop inlet angles)
27
IMPORTANT: WHEN FITTING THE MOP THE UNIT MUST BE TURNED OFF AND THE SAFETY COVER MUST BE REPLACED BEFORE THE UNIT IS OPERATED.
If the mop is to be deployed around guide pulleys or rollers then the debris/drip tray should be fitted onto the inlet roller shaft in the forward position, and if the mop is being deployed vertically then the tray should be in the rearward position.
There is some adjustment for the squeeze pressure of the main rollers by adjusting the position of the toggle lever rod, however the degree of pressure is not critical and it should not be necessary to adjust the setting from that set in the factory. There is a limit to the height above the oil/water surface at which at the machine will operate satisfactory and this is dependant on a number of factors including oil type and viscosity but as a guide the general maximum can be considered to be in the order of 40 meters.
In order to ensure long life from the mop it is essential that when installing the unit care is taken to make sure the mop does not rub on any rough surfaces such as brick or concrete, this would reduce the amount of oil recovered by wiping the oil from the mop as it passes over the obstruction. It is also desirable to ensure that there are no projections at water level which could snag the mop if it is moved around by water turbulence or wind. When contact is not avoidable a guide roller must be added to ensure mop is only in contact with a rotating surface. The following section describes the mop in more details and suggests ways of repairing or altering the length of the mop during commissioning and routine maintenance procedures. 2.6.2 HV The unit is provided with two methods of mounting, one is a tapped hole in the top of the frame positioned over the centre of gravity and to which various types of bracket may be attached, the other is the drain stub of the sump which is designed to act not only as a drain connection but also as a support for the machine when plugged into a pipe stand. The mop guide tube rollers on the moveable arms should be positioned with as much spread as possible depending on whether the mop is passing through an aperture such as a man access or drain cover. If only a narrow spread is possible then the roller arms should be positioned in the upper mounting holes, the tube rollers can then be positioned at their narrowest and conversely if the widest spread is required then the roller arms should be positioned in the lower holes. If the unit is being set up on the standard deployment stand it should be carefully fitted by entering the drain stub into the upper end of the angled stand pipe and screwing the locating bolt.
Page
To fit the mop to the ‘HV’ Series mop drive/oil extraction unit it is ready joined loop it is necessary to remove the machine cover. This is removed by undoing the two knob screws and withdrawing the cover endways, it should be lifted slightly to clear the end flange of the sump. With the rollers now exposed the direction of rotation should be checked by flicking the control switch on and off, the mop should then be held, with the hands wide apart, diagonally across the ends of the roller so that it will feed in between the rollers when the control switch is again flicked on and off. GREAT CARE SHOULD BE EXERCISED TO KEEP HANDSCLEAR OF THE ROLLERS WHILE THEY BRIEFLY ROTATE. Once the mop is positioned between the rollers (it does not necessarily need to be at the mid point of the roller width) the cover MUST be replaced fully and then the machine may be started up, the guide strips on the cover apertures will guide the mop into the centre of the roller.
28
There is a limit to the height above the oil/water surface at which the machine will operate satisfactorily and this depends on a number of factors which are site dependant, they include viscosity of the product, type of product, situation of machine, whether it is affected by wind, etc., but as a general rule the unit should not be operated more than 5 metres above the liquid level without consulting the manufacturers.
In order to ensure long life from the mop it is essential that the unit is set up with the rollers as near to level as can be practically achieved, this ensures that the mop runs in the centre of the mop aperture and does not bear excessively on the wear strips as this would not only cause premature wear on the guide strips but also on the mop itself. Care should be taken to make sure the mop does not rub on any rough surfaces such as brick or concrete, this would reduce the amount of oil recovered by wiping the oil from the mop as it passes over the obstruction. It is also desirable to ensure that there are no projections at water level which could snag the mop if it is moved around by water turbulence or wind. When contact is not avoidable a guide roller must be added to ensure mop is only in contact with a rotating surface.
2.7 JOINING THE MOP - METHOD 1 Refer to instruction sheet at the end of the section. 2.8 JOINING THE MOP - METHOD 2 Refer to instruction sheet at the end of the section. 2.9 JOINING THE MOP - METHOD 3 Refer to instruction sheet at the end of the section. IMPORTANT INSTALLATION NOTICE These systems are designed to operated unattended for unlimited periods of time, it is therefore essential that they are provided with some form of overload protection, i.e. thermal overload in the case of a unit driven by an electric motor. Should the mop become tangled in an obstruction or get trapped for some reason then the overload protection device will prevent damage to the mop or main rollers. The setting of any overload device should be just above the normal system operating condition and not necessarily at full load condition of the prime mover. (for machines operating within a potentially explosive atmosphere the overload device and an emergency cut of switch fitted must be ATEX approved to operate within the specific zone).
ANY WARRANTY IS NULL AND VOID IF SUITABLE OVERLOAD PROTECTION HAS NOT BEEN FITTED AND PROPERLY SET AT THE TIME OF INSTALLATION. CAUTION: The equipment should not be left to operate unattended if ambient temperatures fall below 0C and when there is a likelihood of the water surface freezing because if the mop becomes frozen into an ice covering the drive rollers would continue to turn and serious damage could occur to the drive rollers, mops, and guide rollers.
Page
IMPORTANT: When connecting the motor to the power supply the instructions and procedures stated in the motor handbook (See Appendix 1) must be strictly followed.
29
Its is important for units which are installed in standby situations, and where the water surface is normally clean and at ambient temperatures, that the power supplies are switched off when there is the possibility of air temperatures falling to, or below, freezing point. If this is the case, it is recommended that a frost thermostat be fitted into the control systems to isolate the power supplies automatically if and when ambient temperatures reach preselected levels.
2.10 MAINTENANCE The ‘E’ Series and HV oil recovery systems have been designed with simplicity of operation and maintenance as the main parameter, there is therefore, relatively little maintenance to be carried out. As all rubbing parts have been eliminated and all bearing surfaces are self lubricating, routine maintenance is mainly limited in inspections and cleaning. 2.10.1 REMOVAL OF THE SAFTY COVER E SERIES MKIII MACHINES This is done by releasing the two toggle fasteners, lifting the front of the cover and pivoting it rearwards over the back or the rear plate. This procedure will then allow access to all parts of the unit.
IMPORTANT: THE MACHINE SHOULD BE SWITCHED OFF AND THE POWER SUPPLY ISOLATED BEFORE REMOVING THE SAFETY COVER OR CARRYING OUT ANY WORK ON THE MACHINE. UNDER NO CIRCUMSTANCES MUST THE MACHINE BE OPERATED WITHOUT THE SAFETY COVER IN PLACE AND FASTENED SECURELY USING BOTH TOGGLE FASTENERS. WE RECOMMEND THAT YOU CONTACT OPEC LTD FOR ADVICE REGARDING THESE MATTERS. HV MACHINES Removal of the main cover is accomplished by undoing the two knob screws and withdrawing the cover by sliding it endways away from he drive motor end, it should be lifted slightly to clear the end flange of the sump, if lifted too much it will not withdraw as the internal deflector plates will foul on the chassis end plate. If there is mop installed on the machine the mop must be fed under the cover bottom edges whilst withdrawing the cover 2.10.2 INSPECTION
• • • • •
Gearbox condition, ensure there is no dust build up (see manufactures manual for full details). Motor condition (see manufactures manual for full details). Condition of mop, visual checking for excess reduction in the surface area. Mop life can reach 9 months when operated 24 hours a day 7 days a week. Note: Mop life is dependant on situational factors e.g. chemicals abrasion, UV and metal deposits. Conditions of rollers gears, alignment, apply a general purpose grease when required. Condition of roller covering, check for cuts, abrasions, and any undue wear. Check tightness of retaining bolts in upper rollers. Condition of scraper on lower roller. This scraper keeps the lower roller clear of any build up of oil when operating in viscous or emulsified oils and prevents any carry over on the outgoing run of the mop. The scraper enhances the efficiency of the unit and should therefore be in position at all times. It is removed by undoing the two hexagonal head M6 bolts which also retain the lower roller shaft bearing arms; the bolts are removed by using a 10mm combination wrench.
Page
•
30
E SERIES MACHINES Inspection of MkIII ‘E’ Series machine should include the following:
• • •
• •
Freedom of movement of lower roller carrier shaft against tensioner. Freedom of movement of tensioner toggle arm. If necessary a few drops of lubricating oil should be put on to the pivot pin and screwed boss pivots. Check for freedom of rotation of inlet roller and for any undue wear. The shaft, roller, and tray assembly may be dismantled for cleaning or repositioning by simply removing the ‘R’ clip which retains the shaft. The nylon distance collars are to enable the inlet guide roller to be repositioned sideways if required in order to lead the mop on to the centre of the main squeeze roller. This should only be necessary if the mop is running to one side of the centre on the main roller which may occur if it approaches the guide roller at a relatively large angle from the side. Condition of all bearings, check for excessive wear and noise. If fitted with a ST tank, clear the sludge as required.
IF THE UNIT IS OPERATING IN A ZONED AREA THEN IT IS NECESSARY TO CARRY OUT THE ABOVE VISUAL CHECKS ON A DAILY BASIS.
‘E’ Series mop drive/oil extraction units may be driven by many different types of power unit, it is therefore essential that the appropriate manufacturers’ handbook be consulted for specific instructions. This is also the case for the gearbox. (These are enclosed in the appendices). HV MACHINES
• • • • •
When reassembling a lower roller on to the main drive shaft the following procedure should be adopted: • Make sure all components are clean and free from dirt and swarf. • Lightly coat the stub shaft mating surfaces with grease as well as the bore hole. • Check the 3mm. drive pin is in position in the hole in the drive shaft flange. • Position the roller on to the main shaft spigot ensuring that the drive pin engages with the slot in the roller end face.
31
• • •
Inspection of a ‘HV’ Series machine should include the following: Gearbox condition, ensure there is no dust build. Motor condition (see manufactures manual for full details). All nuts and bolts are tight. Condition of mop, visual checking for excess reduction in the surface area. Mop life can reach 9 months when operated 24 hours a day 7 days a week. Note: Mop life is dependant on situational factors e.g. chemicals abrasion, UV and metal deposits. Condition of rollers and alignment. Condition of roller covering, check for cuts, abrasions, and any undue wear. Check that the side roller arms are tight and in the correct position to give the required spread to the mop and that the plastic roller tubes are free to rotate easily. If these tubes are found to be tight then they should be removed, the rods cleaned and oiled, and the tubes refitted. These rollers assist in keeping the mop running through the centre of the aperture in the cover, it is desirable therefore that they should rotate freely at all times. Ensure the machine is still set up level so that the mop runs easily in the centre of the apertures. The wear strips on each side of the cover should be checked for wear and replaced if necessary. The sump should be cleaned of any debris or solids which may block the outlet pipe. The mounting bolt which will either be in the top plate if the unit is on a suspended mounting, or in the drain stub if it is pipe mounted, should be checked for tightness. Condition of all bearings, check for excessive wear and noise. It is important that the main lower roller securing bolt is tightened to the correct torque in order to prevent the lower roller from working loose during operation.
Page
• • • • •
•
•
Using engine lubricating oil smear the underside of the retaining bolt head as well as the end threads, position the end plate in the end of the roller, and screw in the retaining bolt. When finger tight check to make sure that the end plate and roller are correctly located. Using a torque wrench tighten the retaining bolt to a torque setting of 19Nm. (14lbs/ft – 2mKg).
Page
32
ALWAYS REPLACE COVERS WHEN INSPECTION AND MAINTENANCE HAVE BEEN COMPLETED: THE MOP IS NOT GUIDED UNLESS THE COVER IS IN PLACE.
2.11 SPARES
E-SERIES OPERATIONAL SPARES Refer to technical section drawings for full parts listings.
MCE014 MCE015 MCE016 MCE017 MCE018 MCE019 MCE020 MCE021 MCE022 MCE027 MCE031 MCE032 MCE033 MCE034 MCE035 MCE036 MCE037 MCE038 MCE039 MCE040 MCE104 MCE107 MCE108 MCE109 MCE160
BEARING COMPLETE-BT25 LOWER ROLLER SHAFT DRIVE PLATE DRIVE PLATE WASHER SCRAPER SCRAPER CLAMP PLATE TENSIONER ARM TENSIONER UNIT TOGGLE LEVER ASSEMBLY SPLASH PLATE TOGGLE FASTENER CATCHPLATE CARRIER BUSH RH CARRIER BUSH LH INLET ROLLER INLET ROLLER SHAFT DISTANCE COLLAR INLET RETAINING CLIP INLET DRIP TRAY "L" BRACKET POLY COATED CLIP REF 507-781 MAIN SHAFT BEARING 1330x306 INSERT UPPER MAIN SHAFT MKII&III LAC UPPER MAINSHAFT KEY SPLASH PLATE
2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 2.00 2.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
MCE007/M
GEARBOX NMRV-50 - ATEX ONLY
1.00
Page
Description GEAR BOX LAC DRIVE GEAR MAIN ROLLER CARRIER SHAFT
33
Quantity Per Unit 1.00 2.00 2.00 1.00
Product Code MCE007 MCE010 MCE011 MCE013
HV OPERATIONAL SPARES
Refer to technical section drawings for full parts listings.
Quantity Per Unit 1.00 2.00 2.00 2.00 1.00 1.00 2.00 2.00 2.00 4.00 2.00 2.00 1.00 1.00
34
Description MAIN DRIVE SHAFT MAIN DRIVE SHAFT KEY MAIN DRIVE SHAFT PIN MAIN DRIVE ROLLER MAIN ROLLER END PLATE MAIN SHAFT BEARING STUB SHAFT UPPER BEARING ROLLER ARM TUBE SET MOP PROTECTION STRIPS KNOB SCREWS ENGINEERING STUD GEARBOX NMRV GEARBOX - FLAMEPROOF
Page
Product Code MCH003 MCH004 MCH005 MCH007 MCH009 MCH010 MCH012 MCH013 MCH016 MCH018 MCH020 MCH022 MCH055 MCH055/A
E-SERIES - Recommended 2 years spares requirement per skimmer head
The following list is intended as a guide only, the local environmental factors in which each machine operates will determine the frequency in which replacement parts are required.
Part Description Number MCE010 MCE011 MCE014 MCE018 MCE021 MCE033 MCE034 MCE035 MCE036 MCE037
QTY
Drive Gear Main Roller Bearing Complete BT25 Scraper Tensioner Unit Carrier Bush RH Carrier Bush LH Inlet Roller Inlet Roller Shaft Distance Collar
2 2 2 1 1 1 1 1 1 2
HV-SERIES - Recommended 2 years spares requirement per skimmer head
Description
QTY
Main Drive Shaft 18mm Main Drive Roller Main Shaft Bearing Stub Shaft Upper Bearing Roller Arm Mop Guard Tube Set Wear Strip 125 Long
1 2 1 2 2 2 4
Page
Part Number MCH003 MCH007 MCH010 MCH012 MCH013 MCH016 MCH018
35
The following list is intended as a guide only, the local environmental factors in which each machine operates will determine the frequency in which replacement parts are required.
Fitting the Mop E-Series
To fit the mop into the ‘E’ Series mop drive/oil extraction unit when it is joined it is necessary to remove the safety cover (this is done by unfastening the toggle clips and hinging the cover towards the rear of the machine), open the main squeeze rollers by moving the tensioning toggle lever from the upright position until roller pressure is released. This opens up a gap which allows the mop to be positioned between the rollers. The mop should pass over the shaped inlet guide roller to the upper main roller, then around and between the rollers finally passing out from the machine back to the water surface. The debris/drip tray which pivots on the inlet guide roller shaft should rest on its bracket to prevent it from touching the lower roller. (See Fig.1-6)
IMPORTANT: WHEN FITTING THE MOP THE UNIT MUST BE TURNED OFF AND THE SAFETY COVER MUST BE REPLACED BEFORE THE UNIT IS OPERATED.
Figure 1 Mop Installation Step 1
Figure 2 Mop Installation Step 2
Figure 3 Mop Installation Step 3
Figure 4 Mop Installation Step 4
Figure 5 Mop Installation Step 5
Figure 6 Mop Installation Step 6
Fitting the Mop HV
To fit the mop into the ‘HV’ Series mop drive/oil extraction unit when it is joined it is necessary to remove the machine cover. This is removed by undoing the two knob screws and withdrawing the cover endways, it should be lifted to clear the end flange of the sump.
With the rollers now exposed the direction of rotation should be checked by flicking the control switch on and off, the mop should then be held, with the hands wide apart, diagonally across the ends of the roller so that it will feedin between the rollers when the control switch is again fliked on and off. GREAT CARE SHOULD BE EXERCISED TO KEEP HANDS CLEAR OF THE ROLLERS WHILE THEY BRIEFLY ROTATE. Once the mop is positioned between the rollers (it does not necessarily need to be at the mid point of the roller width) the cover MUST be replaced fully and then the machine may be started up.
0° ° 30, 0
30,00
0°
30,0
0°
30,0
,0 0 9
0°
NA
Approved by
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
Checked by
Date
Edition
05/10/2009
Date
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
MOP INLET ANGLES-MANUAL VERSION
MATERIAL: SEE INDIVIDUAL FINISH: DRAWINGS
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
www.opec.co.uk
A.PECKSTON
Designed by
CUSTOMER: NA
W/O REF:
1/1
Sheet
THE MOP MAY ENTER THE MACHINE OVER THE INLET GUIDE ROLLER AT ANY ANGLE FROM HORIZONTAL TO VERTICLE FORE AND AFT AND UP TO APPROXIMATELY 30° EITHER SIDE OF THE LONGITUDINAL AXIS BUT THIS MAY BE INCREASED IN CERTAIL CIRCUMSTANCES IF REQUIRED.
ST5 TANK
E SERIES SKIMMER
Joining the Mop Staples & Stapler
4.6.2 Joining the Mop – Method 1 (Specially selected staples and hand stapler required). Cut the mop to the required length allowing for about 3% initial stretch, use a large pair of scissors or a sharp knife. Check to ensure that there are no twists in the run of the mop then strip back the fibre packs on one side only of the centre tape at each end for a distance of about 120mm. Remove the fibre packs from the upper side on one end and the underside of the other end (fig.C1). Place the ends of the mop together so that the centre tapes overlap the amount that they have been trimmed (Fig.C2) and then insert the staples according to the pattern shown in Fig.C3 starting with those which are inserted lengthways at the ends of the tapes. These prevent the tape ends and fibre packs from peeling back. The staples which are inserted transversely should be inserted evenly, every other one being inserted from the opposite side. (Fig.C3). The staples should be checked to ensure that each one has penetrated the mop and that the staple ends have turned over correctly.
Figure .C1
Figure C2
Figure C3
Note: Overlap
Joining the Mop Stitch
Joining the Mop – Method 2 (Sewing mop ends, using a heavy synthetic thread e.g. No.8 polyester whipping twine, sail makers thread, or similar). Cut the mop to the required length allowing for about 3% initial stretch, use a large pair of scissors or a sharp knife. Check to ensure that there are no twists in the run of the mop then strip back the fibre on one side only of the centre tape at each end for a distance of about 60-70mm. Remove the fibre packs from the upper side on one end and the underside on the other end. (Fig.S2). Place the ends of the mop together so that the centre tapes overlap the amount that they have been rimmed (Fig.S3) and sew the ends together firmly ensuring that the exposed ends of the fibre packs are well secured by the sewing so they will not strip back in use, and that where the thread is stopped off it is also secured firmly to prevent it from becoming undone. Position the sewing as shown for the staples in Fig.S4.
Figure S1
Figure S2
Figure S3
Figure S4
Note: Overlap
Joining the Mop Emergency
Method 3 (Tying, for emergency purposes only) Follow the steps as previously described in method two but continue with the preparation and tying of mops as illustrated in Figures 1 - 4 inclusive.
Figure 1. Emergency Mop Joining: Step 1
Figure 2. Emergency Mop Joining: Step 2
Figure 3. Emergency Mop Joining: Step 3
Figure 4. Emergency Mop Joining: Step 4
Page
42
3.0 TECHNICAL INFORMATION
3.1 SERVICE ENQUIRES
All service enquiries should be referred to OPEC Ltd at:OPEC Ltd 1 Nab Lane Birstall West Yorkshire WF17 9NG UK +44 (0) 1924 442701 www.opec.co.uk
Page
43
Or via your Local Representative.
3.2 TROUBLE SHOOTING In the case of malfunction stop the mop drive / oil extraction unit immediately (emergency cut off) Electrical motors must be disconnected from the power supply. In the case of diesel or petrol driven engines spark plugs must be disconnected and the emergency cut off activated until the engine shuts down. In the case of compressed air or hydraulic motors power supply lines and return pipes must be disconnected.
(E SERIES) Gears banging together.
Excessive quantities of oil leaking where the mop enters the machine. (E SERIES) Mop scraping on the splash plate causing excessive spillage. (HV) Mop scraping on the safety cover causing excessive spillage.
No or small quantities of oil being recovered.
Motor, gearbox and /or bearing Malfunctions Gearbox
44
Excessive noise
REASON/ACTION Main rollers are open, ensure they are closed.(E SERIES) Mop slipping, ensure mop is not caught and that the length is not to long.(HV) Clogging due to obstructions carried into the machine. -Remove any obstruction, check rollers and mop for damage. Mop is tangled/ trapped on an obstruction outside of machine. -Check path of the mop, set free and reposition. Motor wired incorrectly and the rollers are running backwards. -Check rollers running in correct direction, rewire motor if necessary. Mop incorrectly fitted. -Refit following installation instructions. Mop entering at incorrect angle. -Adjust the position of mop and or ‘E’ Series unit. (See Installation section) Mop entering at incorrect angle. -Adjust the position of mop and ensure the HV is level. If fitted to a deployment frame adjust the frame angle. Mop does not reach water surface. -Check mop length and guiding. No oil present on water surface -Use Oil booms to collect and divert oil if necessary -Change installation site and or mop position. Excessive wear on the mop -Check mop for loss in fibres. Replace if required See the Manufactures instructions See the Manufactures instructions
Page
MALFUNCTION Although motor is running, mop stands still
449
449
330,00
280,00
330,00
308
302,00 281,00
164,00
479
551
715
STD MOTOR SHOWN DIMENSIONS WILL BE DEPENDANT ON THE INDIVIDUAL MOTORS USED.
MOP SPEED = 16 m/MIN RECOVERY RATE (MAX) = 6000L/Hr MOP LENGTH (MAX) = 120m MAIN ROLLER SPEED = 34 rpm MACHINE MATERIAL = 304 S/S MACHINE WEIGHT (NO DRIVE) = 49 KG AIR = 4.2 BAR/ 800l HYDRAULIC = 136 BAR/ 15l
W/O REF:
NA
CUSTOMER:
NA
Designed by
MATERIAL: SEE INDIVIUDUAL FINISH: DRG. Checked by
Approved by
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
Date
05/10/2009
A.PECKSTON
www.opec.co.uk
Date
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
E-SERIES-LAC-MKIII-MANUAL VERSION 212.05.10.09.001
Edition
Sheet 1/1
MOP SPEED = 16 m/MIN RECOVERY RATE (MAX) = 6000L/Hr MOP LENGTH (MAX) = 120m MAIN ROLLER SPEED = 34 rpm MACHINE MATERIAL = 304 S/S MACHINE WEIGHT (NO DRIVE) = 49 KG TANK WEIGHT = 43 KG TANK CAPACITY (REAR COMPARTMENT) = 30l
281
884
E SERIES SKIMMER
BAFFLE PLATE
435,00
SLUDGE DEFLECTION PLATE
73,00
400,00
DEBRIS BASKET
FREE WATER RETURN 75
50,00
590,00
25,00
A
FRONT OUTLET 2" BSP
135,00
A ( 0.14 : 1 )
15,00
305,00 REAR OUTLET 2.5" BSP OVER FLOW OUTLET 2"BSP RAIN COVER
M1
25,00
2X
30 D
EEP
750
1017
M12
ST5 - gravity oily/water separator and temporary oil collection tank fitted with a 2.5" BSP discharge pipe connection, for pumping out or gravity feeding recovered oil to permanent/semi-permanent storage. Also complete with, removable debris screen, removable baffle and sludge deflector plates, adjustable weir height for change in oil viscosities and rain cover. W/O REF:
NA
MATERIAL: 304 S/S
CUSTOMER:
NA
FINISH:
Designed by
Checked by
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
BEADBLAST
Approved by
Date
05/10/2009
A.PECKSTON 311 610,00
122 www.opec.co.uk
Date
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
E150-LAC-MKIII-ST5-MANUAL VERSION 210.05.10.09.001
Edition
Sheet 1/1
MOP SPEED = 16. m/MIN RECOVERY RATE (MAX) = 6000L/Hr MOP LENGTH (MAX) = 120m MAIN ROLLER SPEED = 34 rpm MACHINE MATERIAL = 304 S/S MACHINE WEIGHT (NO DRIVE) = 49 KG TANK WEIGHT = 52 KG TANK CAPACITY (REAR COMPARTMENT) = 120l
E SERIES SKIMMER
DEBRIS BASKET
OVERFLOW OUTLET 2"BSP BAFFLE PLATE
435,00
376
44
50,00
FRONT OUTLET 2" BSP
SLUDGE DEFLECTION PLATE
73,00
69
FREE WATER RETURN
25,00
379,00
1070,00
135,00
A REAR OUTLET 2.5" BSP A ( 0.14 : 1 )
15,00
RAIN COVER
M12X30 DEEP
25,00
1229
M12
1497
ST25 - gravity oily/water separator and temporary oil collection tank fitted with a 2.5" BSP discharge pipe connection, for pumping out or gravity feeding recovered oil to permanent/semi-permanent storage. Also complete with, removable debris screen, removable baffle and sludge deflector plates, adjustable weir height for change in oil viscosities and rain cover.
W/O REF:
MATERIAL: 304 S/S
NA
CUSTOMER: NA Designed by
FINISH: Checked by
UNLESS OTHERWISE STATED ALL DIMENSIONS IN MILLIMETRES. SCREW THREADS TO ISO METRIC COARSE MACHINED DIMENSIONS±0.25mm FABRICATED DIMENSIONS±2mm HOLE CENTRES ±0.5mm ANGULAR TOLERANCE ±1%
BEADBLAST
Approved by
Date
05/10/2009
A.PECKSTON 750,00 311
217 www.opec.co.uk
Date
oil pollution environmental control ltd. 1, Nab Ln, Birstall, W.Yorks. WF17 9NG. TEL:01924 471924 FAX:01924 442701
THE COPYRIGHT OF THIS DRAWING BELONGS TO O.P.E.C. LTD. AND DETAILS MAY NOT BE COPIED OR DIVULGED WITHOUT PRIOR PERMISSION
E150-LAC-MKIII-ST25-MANUAL VERSION 211.05.10.09.001
Edition
Sheet 1/1
6
5
4
3
2
1 PARTS LIST ITEM 1 2 3 4 5
D 22
6 7 15
8 9 10
18
11 12 13 14
19
C
20
4
22
21
17
23 6 14
PART NUMBER MCE033-RH CARRIER BUSH MCE040-L BRACKET MCE159-RH DRIP CHANNEL D MCE022- TOGGLE LEVER MCE072-CROSSBEAM MCE102-BACK PLATE MCE151- LABEL PLATE MCE160-SPLASH PLATE MCE161-SIDE PLATE MCE034-LH CARRIER BUSH
1 1
MCE035- INLET ROLLER MCE039- INLET DRIP TRAY MCE037- DISTANCE COLLAR MCE036- INLET ROLLER SHAFT MCE172-SAFETY COVER MK3 C MCE164-MAINPLATE MCE139- BEARING SEAT E150-GEARBOX AND MOTOR MCE065-OUTPUT COVER MCE140-RETAINING WASHER LAC MCE031_FASTENER MCE032_CATCHPLATE MCE038_INLET RETAINING CLIP
2 1
15
1
16 17 18
1 1 1
19 20
1 1
21 22 23
2 2 1
7
2 B
QTY 1 1 1 1 1 1 1 1 1 1
16
B
1
3 12 10
5
11
9
13
21 Designed by
A
Checked by
Date
Approved by
6
OPEC LTD 23.10.08.095 5
A
MAIN PLATE ASSEMBLY
8
OPEC LTD E150 MKIII MAIN PLATE ASSEMBLY FIXINGS NOT INCLUDED
Date
27/10/2008
A.PECKSTON
4
3
2
Edition
Sheet
1/1 1
6
5
10 D
4
3
2
1
OPEC LTD
9
D 4
8
2
1
5
7
6 C
B
A
C
3
ITEM 1 2 3
QTY 1 1 1
4
6
5 6 7 8
4 4 4 1
9
1
10
1 6
Parts List PART NUMBER MCE010-DRIVE GEAR MCE011-MAIN ROLLER MCE109-UPPER MAIN SHAFT KEY M6 x 10
M8 FLAT M8 x 25 MCE108-UPPER MAIN SHAFT MCE107- MAIN SHAFT BEARING MCE107- MAIN SHAFT BEARING COLLAR 5
DESCRIPTION
B
Hexagon Socket Countersunk Head Screw Spring Washer Washer Hex-Head Bolt
E150. UPPER ROLLER ASSEMBLY DRAWING. FOR SEPERATE COMPONENT DETAILS SEE THE INDIVIDUAL PART DRAWING. Designed by
Checked by
Approved by
Date
OPEC LTD 4
3
A
Date
23/10/2008
A.PECKSTON
E SERIES UPPER ROLLER ASSEMBLY 23.10.08.094-LAC 2
Edition
1
Sheet
1/1
Parts List ITEM
QTY
PART NUMBER
1
1
MCE011-MAIN ROLLER
2
1
MCE015- LOWER ROLLER
6
DESCRIPTION
4
1
2
9
8
5
SHAFT 3
1
MCE016-DRIVE PLATE
4
4
M8 x 25
Hex-Head Bolt
5
4
M8
Spring Washer
6
4
FLAT WASHER
Washer
7
1
MCE010-DRIVE GEAR
8
6
M6 x 10
Hexagon Socket Countersunk Head Screw 7 3
9
2
MCE014-BEARING LEG
10
1
MCE013-CARRIER SHAFT
11
2
M6 x 20
Hex-Head Bolt
12
2
M6
Hex Nut
13
1
MCE017-DRIVE PLATE
14
1
10
13
11
14
12
WASHER M8 x 20
Hexagon Socket Countersunk Head Screw
15
1
MCE018
16
1
MCE019-SCRAPER CLAMP
17 15
SCRAPER
16
PLATE 17
2
M6 x 16
Hex-Head Bolt
18
2
M6
Spring Washer
19
2
FLAT WASHER
Washer
20
1
MCE021- TENSIONER UNIT
21
1
MCE020-TENSIONER ARM
19
20
18
Designed by
OPEC LTD
E150-LAC MK III.& B TYPE LOWER ROLLER ASSEMBLY DRAWING. FOR SEPERATE COMPONENT DETAILS SEE THE INDIVIDUAL PART DRAWING.
Checked by
Approved by
Date
Date
23/10/2008
A.PECKSTON
E SERIES LOWER ROLLER ASSEMBLY 23.10.08.093
Edition
Sheet 1/1
1074
SIDE VIEW
OIL OUTLET
SLUDGE OUTLET
15,00
590,00
2
610,00
M1
FREE WATER RETURN
435,00
400,00
795
FRONT VIEW
640,00
1
2
3
1075
ISOMETRIC VIEW
PLAN VIEW
Parts List
ST5 – gravity oily/water separator and temporary oil collection tank fitted with a 2.5” BSP discharge pipe connection, for pumping out or gravity feeding recovered oil to permanent/semi-permanent storage. Also complete with, removable debris screen, removable baffle and sludge deflector plates, adjustable weir height for change in oil viscosities and rain cover.
Designed by
Checked by
ITEM
QTY
PART NUMBER
1
1
ST5
SEE IND. GA's
2
1
MCH019-TANK
SEE IND. GA's
DESCRIPTION
BRACKET-REV01 3
1 Date
Approved by
HV
SEE IND. GA's Date
24/04/2008
A.PECKSTON
HV SKIMMER & ST5 TANK OPEC LTD HV-ST5
Edition
Sheet 1/1
462 FRONT VIEW
313
416
145,00
ISOMETRIC VIEW
SIDE VIEW
262 2" BSP SOCKET
Designed by
Checked by
Approved by
Date
27/09/2007
A PECKSTON PLAN VIEW
Date
OPEC
HV GENERAL ARRANGEMENT HV-Manual Version
Edition
Sheet
1/1
PARTS LIST
OPEC LTD : HV OIL EXTRACTION UNIT
ITEM QTY 13
22
14 18
PART NUMBER
1
1
MCH001- MAIN FRAME CHASSIS
2
1
MCH014-SUMP
3
2
MCH022-ENGINEERING STUD
4
2
MCH013- UPPER BEARING
5
1
MCH010- MAIN SHAFT BEARING
6
1
MCH003- MAIN DRIVE SHAFT
7
2
MCH007-MAIN ROLLER
8
1
MCH009- MAIN ROLLER END
9
2
MCH012- STUB SHAFT
10
4
M10 x 25 HEX HD
11
2
MCH015- ROLLER ARM
12
8
M10- NYLOC NUT
13
1
MCH017- WEATHER COVER
14
2
M6 KNOB SCREW
15
1
MCH006-STEP WASHER
16
2
M8- NLYOC NUT
17
2
M8 x 20 HEX HD
18
1
MCE151- LABEL PLATE
19
3
M6 x 16, SPRING & PLAIN
20
2
21
4
22
1
HV-GEARBOX AND MOTOR
23
4
MCH033-INLET ROLLER SPACER
24
1
M10_ LOOP MOUNTING
25
1
MCH005_MAIN SHAFT PIN
26
1
MCH004_MAIN SHAFT KEY
27
4
MCH016-MOP PROTECTION
28
1
MCH024_SETSCREW M8X150
29
1
MCH023_SETSCREW M8X260
18MM 22
PLATE
27 24
17 16
15 4
10
9
26
21 23
11
23
20
12
1
5
25
6
19
29
3
WASHER MCH016-ROLLER ARM TUBE-40MM
7
9
12
8
MCH016-ROLLER ARM TUBE-84MM
28
7 2
STRIP
Designed by 11
21
23
21
23
20
12
Checked by
Date
Approved by
Date
20/05/2009
A.PECKSTON
HV ASSEMBLY
THE UPPER (M8X260) AND LOWER (M8X150) SET SCREWS NOT SHOWN SHOWN ON THIS DRAWING. REFER TO OPEC LTD FOR DETAILS
Edition HV-A-1
Sheet 1/1
Page
54
Page
55
4.1.1 MOTOR
Page
56
4.1.2 GEARBOX
Page
57
4.1.3 MISC
4.2 CERTIFICATES
Quality Policy Oil Pollution Environmental Control Ltd Opec Ltd. is committed to a comprehensive and developing policy of assuring the quality of their products and services. In accomplishing this aim our policy shall be one of providing product to the highest standards in order to meet the specified requirements and implied expectations of our customers together with legislative requirements associated with our products. In carrying out work on a customer’s behalf, the Company shall proceed in a reasonable and safe manner and shall take due account of relevant legislation and good industry practices. The Company is committed to the continual improvement of its quality management system through the application of appropriate requirements of the Quality Management Systems Requirements Standard BS EN ISO 9001:2000 including the systematic ongoing review of its internal operations and feedback from its customers, suppliers and other interested parties. In achieving these objectives the quality assurance system operated by the Company is designed to control all aspects of contract review; the purchase, assembly, installation and distribution of product. The Managing Director has the responsibility to provide the necessary working environment and resources to ensure that all procedures are strictly applied. The Managing Director shall ensure that this policy statement is implemented and maintained throughout the Company.
…………………………….
Mr. J. Ilsley, Managing Director
1
Issue Date:
14-02-05
Page
Issue:
58
Document No.: QM02
Page
59
ISO 9001 CERTIFICATE
EC MACHINERY DIRECTIVE
EC MACHINERY DIRECTIVE 89/392/EEC amended by 98/37/EEC
DECLARATION OF CONFORMITY We hereby certify that the machinery stipulated below complies with all the relevant provisions of the EC Machinery Directive as amended and the National Laws and Regulations adopting this Directive.
Machine Description: Make:
E-Series and HV Equipment Range
Type:
Rope Mop Skimmer
Name:
Oil Pollution Environmental Control Limited
Address:
1 Nab Lane, Batley, West Yorkshire, WF17 9NG, ENGLAND
Is in conformity with the provisions of the following other EEC Directives:
Page
60
89/336/EEC (EMC) amended by 91/263/EEC and 73/23/EEC (Low Voltage) amended by 93/68/EEC
WARRANTY APPLICABLE FOR O.P.E.C MOP SKIMMER SYSTEMS ONLY
BRAND NAME: SKIMMER TYPE:
E-SERIES AND/OR HV E-Series & HV Range of Equipment
TERMS AND CONDITIONS: Should any part of the mechanical system require repair or replacement as a result of a manufacturing or material defect within the date of expiry (above) that part will be repaired or replaced completely free of charge, either directly or via an authorised agent of Oil Pollution Environmental Control Ltd. The mop component will be covered as per the conditions above for a period of not more than six months from the date of delivery. Under normal circumstances no responsibility will be accepted where the part has required repair or replacement as a direct result of: 1. The equipment not having been maintained by O.P.E.C Ltd agent in accordance with the manufacturers’ recommendations using only specified O.P.E.C Ltd genuine parts. 2. The system having been damaged by neglect, accident or improper use, including not having a suitable thermal overload installed. 3. The system having been altered from the manufacturers’ specifications. No liability can be accepted for the accessories or equipment not supplied by O.P.E.C Ltd. Your statutory rights and obligations against the supplier are not in any way affected by these statements. Items which are subject to the level of wear which usually involves replacement during normal service and maintenance operations will not generally be covered unless such items have suffered undue wear and tear as a direct result of an original manufacturing defect. Similarly these arrangements do not cover adjustments which may be needed from time to time and which depend upon the way in which the equipment is operated. WARRANTY TERM:
Page
61
This warranty shall remain valid for 12 months after the Goods, or any portion thereof as the case may be, have been delivered to or accepted at the final destination indicated in the Contract, or for 18 months after the date of shipment from the port of loading in the source country, whichever period concludes earlier.
RE-ORDER LIST - E SERIES SPARES Company Name: Contact: Purchase order number: Fax to: Email:
44 (0) 1924 471925
Product Code MCE007 MCE010 MCE011 MCE013 MCE014 MCE015 MCE016 MCE017 MCE018 MCE019 MCE020 MCE021 MCE022 MCE027 MCE031 MCE032 MCE033 MCE034 MCE035 MCE036 MCE037 MCE038 MCE039 MCE040 MCE104 MCE107 MCE108 MCE109 MCE180
Description GEAR BOX PUJOL LAC 49/40/160-14: 40:1 RATIO DRIVE GEAR MAIN ROLLER CARRIER SHAFT BEARING COMPLETE LOWER ROLLER SHAFT DRIVE PLATE DRIVE PLATE WASHER SCRAPER SCRAPER CLAMP PLATE TENSIONER ARM TENSIONER UNIT TOGGLE LEVER ASSEMBLY SPLASH PLATE TOGGLE FASTENER CATCHPLATE CARRIER BUSH RH CARRIER BUSH LH INLET ROLLER INLET ROLLER SHAFT DISTANCE COLLAR INLET RETAINING CLIP INLET DRIP TRAY "L" BRACKET POLY COATED CLIP REF 507-781 MAIN SHAFT BEARING 1330x306 INSERT UPPER MAIN SHAFT MKII&III LAC UPPER MAINSHAFT KEY SPLASH PLATE
MCE007/M
GEARBOX NMRV-50 - ATEX UNITS ONLY
sales@opec.co.uk Quantity Per Unit 1.00 2.00 2.00 1.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 1 00 1.00 1.00 1.00 2.00 2.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
RE-ORDER QTY
RE-ORDER LIST - HV UNIT SPARES Company Name: Contact: Purchase order number: Fax to: Email:
Product Code MCH003 MCH004 MCH005 MCH007 MCH009 MCH010 MCH012 MCH013 MCH016 MCH018 MCH020 MCH022 MCH055 MCH055/A
44 (0) 1924 471925
sales@opec.co.uk
Description MAIN DRIVE SHAFT MAIN DRIVE SHAFT KEY MAIN DRIVE SHAFT PIN MAIN DRIVE ROLLER MAIN ROLLER END PLATE MAIN SHAFT BEARING STUB SHAFT UPPER BEARING ROLLER ARM TUBE SET MOP PROTECTION STRIPS KNOB SCREWS ENGINEERING STUD GEARBOX NMRV40-30-11-140MM GEARBOX - FLAMEPROOF
Quantity Per RE-ORDER Unit QTY 1.00 2.00 2.00 2.00 1.00 1 00 1.00 2.00 2.00 2.00 4.00 2.00 2.00 1.00 1.00