5.1 Assembly
The separator is delivered fully assembled and requires a minimum of work for installation. The oil discharge
controls are pre-wired and tested prior to despatch.
5.2 Installation
5.3 Location
The separator system should be installed in an accessible location. It should be bolted down to steelwork
sufficient to withstand the overturning movement of the system when full, at maximum roll and pitch of the
ship. Sufficient space around the separator should be allowed for maintenance and servicing.
5.4 Piping
Piping and valves to and from the separator should be installed strictly in accordance with the process flow
diagrams supplied. Piping runs should be kept to a minimum length and changes in direction avoided where
possible to prevent unnecessary turbulence in the inlet piping and keep back pressures to a minimum on the
discharge side.
5.5 Headroom
There should be adequate headroom for the removal of the first stage Hi-VOR plate and second stage coalescer
– required height is shown on the general arrangement drawing.
Check all vessel lids for tightness, that there is an air supply and that there is power to the unit. Make sure that
all drain and sample valves are shut and that the overboard discharge and recovered oil line valves are open. All
internal connections should already been provided.
There are three air lines required for the operation of the valves. The connection is ¼” BSP and 5-7bar air
pressure is required. Please see diagram for connection.
Power should be provided by the vessel. Standard armoured cable should be used to wire into the control
panel. The CS Series is design for three phase power but other supplies are available on request.
Pipe Sizes
Oil Oil Pressure Feed/Drain Back to Overboard
Model No Feed Inlet
Discharge Discharge Relief Valve Valves Bilge Discharge
Pump 1st Stage 2nd Stage Diverter Diverter
CS250 1¼" BSP 1" BSP ½" BSP ½" BSP ½" BSP 1" BSP 1" BSP
CS500 1¼" BSP 1" BSP ½" BSP ½" BSP ½" BSP 1" BSP 1" BSP
CS1000 2" BSP 1½" BSP ½" BSP ½" BSP ½" BSP 1" BSP 1" BSP
CS2000 2" BSP 1½" BSP ½" BSP ½" BSP ½" BSP 1" BSP 1" BSP
CS3000 2" BSP 1½" BSP ½" BSP ¾" BSP ½" BSP 1½" BSP 1½" BSP
CS4000 2" BSP 1½" BSP ½" BSP ¾" BSP ½" BSP 1½" BSP 1½" BSP
CS5000 2" BSP 1½" BSP ½" BSP 1" BSP ½" BSP 1½" BSP 1½" BSP
During separation the majority of the oil separated from the oily water will collect at the top of the first stage
vessel. When the depth of oil (oil/water interface) reaches the control probe the oil valve will open and
recovered oil will be discharged to oil dump storage.
The duration of the oil discharge is controlled by an adjustable, preset, time delay relay which allows the oil
valve to remain open for several seconds after the probe has again detected water. This cycle will repeat each
time the oil/water interface reaches the probe. Only a small amount of oil passes to and is recovered in the
second stage coalescer and this is discharged through the second stage oil water discharge valve.
Note: The probe is factory calibrated and should not require any alteration to provide efficient operation.
However if the probe fails to operate correctly during the commissioning of the unit, refer to the fault finding
procedures in this manual. There are no replaceable and serviceable parts in this unit.
Position:
1. Drain valves on all vessels.
2. Bilge oily water feed valve.
3. Over board discharge valve (in normally closed position)
4. Oil test cock [SP1] & [SP2]
5. Oil Dump Valve
Position:
1. Clean water inlet valve open
2. Return to Bilge Service Valve
When the system is filled with clean fresh water or seawater, the AGMF will be activated and ready to use.
CHECK THAT SYSTEM IS FILLED CORRECTLY – sampling valve in the second vessel, if opened and water is
running out then the two stages is filled. Remember to close the valves afterwards.
Ensure the water valve is set-up correctly and that the system is ‘pre-set’ to operate at 20psi (1.35bar), see
Section [7.5] to reset this.
IMPORTANT
It is essential that the vessels are initially filled with clean, fresh water or clean sea water. If suction is taken
from the bilges/holding tank, it is likely that oily water will contaminate the clean areas of the system.
Close the Clean Water Inlet to the pump and open the Bilge Oily Water Inlet Valve.
Check the gland packing stuffing box on the separator feed pump and adjust as necessary to avoid air priming.
Gland packing should be replaced when stuffing box contacts the gland housing. Refer to pump manual for full
instructions.
6.4 Annually
Drain both separator stages and remove top covers and all valves etc. Thoroughly wash through the separator
vessels using hot water and clean all valves. Reassemble, then using new second stage coalescer cartridge(s)
and joints test and reset if required pressure relief/water valve as previously indicated.
We would recommend full service and re-commission by one of our qualified service engineers.
We offer a worldwide service. Please contact our office or one of our agents for a quote.
info@victormarine.com
Maintenance of the first stage Hi-VOR vessel should be infrequent and assumed on an annual basis, during a
full service period.
(50mm)
(50mm)
When pressure within the first stage vessel exceeds 42psi (~3bar) the coalescer cartridge in the second stage
vessel is blocked so will replacing. When the second gauge reaches 30psi (~2bar) the media (AGM) is saturated
in oils to and should be replaced as follows. The pressure relief valve will release at 50psi (3.45bar), thus it is
important to replace the items before this pressure.
Number of Coalescer(s):
Separator Model Coalescer (s)
CS250, CS500, 1 X 11” (Vertical)
CS1000, CS2000 2 x 11”
CS3000, CS4000, 2 X 11” + 1 x 14” (middle)
CS5000 3 x 14”
The need for these operations and their frequency is entirely dependent upon the maintained condition and
the solids loading of the bilges.
Important: Do not empty the second stage vessel, as clean areas of the internals will be contaminated with oil.
These will need to be thoroughly cleaned before the unit can be operated effectively.
Replace lower mesh fit new felt and fit mesh; Fit
lower frame. Refill with new media up to ~50mm
K below the middle mesh support bars. Replace
middle mesh and refill with new media up to
~50mm gap from top mesh.
Separator Model Number of Buckets in Top Section Number of Buckets in Bottom Section
CS250, CS500, 2 (25 Kg) 2 (25Kg)
CS1000, CS2000, 4 (50Kg) 4 (50Kg)
CS3000, CS4000, 6 (75Kg) 6 (75Kg)
CS5000 8 (100 Kg) 8 (100 Kg)
7.3.1 General*
The bilge pump is an integral part of the separator and should come mounted and pre-wired on arrival.
Normally the bilge pump would be installed with a direct on-line starter to ensure maximum start torque. The
motor would have been checked for rotation during factory assembly and wiring. When placing the separator
ensure the bilge pump has aqueduct ventilation, space and lighting to ensure effective maintenance and
operation. Suitable arrangement must also be available for gland draining and dismantling. The bilge pump is
designed only to handle oil and water.
7.3.2 Handling
The bilge pump if dismantled should be handled with due care. For lifting and assembling, use suitable lifting
tackle and slings, if the pump or any of its components weigh more than 20 kg. The position of slings will
depend on specific pump model and mounted accessories. If eyebolts are provided, they should be used for
lifting.
7.3.3 Safety
In the interest of safety of personnel and in compliance with statutory requirement of various countries, the
pump pulleys and couplings must be enclosed with proper guards. The surface temperature of the pump
depends upon factors like ambient temperature and temperature of the fluid being pumped. If the external
pump surface temperature goes above 50°C, personnel must be made aware of this and suitable warnings must
be issued or guarding must be employed. Experienced personnel should carry maintenance, servicing and gland
adjustments, so that safety of the personnel is not endangered.
NEVER RUN THE PUMP IN A DRY CONDITION EVEN FOR A FEW REVOLUTIONS
OTHERWISE THE STATOR & ROTOR WILL BE DAMAGED IMMEDIATELY.
The wear rate of these components depends on many factors, such as product abrasiveness, speed, pressure
etc. One or possibly both items will need to be replaced when the pump performance has reduced to an
unacceptable level.
*Note: For more information Victor Marine may supply a separate pump manual for the service and operation
of the pump supplied with the separator.
RATING
RATING
(MAX)
(BAR)
(BAR)
TYPE
WGT
MAX
ØSD
ØSD
(KG)
A1 A2 A3 B1 B2 C1 C2 E1 E2 F1 F2 F3 H1 H2 K L M N
ØX
ØY
CS250
472 94 443 540 455 290 32 32 22.5
CS500
CS1000 34 387 75 104 38 26 87 358 40 90 170 40 557 343 180 150 25 21.5
96 5 12 50 16 50 16
CS2000
432 403 602 388 225 22.5
CS3000
CS4000
65 531 103 85 115 29 30 109 502 44 112 212 31 730 482 290 200 30 65 65 35.5
CS5000
IMPORTANT WARNINGS
DO’S
1. When re-starting after a prolonged stoppage, always fill the pump with fluid and give a few turns to
provide necessary lubrication.
2. Always check that the pressure relief device is operating for safety.
3. Use only direct on-line starters or starter’s provided by Victor Marine for meeting starting torque
requirement of pump.
4. Always uncouple pump while motor is being wired and checked for rotation to prevent dry running of
pump.
5. Always use genuine Victor Marine spares for sustained pump performance and longer life of critical parts.
Request spare’s list from manufacturer or agent.
6. Always consult Victor Marine in case of any change in operating parameters, like temperature, viscosity,
percentage of solids, liquid composition etc.
DON’TS
1. Never run the pump in a dry condition even for a few revolutions otherwise the rotor will damage the
stator immediately and will require replacement.
2. Never run the pump against a closed inlet or outlet valve.
3. Never use foot valve for slurry applications.
4. Never vary flow rate by throttling suction and delivery line.
5. Never exceed recommended pump speed or change the motor provided.
6. Never reverse the recommended direction of rotation of pump.
NOTE: Disassembly of the dump valve can cause injury. ONLY undo head section of valve with compressed air
present and valve in the open position.
The oil dump valve is fully assembled into the system on arrival. To maintain ensure that the system is off and
pump is not running. To test the oil dump valve, use the ‘test’ button housed inside the oil capacitance probe.
Pneumatic seat and pinch valves are to be operated by the signals from the control panel. An air inlet of the
recommended pressure; see data sheet is required.
Operation simply requires normal manual force. The use of extensions to increase the operating torque is not
permitted.
The valves do not require regular maintenance work. During checks on the pipeline section, no leakage must be
found in a valve. If this occurs please contact the manufacturer for further instructions or replacement.
It is recommended that valves that remain in the same position over long periods should be switched to the
"ON" and "OFF" positions one or two times per year. To operate this use the ‘test’ button on the oil capacitance
probe.
1. Check that the manual operation lever on the side of the air valve is in the correct position and not in
the override position.
2. Check the air supply to the valve is correct.
The seal on the water valve when closed is provided by an “O” ring located on the underside of the valve
piston, both of which are replaceable. The piston is held in position by a compression spring tensioned by an
adjusting screw.
To replace the valve internals remove the valve bonnet. The piston “O” ring, piston or spring etc. may then be
removed and replaced.
The valve is pre-set to open at 20psi (1.38 bar). If this is in doubt or if the valve has been removed from the
separator for overhaul, the valve should be reset as follows:
To set the water valve: Start the separator feed pump and deliver clean water to the system. Screw down the
pressure adjusting screw until the pressure gauge on the first stage vessel shows 20psi (1.38bar) – lock the
compression screw and replace the leak proof dome.
1) Body 4
2) Piston
3) Bonnet 9
4) Dome
5) Spring 7
6) Spring Cap
7) Compression Screw 8
8) Compression Locknut
9) “O” Ring Seal 3
10) “O” Ring Seal
11) “O” Ring Seal 6
10
11
The probe is adjusted to a ‘water finding’ state and when in water the relay in the probe head is energized.
When immersed in oil the probe switches, the relay de-energizes; the oil valve solenoid energizes causing the
oil discharge valve to open. The ‘set point’ trimmer is adjusted clockwise to see water and anti-clockwise to see
oil.
With the probe in water and the power on, the relay should be switched and the LED should be illuminated. If
this is not so the set point trimmer in the probe head should be adjusted slowly clockwise until the LED is
illuminated.
Note: Switching of the probe from oil discharge to water discharge is delayed by the timer for instant operation
make a note of the timer settings and set jumper into 0 seconds. Ensure power is off when changing jumpers.
Assuming that the controls are switched on, the probe is in oil (test at the sampling valve) and the solenoid
operated oil discharge valve fails to open:
1. Slowly turn the set point trimmer anti-clockwise until the probe relay switches. If the relay switches
and the valve remains closed, check with a meter, the solenoid coil. Replace if defective.
2. If relay fails to switch in the foregoing test, check the appropriate terminal out-put with a test meter in
the probe head, replace if defective and re-trim the probe.
3. The override relay test button can be used when the capacitance circuitry is not working. Pressing the
button will open the oil discharge valve.
4. If this fails to switch the relay/valve fails to open after all the previous noted checks then there is a
failure in the probe circuitry and a new PCB internals must be fitted.
As noted on the previous page the probe is factory set and should not require any alteration other than the
minor corrections to the set point as indicated in the above checks. If any damage occurs to the capacitance
probe, order a replacement from the manufacturer.
7.6.3 Installation
Mechanical: Install the probe into position, ensuring that all joints are leak free
Electrical: Install the unit, ensuring that all local and national regulations are adhered to. Ensure that the power
supply is externally fused with a minimum of 2A, anti-surge and that the power supply is within the specified
range before energising.
Set Points under normal conditions when CS250 CS500 CS1000 CS2000 CS3000 CS4000 CS5000
probe is in clean water
Power LED (green) ON ON ON ON ON ON ON
In-Water LED (yellow) ON ON ON ON ON ON ON
SetPoint Adjust Centre Centre Centre Centre Centre Centre Centre
Sensitivity Adjust Low Low Low Low Low Low Low
Timer Adjustment (seconds) 60s 60s 60s 30s 30s 15s 15s
Relay Mode Switch A A A A A A A
NOTE: Overboard connection is downwards for safety reasons. The valve and its components are shown below:
dimension increase
BACK TO B P B P
INLET INLET
BILGE
seating seal
screwed seat A A
seal
OVERBOARD
NOTE: Disassembly of the diverter valve can cause injury. ONLY undo head section of valve with compressed air
present and valve in the open position.
The diverter valve is fully assembled into the system on arrival. On initial power up, the solenoid valve will self
check by opening and closing once. This will indicate that the valve is operating correctly.
To maintain the valve, ensure that the system is off and pump is not running. To test the three-way diverter
valve, use the oil content monitor (Bilge Alarm). If monitor is in the alarm state the valve should be in the
closed position (fig 1). If the monitor is in non active state, the valve should be in the open position (fig 2).
An air inlet of the recommended pressure is required, see data sheet provided.
The valves do not require regular maintenance work. During checks on the pipeline section, no leakage must be
found in a valve. If this occurs please contact the manufacturer for further instructions or replacement.
It is recommended that valves which remain in the same position over long periods should be switched to the
"ON" and "OFF" positions one or two times per year. To achieve this, use the oil content monitor by activating
the alarm on/off status (OFF is sample water below 15ppm and ON is sample water above 15ppm).
1. Check that the manual operation lever on the side of the air valve is in the correct position and not in
the override position.
2. Check the air supply to the valve is correct.
The CS Series is normally provided with an oil content monitoring device and three-way diverter valve set. The
unit will already been prewired and test upon dispatch. Please revert back to our supplier’s manual for further
information and certification.
This assumes that there is water flowing through the measuring cell.
NOTE: The ‘Manual Clean’ should not be removed with the power applied to the monitor –
a CELL BREACH error will be displayed on the LCD screen that will render the monitor inoperable.
This will require the unit to be returned back to manufacturer for resetting!
8. Optional Items