OPEC FOG REMOVAL SYSTEM GUIDANCE NOTES 1.0 CONTRACT DETAILS Client Contractor Contractor Purchase Order Site Location OPEC Works Order Model Number Equipment serial number Delivery date OPEC Project Manager
Northern Ireland Water Lagan Water 130226-SC61-600-008-AMW Strabane WwTW, Co Tyrone Primary settlement tanks grease tank 10287 E150.7.C.391 1302559 13 March 2013 AIDAN MCLAUGHLIN
2.0
GUIDANCE NOTES TO MAJOR ITEMS
2.1
E-SERIES MOP SKIMMER
2.1.1 REFER TO OPEC OEM MANUAL FOR STANDARD OPERATION. 2.1.2 The E-Series has been fitted with a standard 3-phase 400v motor. The supply is 230v 1-phase. The control panel is fitted with an electronic invertor which converts the input power. The invertor also has pre-set overloads to maximum Full Load Current (FLC) (in amps). This has been factory set and should not be altered. 2.1.3 The invertor is fitted with a potentiometer dial on the panel door to alter mop speed. This has been factory set to a minimum of 30HZ and should not be altered otherwise damage could occur to the motor running at very low speeds. It is safe to use the dial on the door as the electronic invertor in the panel regulates the maximum and minimum frequency’s permitted.
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2.1.4 The safety cover is fitted with a guard switch to ensure any opening of the cover panel will cut OFF power to the machine via the control panel.
2.2
IMMERSIBLE PUMP
2.2.1 REFER TO HIDROSTAL OEM MANUAL FOR STANDARD OPERATION 2.2.2 The pump has been fitted with a 3-Phase 400V motor. The supply is 230V 1Phase. The pump is governed by the invertor in the panel which converts the input power. The invertor also has present overloads to a maximum FLC (in amps) This has been factory set and should not be altered. 2.2.3 The invertor is fitted with a potentiometer dial on the panel door to alter pump speed. This has been factory set to minimum of 40HZ and should not be altered otherwise damage could occur to the motor running at very slow speeds. It is safe to use the dial on the door as the electronic invertor in the panel regulates the maximum and minimum frequency’s permitted. 2.2.4 With the Panel in Auto Mode, once the pump has been activated, (by the level switch engaging at tank ‘High’ Level setting) a built in timer is activated. This is a safety control to ensure that if there are any issues regarding the pump operation are detected, the pump will time out avoiding equipment damage. This pump protection feature sends an alarm to the site controls facility for immediate inspection. The potential issues that would trigger this alarm are as follows: • • •
Pump failure, Pump suction blockage Pump discharge blockage
This is currently set at an increment of 1-10 minutes with the main dial set at the maximum of 10 minutes. The OPEC factory test (with clean water) emptied the tank in approximately 8 minutes The test was repeated on site during commissioning. The liquid transfer times will vary as it depends on a number of factors such as: OPEC FOG REMOVAL SYSTEM GUIDANCE NOTES Page 2 of 6
• • •
The viscosity and type of the materials recovered The volume of materials available for recovery. The change in liquid and particles consistency as the tank liquid level changes during each operating cycle.
Image illustrates the factory setting for the timer as 3.5 minutes. This was increased to 10minutes during site the commissioning carried out by Aidan McLaughlin
Additionally, a localised visual alarm beacon is included in the standard specification. This will also alert the site operative who can provide immediate support if required.
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2.2.5 The pump is lowered to position inside the tank by attaching to the factory fitted davit arm (image 6). The pump pipe connections are 2” flexible plastic pipe fitted with 2” plastic camlock couplings (image 7). These can be easily snapped on and off for service and installation. The cable is fitted with an EEXD flameproof (spark proof) plug and socket within the tank as this is operating in a confined space (image 7).
(image 6)
(image 7).
2.2.6 The panel door speed control (Potentiometer dial) should only be used if absolutely required. Once the pump timer has been set, altering the dial on the door will also alter the pump out time and set a false alarm. The pump speed should only be altered in manual mode – NOT auto mode on the panel. 2.3 LEVEL SWITCH The level switch has been factory set to minimum and maximum operating levels within the tank and should not be altered. The level switch activates the pump at high level and cuts off the power to the skimmer whilst the tank is being automatically emptied. The level switch stops the pump at low level and resumes power to the skimmer for re-filling the unit. This is repeat cycle. 2.4
CONTROL PANEL
REFER TO WIRING SCHEMATIC FOR FULL DETAILS. 2.4.1 ELECTRIC SUPPLY: Supply voltage is 230v single phase supply. We will be supplying a three phase pump and skimmer with single phase 230v supply via invertor mounted in panel with external potentiometers. The control panel will have an internal transformer to reduce switch voltage on the panel from 230/110v.
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2.4.2
CONTROL PHILOSPHY:
1. The main control panel is mounted to the package and wired and tested at our workshop for all the main components. Only mains supply is required to the panel to begin operation. 2. Both the pump and the skimmer operate automatically by way of relay switches in the panel. This is all controlled by the level control switch in the buffer collection tank. (All within one package) 2.1 At LOW level skimmer is turned on and pump is off 2.2 At HIGH level skimmer is turned off and pump is turned on 3. Both the pump and the skimmer can be operated manually by push buttons which will by-pass the automatic operation if required. 4. There is an auto-switch on the outside to put the operation into the automatic mode 5. There are red stop push buttons for auto and manual mode. 6. There is a lockable isolator on the outside 7. There is a common alarm for anything which trips on the machinery. When this happens a flashing warning beacon starts on the top of the panel, a signal is sent to the profibus module and a specific warning light activates on the panel door alerting operators there is a problem which requires attention. 8. There are green LED lights for plant operation (will light up when either the skimmer or pump is in operation) 9. There are red LED lights for any part of the plant which has tripped. 9.1 Skimmer motor overload trip light 9.2 Pump motor overload trip light 9.3 Pump failure – ‘High Pressure’ light activated by pump time out (Refer to 2.2.4 above) 10. The control voltage in the panel is transformed down from 230v/110v with yellow cabling. 11. There is an on/off switch to control the heat tracing for the pipework 12. There is a relay switch in the panel which will need to be linked up to the main FOG/Storage tank to turn off all power to our machinery when this tank is full as well as activate a flashing beacon on top of our panel. 13. There are 4 signal outputs to which you can take a signal to a control room for the following: 13.1 13.2 13.3 13.4
Auto Run Common Alarm Skimmer Run Pump Run OPEC FOG REMOVAL SYSTEM GUIDANCE NOTES Page 5 of 6
2.5 HEAT TRACE AND THERMOSTAT REGULATOR Heat tracing cable temperature is regulated by the 230v, 0-40 degrees C thermostat mounted to the machinery close to the pump outlet pipework and controlled by the control panel.
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