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HFM 15ppm Bilge Separator Operation Manual
HFM 15ppm Bilge Separator Operation Manual
OPERATION MANUAL
FOR
15ppm BILGE SEPARATOR
Dec. 2011
6
12-06-04
䞉 0Q 䞉
H E I S H I N P U M P W O R K S C O . , LT D
OPERATION MANUAL
FOR
CONTENTS
3. Operation䢢 ············································································································ 4
6. Maintenance䢢 ······································································································· 5
* * * * * * * *
凣 CONSTRUCTION OF THE HFM-MODEL 15ppm Bilge Separator
Heishin 15ppm Bilge Separators, model HFM, are approved under the terms of IMO
Resolution MEPC 107(49) for 15 ppm criteria, by various Governments and have been
issued with Type-approval Certificates. HFM separators have 4 stages that are connected
with a water passage pipe and an oil discharge pipe.
-1-
1-6 Oil discharge pipe
Each oil discharge pipe from the 1st stage to the 4th stage is fitted with valves
(a motor-driven valve for the 1st stage and ball valves for the 2nd, 3rd and 4th stages.).
These pipes join together to form a single oil outlet.
-2-
SW3: Test switch
-3-
3 OPERATION
3-2 Operation
Procedures for daily service of 15ppm Bilge Separator:
1. Turn on the power supply to the automatic oil discharge device.
2. Open all the valves fitted to the bilge discharge pipe line and start the bilge pump.
Caution
Where the 15ppm Bilge Separator has been unused for more than one week, flush
the 15ppm Bilge Separator with seawater using bilge pump for 15 - 20 minutes prior to
handling the bilge. This is because oil, suspended solids (SS), sediment and bacteria
staying in the 15ppm Bilge Separator may have changed into containments by
biochemical reaction and affect the 15ppm Bilge Separator’s performance.
3. During the operation of the 15ppm Bilge Separator, oil is separated from bilge water
and accumulates at the upper part of each stage, and eventually this separated oil
should be discharged into the waste oil tank.
The separated oil in the 1st stage is discharged automatically by an automatic oil䢢
discharge device. Oil in the 2nd, 3rd and 4th stages, however, must be discharged
manually at any time when considered necessary upon checking by the test cock
fitted to the stage. The recommended time for oil discharge is 2 - 3 minutes.
4 SUSPENSION OF OPERATION
In finishing the operation,
1. Flush the 15ppm Bilge Separator with seawater for about 15 minutes.
2. Stop the bilge pump, and switch off the electric power supply.
3. Ensure that the 15ppm Bilge Separator is kept full of water and should not be emptied
whilst it is unused.
-4-
5 SPECIAL NOTE DURING OPERATION
6 MAINTENANCE
In order to keep the performance and function of the 15ppm Bilge Separator in good
condition, proper maintenance is always required considering the bilge water contains a
variety of contaminants including waste oil, sludge, suspended solids (SS), chemical
substance, bacteria, etc. all in different forms.
-5-
6-2 Washing
HFM-model 15ppm Bilge Separator is provided with a washing port fitted on the front
cover of the 1st stage and at the inlet pipe of the 3rd stage. The 15ppm Bilge Separator
should be washed with steam (or hot water) periodically once a month or whenever
considered necessary. Washing can done for both stages either at one time or one stage
at a time.
Washing process:
1. Ensure that the separator is filled up with either bilge or seawater.
2. Connect the steam line to the washing port.
3. Open the motor-driven valve of the 1st stage manually in accordance with 7 - 4 and
also open the oil discharge valves of the 2nd, 3rd and 4th stages.
Important Note !!
Keep these two valves open until the washing out process finishes.
4. Run the bilge pump for a short time to discharge separated oil from one by one stage.
5. Supply live steam (or hot water) in order to heat up water in the 15ppm Bilge Separator
up to 70 - 80䰳. When the temperature rises, stop the supply of steam and keep the
15ppm Bilge Separator in this condition for 2 hours.
6. Run the bilge pump for 2 - 3 minutes to discharge the remaining oil.
7. Drain the water of only the 1st stage to the bilge well from the bottom of the stage.
When draining the water out of the 2nd, 3rd and 4th stages, ensure that separated oil
has been completely discharged out of the stage.
8. Close all valves but open the valves on the pipe for bilge treatment if closed.
9. Start the operation of the 15ppm Bilge Separator for bilge.
Caution
The 15ppm Bilge Separator should be filled with seawater prior to the switch over to
bilge. Washing is completed when seawater is fed into the system.
Important note !!
1. When the 15ppm Bilge Separator is first used, the pressure loss in the coalescer in
the 3rd stage is about 0.01 MPa.
2. When the pressure difference becomes more than 0.07 – 0.1 MPa, washing should
be carried out. There should be no problem if the pressure loss in the coalescer is
over 0.01 MPa even after washing unless it is more than 0.05 MPa.
3. Direct and thorough cleaning by complete dismantle and overhauling of the
coalescer should be done provided the pressure loss is over 0.05 MPa after steam
or hot water washing.
4. It is necessary to replace the existing coalescer in the 3rd stage with a new one if;
(1) the pressure loss still remains over 0.05 MPa after cleaning by overhaul, or
(2) any damage to the coalescer is observed.
-6-
6-3 2nd stage
The 2nd stage contains hard type of emulsion breaker. Filled quantity is checked once per
6 months and the breaker is supplemented with the following procedure if necessary.
(1) Open the oil discharge valve on the 2nd stage and run the bilge pump for a short time
to discharge separated oil from 2nd stage.
(2) Remove the top cover and discharge the inside water from drain port of the 2nd stage.
(3) When the emulsion breaker is seen, stop the discharge from the drain port.
(4) Supplement the emulsion breaker up to *0 high when filling height of the breaker is *1
high as shown below.
凜Amount of spare emulsion breaker is considered by the average of consumption rates for 1 year to 2 years.
凜Consumption rates depends on operating condition.
凜Sales unit of the emulsion breaker is 15kg / 1unit.
-7-
6-4 Overhaul and inspection
Prior to overhauling, it is recommended that washing by steam is carried out and
separated oil in all stages is discharged.
1. 1st stage
(1) Disconnect the influence inlet pipe fitted to the body of the stages.
(2) Unbolt the right body to remove it from the main body.
(3) Unbolt the inner cover for the parallel plates section and remove it.
(4) After removing the front cover, pull out all the parallel.
At the centre of each parallel plates, there is a hole with which the plate can be
pulled out.
(5)䢢 Zinc anodes fitted inside the front cover should have an visual inspection at least
once every 6 months.
Please replace with new ones if heavily corroded.
2. 2nd stage
(1) Unbolt the manhole cover and emulsion breaker can be pull out.
(2) Remove the top cover in order to check inside condition of the stage.
3. 3rd stage
(1)䢢 Unbolt flange on the body flange of right side to pull out the coalescer complete.
(2)䢢 Zinc anodes fitted inside the front cover should have an visual inspection at least
once every 6 months.
Please replace with new ones if heavily corroded.
4. 4th stage
Remove the top cover to pull out the coalescer element.
5. Clean each component and inside the wall of the stage by wiping off or washing with
light oil if necessary. Special attention should be given to check if corrosion has
occurred.
6. If any damage is found, repair it properly.
(a) When replacing a gasket with a new one, the flange face should be cleaned up.
(b) When replacing the internal coating, first clean the damaged or peeled off parts
thoroughly and repaint with epoxy tar on the oil-and rust-free surface. Dry the
coating completely prior to re-assembly.
7. Re-assemble the 15ppm Bilge Separator exactly in the reveres order to the
disassembly.
8. Carry out a leakage check test after re-assembly.
-8-
6-5 Adjustment of oil level probe
The automatic oil discharge device has already been adjusted at our workshop before
shipment, and generally no further adjustment is necessary before 15ppm Bilge Separator
is put into operation. Should further adjustment be required for some reasons the following
re-adjustment can be feasible only when the 15ppm Bilge Separator is full of seawater:
1. External wiring
3 (N) common
2 (N)
Power source (AC 100 - 230V)
1 (P)
-9-
2. Sensitivity adjustment
(1) Sensitivity level is adjusted with dip1 to 4 of SW1 according to table shown below.
(2) Sensitivity level has been set to “7” at our workshop.
(3) If water content in the separated oil is very high, i.e., eclectic conductivity is as
high as that of water, the level is adjusted to more high number, i.e., level “8” –
“10”.
Note: More than level “4”: motor-driven valve is opened if the probe detects heavy or
light oil.
More than level “12”: motor-driven valve is opened if the probe detects sea or
fresh water.
Sensitivity level D4 D3 D2 D1
0 0 0 0 0
1 0 0 0 1
2 0 0 1 0
3 0 0 1 1
4 0 1 0 0
5 0 1 0 1
6 0 1 1 0
7 0 1 1 1
8 1 0 0 0
9 1 0 0 1
10 1 0 1 0
11 1 0 1 1
12 1 1 0 0
13 1 1 0 1
14 1 1 1 0
15 1 1 1 1
Note: 1: ON, 0: OFF
- 10 -
3. Time adjustment
(1) Time is adjusted with dip1 to 4 of SW2 according to table shown below.
(2) Time has been set to 2 seconds at our workshop.
Time (sec.) D4 D3 D2 D1
0 0 0 0 0
2 0 0 0 1
4 0 0 1 0
6 0 0 1 1
8 0 1 0 0
10 0 1 0 1
12 0 1 1 0
14 0 1 1 1
16 1 0 0 0
18 1 0 0 1
20 1 0 1 0
22 1 0 1 1
24 1 1 0 0
26 1 1 0 1
28 1 1 1 0
30 1 1 1 1
Note: 1: ON, 0: OFF
4. Confirmation of operation
A: Detecting function of oil
(1) Check that the wiring is correct.
(2) Check that 1st stage is filled up with seawater.
(3) Turn off all switches of SW1 and SW2. Operation indicate LED (R) goes off and
motor-driven valve is closed.
(4) Turn on all switches of SW1. (sensitivity level: 15)
Operation indicate LED flickers for 1 second and motor-driven valve is opened
after 1 second.
(5) Return to pre-set value of SW1 and SW2 after above check.
Sensitivity adjusting switch : level “7”
Time adjusting switch : 2 seconds
Note: Motor-driven valve is opened when test switch is set to “TEST”.
At normal operation, the test switch should be set to “RUN”.
- 11 -
B: Stopping function of pump
(1) After supplying power to the bilge separator, run the bilge pump.
(2) During the bilge pump is running, remove either one fuse of F1 (Power supply line)
or F2 (Output line) by pulling out its cover of the fuse. (The fuse is set on this
cover.)
(3) Confirm the bilge pump has now stopped.
(4) Cut off the power supply to the bilge separator, and then reset the fuse that was
removed in the step (2).
- 12 -
7 TROUBLE SHOOTING
If any troubles occur to 15ppm Bilge Separator, find the cause immediately for a proper
countermeasure in accordance with the following table.
- The coalescer in the 3rd stage is not - Wash the coalescer to restore
functioning properly due to sludge & it to its original condition.
solid substances.
- The coalescer in the 4th stage is not - Replace the coalescer with
functioning properly due to sludge & new one
solid substances.
兟A short pass in the low passage in 15ppm - Check and repair it.
Bilge Separator occurs caused by; For closer check, hydrostatic
pressure test is recommended.
- Corrosion in the inner compartment - Wash the coalescer in the 3rd
walls of the all stages. stage if badly contaminated, or
correct the fitting of the unit.
- Short pass in the coalescer unit occurs - Replace the coalescer in the
by clogging in the coalescer element or 4th stage if badly
poor fitting of the unit. contaminated, or correct the
fitting of the unit.
- 13 -
TROUBLE CAUSE COUNTERMEASURE
兟 15ppm Bilge Separator is operated with
water lowered for the following
reasons:
兟Before the operation, fill up
- 15ppm Bilge Separator has hot been 15ppm Bilge Separator with sea
filled up with seawater at the beginning water and check it is full with
of the operation. bilge water during operation.
See pressure reading is positive.
- The siphon breaker of the effluent pipe - Check and repair it.
is cogged.
- 14 -
TROUBLE CAUSE COUNTERMEASURE
兟Air enters form the bilge pump. 兟Check the gland packing in the
stuffing box and all the
connecting flanges fitted to the
bilge pump.
For closer check, hydrostatic
pressure test is recommended.
兟Suction pipe of the bilge pump is blocked. 兟Check the pipe and remove any
obstacles if any.
兟Leakage occurs from the relief valve of 兟Check the valve and valve seat
the 15ppm Bilge Separator and/or bilge of the relief valve.
pump.
兟Leakage occurs from the test cock. 兟Repair or replace with new one.
兟Leakage occurs from the oil discharge 兟Check the valve of the 2nd, 3rd
valve. and 4th stage to repair.
- 15 -
TROUBLE CAUSE COUNTERMEASURE
Too much water 兟Malfunction of an automatic oil discharge
contains in the device of the 1st stage
separated oil
- Sensitivity of the oil detecting probe is - Check the probe rand repair or
not properly set. replace it with a new one if
defect is found.
兟Leakage occurs from the oil discharge 兟Close the valve fully if open.
valve of the 2nd, 3rd and 4th stage. Replace with a new one.
Bilge pump 兟The fuse in oil level probe is blown away. 兟Check if supplied power (voltage)
cannot run. to the motor valve and the oil
level probe is correct.
Nowadays when environmental protection is the main world issue, it is very important for a
ship’s crew who directly handle bilge to know the characteristics of the actual bilge prior to
and during the operation of the 15ppm Bilge Separator.
In fact, besides there being many kinds of oil, there are a variety of complicated
characteristics in bilge water for each individual vessel. Even in one particular ship, the
characteristics of bilge water change chemically, physically or biochemically every time
bilge water is generated. In many cases, these factors give a negative influence to the
performance of the 15ppm Bilge Separator.
Our 15ppm Bilge Separators have passed type-approval tests and have been approved
under the terms of IMO MEPC 107(49).䢢 However, satisfactory performance can not be
kept up unless proper maintenance work is carried out. In order to keep the oil content in
the effluent from the 15ppm Bilge Separator within the criteria of IMO regulations, it is
necessary to carefully note and carry out the following procedures.
- 16 -
8-1 Periodical inspection
1. Cleaning
Periodical checks if bilge water is contaminated by detergent and cleaning by system
(or hot water) from time to time is one of the most important maintenance duties for
ship’s crew.
2. Discharge of sludge
Bilge water entering the 15ppm Bilge Separator contains oily sludge including sand,
mud, iron rust, carbon, etc. This oily sludge settles and accumulates in the 15ppm
Bilge Separator and causes clogging resulting in deterioration of separation efficiency.
In particular, F.O. and L.O. sludge create strong corrosion making holes through the
wall of the 15ppm Bilge Separator.
Therefore, it is necessary to remove sludge periodically by either steam washing or
overhaul cleaning and touch up the coating whenever the inner coating is damaged.
3. Maintenance of bilge pump
As the bilge pump is used to handle bilge water which contains a lot of solids and
trash, it has a greater chance of being damaged than any other pumps in the engine
room. It should be carefully noted that inner leakage between suction and discharge,
damage created by solid substances, may easily cause particles of oil to become very
small and minute, in other word, forming a physically emulsion.
Our 15ppm Bilge Separator design is based on the gravitational difference between oil
and water and is not capable of separating emulsion and oil particles of less than 20
microns is size. Therefore, the separation efficiency will definitely decrease if such
small particles of oil continuously enters the 15ppm Bilge Separator.
It is necessary to check the pump bucket, pump valve and valve seat where if
damaged inner leakage will often occur, and these parts must be kept keep in good
condition.
- 17 -
Without exception, all detergents in the market react against oil to make it chemically
emulsified when mixed with water. The size of an oil particle in a chemical emulsion is
far less than 1 micron and will not float at all. For the above reason, in general
detergent has a substantial influence on the 15ppm Bilge Separator.
Physical separation method based on the gravitational difference between oil and
water is not capable of separating particles of oil of less than 20 microns in size for
light oil and 10 microns for heavy oil. Chemically emulsified oil makes maintenance
term of coalescer in the 3rd and 4th stage shorten due to burden enlargement of the
coalescers for emulsion separation.
Therefore, it is very important to avoid mixing any detergent into bilge as less
as possible.
2. Anti-corrosive oil for engine cooling water
Some brands of anticorrosive agent (soluble oil type) have exactly the same
characteristics and ingredients as the above detergent, which is chemically emulsified
when it is dissolved in water.
Therefore, it is recommended not to mix this soluble oil type of anticorrosive oil into
the bilge.
3. Compressor drain
Although drain fluid discharged from air compressors is very small in quantity, this
drain fluid is in most cases emulsified which may cause a negative effect on the
15ppm Bilge Separator.
Attention should be paid to the quantity of compressor drain fluid and proper
countermeasures are necessary if the quantity increases for any reason.
4. Sludge
Sludge is equally as bad a factor on 15ppm Bilge Separator performance as detergent
when it enters the 15ppm Bilge Separator in any great amount. In any case, it is
strongly recommended that mixing sludge into bilge water should be minimised.
- 18 -
9 OTHER FACTOR FOR SEPARATION EFFICIENCY
* * * * * * * *
- 19 -
CLEANING OF COALESCER
Under the condition where an oily water separator is used for a long time, a coalescer installed in the 3rd
chamber (stage) is gradually getting dirty to make separation performance less by clogging the coalescer.
The clog of the coalescer mainly happens when the separator is supplied the bilge containing much sludge
and/or suspended solid, and big amount of oil floating the surface of the bilge. In case that the coalescer is
clogged, differential pressure between 2nd and 3rd chambers (stages) becomes bigger and bigger.
In general, it is recommended to clean the coalescer with steam or hot water when the differential pressure
goes up to 0.07-0.1 MPa except the differential pressure comes from clog of a T-shape strainer fitted on the
connection pipe between 2nd and 3rd chambers (stages). If the strainer is clogged, the strainer is cleaned by
handle fitted on top of the strainer. In either case, cleaning work is carried on in accordance with operation
manual.
In condition where the coalescer is heavily clogged (the differential pressure goes up to about 0.1 MPa.), it is
requested to take out the coalscer from the separator in the following manner for cleaning purpose.
1. The coalescer is taken out from the separator, and immerses the coalscer element into light oil for a half
day to dissolve sludge therein.
2. The coalescer element is taken out from the light oil, and the wire for forming is cut. Then, spread the
element sheets on an iron plate or equivalent plate.
3. The element is washed by sea or fresh water which pressure should be less than 0.1 MPa.
Caution:
1. To avoid damage of glass fiber of the coalescer element, attention shall be taken;
a) not to spray fresh or sea water to the element with pressure of more than 0.1 MPa.
b) not to spray the fresh or sea water to the element in condition where the element sheets are not
spread on the flat plate.
c) not to shake the element sheets in water very hard.
2. It is not necessary to remove color of iron rust on the element. If the element is strongly washed to
remove the color, glass fiber of the element is damaged.
3. Cleaning detergent is not allowed for washing the element. If the detergent is remained in the element
after cleaning work, separation performance is adversely affected as oil is emulsified in the coalescer
element.
㻞㻜
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㻞㻝
ᮏ♫兟ᕤሙ Head Office刷Factory
ර⚄ᶵᲔᕤᴗᰴᘧ♫ HEISHIN PUMP WORKS CO., LTD.
傞675-0146 1-5-30, Furuta, Harima-cho, Kako-gun,
රᗜ┴ຍྂ㒆☻⏫ྂ⏣ 1-5-30 Hyogo Pref, Japan 675-0146
ྲྀᢅᗑ
Sales Agent