OPERATOR MANUAL

NFV- BILGE WATER SEPARATOR

PPT - BWS 10000

Stocznia Sczecinska S.A.

Yard No. B178.I.8

Order No. PL/001382794/02-0163

NFV-Project No. N02/173

Flow rate: 10 m³/h

Voltage: 440 V
Frequency: 60 Hz
Serial number: N02/173-5

Rev. 01 from 28.02.2000 -0-

 CONTENTS
INTRODUCTION TO OPERATING INSTRUCTIONS

1 SAFETY INSTRUCTIONS

2 FUNCTIONING

2.1 General Description

2.2 Function principle

3 INSTALLATION

4 PRE OPERATIONAL CHECKING AND SETTING INTO OPERATION

5 OPERATION AND SUPERVISION

5.1 Setting the unit into operation - switching OFF the unit

5.2 Supervision during operation

6 MAINTENANCE

6.1 Cleaning of the oil level electrodes

6.2 Sludge outlet

6.3 Cleaning of the PPT-BWS

6.4 Re-installation of the MPT-insert

6.5 Maintenance intervals

7 TROUBLE SHOOTING

8 SPARE PARTS LIST

.... für bessere Filtertechnik und Phasentrennung

NORDDEUTSCHE - FILTER
VERTRIEBS GMBH - Forschung - Planung - Fertigung

Tarpenring 33, 22419 Hamburg, Tel. 040/5273011-12, Fax 040/5278089

Internet: http:\\www.nfv-gmbh.de e-mail: engineering@nfv-gmbh.de
ENCLOSURE

A. Operating manual oil alarm monitor

B. Operating manual pump
C. Add-on parts
D. Drawings
 Flow diagram
 Overview and parts list
 Electric diagrams

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Introduction to Operating Instructions

The instruction manual should serve to simplify getting familiar with the bilge
water separator and to explain the different applications.

The instruction manual contains important instructions on how to use the bilge
water separator safely, appropriately and economically. Paying attention will
help you to avoid danger, to minimize repair costs and breakdown times, as
well as increasing the life of the bilge water separator.

The instruction manual is to be adjusted according to the country regulations in

regard to accident prevention and environmental protection.

The instruction manual must be available at the place of operation at all times.
Each person that works with the bilge water separator must read and follow the
instruction manual.

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1 Safety instructions

 The bilge water separator must only be used in technically perfect condition in
accordance with its designated use and the instructions set out in the operating
manual.
 Faults should be rectified immediately
 The manufacturer/supplier cannot be held liable for any damage resulting from
improper use.
 Operating the bilge water separator within the limits of its designated use also
involves observing the instructions set out in the operating manual and complying with
the inspection and maintenance directives
 In addition to the operating instructions other generally applicable legal and other
mandatory regulations relevant to accident prevention and environmental protection.
 Observe all safety instructions and warnings attached to the bilge water separator.
 Never make any modifications, additions or conversions which might affect safety
without the supplier’s approval. This also applies to the installation and adjustment of
safety devices and valves as well as to welding work on load-bearing elements.
 Spare parts must comply with the technical requirements specified by the
manufacturer. Spare parts from original equipment manufactures can be relied to do
so.
 Employ only trained or instructed staff and set out clearly the individual responsibilities
of the personnel for operation, set-up, maintenance and repair.
 Work on the electrical system and equipment of the bilge water separator must be
carried out only by a skilled electrician or by instructed persons under the supervision
and guidance of a skilled electrician and in accordance with electrical engineering
rules and regulations.
 When handling mineral oil as well as cleansing agents observe product-related safety
regulations

Rev. 01 from 28.02.2000 -4-

2 Functioning

2.1 General Description

The NFV - bilge water separator PPT-BWS is used for the separation of
mineral oil and solids from waste water. It is only working by gravity.

The separator consists of the following main components:

1. Separator housing with oil collecting dome and Plate-Phase-Separator

2. Eccentric screw pump with gear motor.
3. Internal safe level sensor for control of automatic oil drain.
4. Control box.
5. Oil-monitor
6. 3-way-valve.

Attention !

Detergents should not be used for cleaning of machine parts onboard,

because nearly all cleaning agents are causing stable oil/water emulsion,
which could not be separated by any bilge water separator.

If the use of a cleaning agent is absolutely necessary, do only use quick

separating agents!
We recommend the following cleaner:
HAKU 1025/965
The examination of cleaning agents concerning their compatibility with
bilge water separators and oil monitors will be continued.

For further information, please, call NFV-Hamburg ++49 - 40-5273011/12

Rev. 01 from 28.02.2000 -5-

2.2 Function principle

The eccentric screw pump transfers the oily water mixture from the bilge or
the bilge water collector tank through the patented plate phase separator
(PPT).

The separating profiles of the PPT are causing a slow laminar flow. Inside
the PPT all oil droplets of a diameter down to 20 micron will be catched and
separated by the oleophil profiles.
A slightly pulsating flow, caused by the wave form of the PPT-profiles
intensifys the coalescing possibility (particle collision) of even oil drops
smaller than 20 micron into bigger droplets, which than can be separated by
the oleophil profiles, too.
Through holes in the profile tops the collected oil is led to the top of the
PPT separator and further into the oil collecting dome.
The slits between the PPT profiles make possible the simultaneous
separation of oil and solids. The effluent water of the bilgewater separator
has now a rest oil content of < 15 ppm in accordance with the IMO-
Resolution MEPC. 60 (33) and can be given overboard.

Safety valve
The safety valve opens at a pressure of 3,2 bar.

Automatic oil discharge valve

The level sensor fitted in the oil collecting dome is controlling the opening of
the oil discharge valve when maximum oil level is reached. The separatied
oil is then discharged into the waste oil tank automatically. The level sensor
also reacts on air occuring in the oil collecting dome which is then ventilated
automatically, too.

Dry run protection

When the pump is getting air, the air will go up into the oil collecting dome.

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 The level sensor reacts on this air and opens the oil discharge valve for
ventilation and activates the internal dry run protection, which stops the unit
automatically.

Motor protection
The pump drive motor is protected against overload.
When the max. permissible current is exceeded or in case of a „phase out
of action“, the motor protection relay will be activated and the pump
switched off. In this case the indicator light „motor overcharded“ is
illuminated. The motor has to cool down and the motor protection relay has
to be reset, before the pump can be swithced on again.

Oil-dome heater
There is an electric screw-in heater installed in the oil collecting dome to
keep the oil flowing. The operation of the heater is controlled by the oil level
sensor and supervised by an integrated temperature sensor, which switches
the heater off, when max. oil temperature is exceeded. The heater is
switched on, until the oil collecting dome is completely filled with oil and the
collected oil will be discharged by the oil discharge valve. During the oil
discharge valve is open, the heater remains switched off. Operation of the
heater is indicated by indicator light „heater on“.

Control box
For operation and supervision of the unit, the control box is equipped with:

1. Indicator light „Power on“ - white

2. Indicator light „pump in operation“ - green
3. Main switch 0 - 1
4. Push button/indicator light „oil drain“ - yellow
5. Pump switch „Hand -0-Auto“
6. Hour meter
7. Indicator light „motor overcharged“ - red
8. Indicator light „heating on“ -green

Operation: manual / automatic operation

- manual mode:
pump switch in pos. „Hand“ (manual)-, the unit works until it is switched off,
pump switch in pos. „0“.

Rev. 01 from 28.02.2000 -7-

 There is no automatic control in this operation mode.

- automatic mode:
- pump switch in pos. „Auto“-, the unit can be controlled by two float
switches *. When the max. fluid level in the bilge is reached, the unit will be
switched on by the level when the fluid level has reached minimum.

* no NFV-supply

Discharge water supervising system

In the outlet of the separator is fitted a sample water piping through a 3-way
ball valve to the oil-monitor. The ball valve is connected by the ship yard
with a flushing line (oil free water 1-2 bar) for the oil monitor. Through the
sample line a partial stream of effluent water is continuously analysed by
the oil monitor. Normally, the rest oil content is < 15 ppm and the separated
water will be discharged overbord through the opended internal safe 3-way
valve.
The unsufficient deoiled bilge water is then pumped back to bilge or to bilge
water collecting tank. In case of exceeding the 15 ppm limit the oil monitor
is switching the solenoid valve of the 3-way valve. It is also possible to
integrate one of our new developed Mechanical - Emulsion - Breakers
(MEB) into the system. With this add-on unit, it is possible to reach rest oil
contents of < 5 ppm!
For further information see enc. operator manual of oil monitor.

Rev. 01 from 28.02.2000 -8-

3 Installation
see Appendix C: - Drawing “flow Diagram“ / installation proposal
- Drawing of delivered bilgewater separator
- circuit diagram
- Parts list control box
- Terminal connection diagramm
1. The bilge water separator requires an installation space according to the drawing.
When installing the PPT-BWS, watch for the necessary service space.
2. Tighten the separator unit on the foundation.
3. Arrange and connect the necessary piping according installation proposal.
4. Connect the pump inlet to bilge suction line.
- max. suction = 4 mWs
- max. flow velocity = 1 m/sec.
Remark: Install a strainer filter (min. mesh size 5mm) and check valves in the
suction line of the pump.
Important: A fill and flush line has to be installed and connected to pump inlet
(oil free water max. 1-2 bar which is always available during operation).
5. Connect separator outlet to overboard line with stop valve. In case of installation a
3-way valve for back to bilge operation, check installation position.
Important hint:
3-way valve and intermediate pipe parts have to be installed that way, that after
disassemly, a space is left for maintenance.
6. Connect the oil drain valve to the waste oil collecting tank.
7. Install a drain line with funnel from the safety valve to bilge.
8. Install a sludge drain line with ball valve to sludge tank, not into the bilge!
9. Connect 3-way ball valve in front of oil monitor with seawatersystem (max. 1-2 bar).
10. Install a piping line from oil monitor outlet to a funnel with free outlet for
sample taking possibility. The outlet bow with the funnel has to be installed above the
highest point of the bilgewater separator to avoid running empty of the system.
11. Connect a compressed air line (6 bar, 1/4“) to the solenoid valve of the oil
discharge valve.
12. Connect another compressed air line to the solenoid valve of the 3-way
valve for back to bilge operation.

Rev. 01 from 28.02.2000 -9-

4 Pre-operational checking and setting into operation

A. Checking of compressed air system

1. Open valves in compressed air line, check pressure (6 bar) and see if oil discharge
valve is open.

B. Filling of the system with oil free water through pump of separator (first setting
into operation and after maintenance)
1. open fill and flush line.
2. Open test cock on oil collecting dome.
3. Close valve in scavenger line from separator outlet to eccentric screw pump.(pos. 14
in drawing of the bilgewater separator).
4. Bring main switch in position „on“. Start pump by pump switch. The separator is filling
itself with water and the air vents automatically through oil discharge valve until the
water level has reached the upper level electrode. Then the oil discharge valve closes.
When water comes out of the upper test cock the separator is filled up.
5. Switch off pump close filling line and upper test cock.
6. Open valve described under Pos. 3.
7. The bilgewater separator is now ready to operate.

Rev. 01 from 28.02.2000 - 10 -

5 Operation and Supervision - switching OFF the unit

5.1 Setting into operation

1. switching on the unit

a. Open compressed air line
b. Open valves in suction line from bilge.
c. Open flushing line of oil monitor and set 3-way ball valve into position „sample
water“.
d. Switch on the mainswitch (1) and pump switch (Auto)

2. switching off the unit

a. Open valve in flushing line.
b. Close suction line.
c. After 30 minutes of flushing push button for manual operated oil discharge until
all rest oil is discharged from the oil collecting dome. (Check by sight glass or
upper test cock.
d. Switch off pump switch (0) and main switch (0).
e. Close valves in flushing line.
The system is now ready for the next operation.

5.2 Supervision of operation

1. During operation a supervision of the system is recommended even if there are

installed some technical safety measures.
2. The bilgewater sometimes contains ingredients, which are making the physically
oil/water separation impossible or which are causing a muddy stable emulsion.
This are for instance: false cleaning agents, solvents, emulsifiers or biological mud.
3. Especially on ships lying in harbours or in the roadsted, it should be observated
continuously if any oil traces are showing in the area of bilgewater outlet.
4. If any oil is coming out of the lower test cock on the oil collecting dome, this may be a
hint for the malfunction of the level sensor. In this case stop the system immediately
and check level sensor.

Rev. 01 from 28.02.2000 - 11 -

6 Maintenance

The unit is operating nearly free of maintenance. But the oil in the bilge water sometimes
tends to clogging with dirt. In combination with sea water, there also may happen some
chemical reactions which are causing soapy films and residues in the separator units.
For this reasons periodically cleaning and inspection is recommended.

6.1 Cleaning of the oil level electrodes

The electrodes can be removed with board tools. Sticking oil films can be removed by
some cleaning cloth. This measure is necessary in case of malfunction of the automatic
oil discharge system. (see chapter 7)

6.2 Sludge outlet

After an operating time of approx. 250 hours, however after 1 year at latest, the solids
should be drained into the waste oil tank (not into the bilge). For this the sludge drain
has to be opened for a short time.

6.3 Cleaning of the PPT-BWS

After a 2 years period of operation the PPT-inserts and the separator vessel have to be
cleaned and examined for damages.
Important hint:
The intensive flushing of the bilgewater separator before switching off the system and
the draining of rest oil from the oil collecting dome are guaranteeing a maintenance free
operation for years.
The cleaning of the PPT-BWS has to be carried out as follows:
1. Switch off the separator as described.
2. Drain the vessel completely through the sludge drain.
3. Remove the lid of the unit, inspect the main seal for damages and renew it if
necessary.
4. Pull the trough with PPT-profiles carefully out of the vessel, inspect and renew it if
necessary.

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5. Clean the PPT-profiles with water (max. 50°C) by flushing from the side.
6. Clean the inside of the PPT-BWS vessel also with water.

6.4 Re-installation of the PPT-insert

1. Push the cleaned profile rows back into the vessel, install the main seal and close the
lid.
2. Carry out the preparation for operation according to chapter 4 and set the unit into
operation according to chapter 5.1.

6.5 Maintenance intervals

Component Interval Action Required Material

Electric-motor monthly Clean the housing of
(pump) the fan
Electric-motor every 8000 Clean the bearing, compare:
(pump) operating hours Renew the bearing Operating manual
grease pump, Appendix B
Switch gear every 8000 Renew the compare:
(pump) operating hours lubricating oil Operating manual
pump, Appendix B
Oil alarm monitor weekly Clean of measure oil free flushing
cell by using the water
manual cell cleaning
unit
PPT-BWS every 250 Drain sludge oil free flushing
operating hours water
PPT-BWS every 2000 Clean vessel inside oil free flushing
operating hours and separation insert water
with PPT-profiles

Rev. 01 from 28.02.2000 - 13 -

7 Trouble shooting

trouble possible reason component to action

examine
Pump does not work wrong adjusted flow monitor adjust flow monitor
flow monitor
Pump has no suction valves closed valves in suction line open valves
leaking flanges flanges seal leakages
empty bilge/tank bilge collecting tank fill with water
stator worn out remove and check renew stator
stator
automatic oil-discharge soiled level level sensor remove and clean
doesn’t work sensor level sensor
defective electrode relay renew if necessary
electrode relay
safety valve opens flushing water check pressure gauge
pressure too high during filling
 Operating pressure overboard valve overboard valve and open valve and check
3,2 bar closed or blocked piping piping
check valve check valve open valve
blocked
pressure switch pressure switch at oil adjust or renew if
collecting dome necessary
 Operating pressure  defective safety safety valve renew safety valve
3,2 bar valve
oil occurs in separator stable emulsion take a sample at sample should show
outlet or oil monitor because of separator inlet and clear oil/water
indicates alarm detergents analyze separation in less than
15 minutes
wrong cleaning agent use cleaning agents
which don’t cause
stable emulsions
oil drain valve oil level sensor clean oil level sensor
does not open

Rev. 01 from 28.02.2000 - 14 -

8 Spare parts list
Spare part NFV Code No.
 Main seal PPT-BWS 412 00 167
 Seal 1 412 00 188
 Seal 2 412 00 263
 Pump stator 180 07 026
 Pump gasket set 180 07 029
 Gland packing set 180 07 028
 Level sensor 412 00 112
 Gasket for level sensor 090 35 035
 Electrode relais 24V 50/60 Hz 220 40 502
 3-way solenoid valve 24 V, 50/60 Hz for 412 00 007
scavanger line
 3-way solenoid valve 24 V, 50/60 Hz for 412 00 771
oil discharge valve and 3-way valve
 Fuses (set) for oil alarm monitor 412 00 994

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