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Bilgewater Membrane Separator BMS350, BMS500, BMS1000, BMS2000, and BMS2500 Installation, Operation & Maintenance Bilgewater Membrane Separator Part Number: 95-0018

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Page 1: Bilgewater Membrane Separator - Village MarineBMS)_2012.pdf ·  · 2017-06-143.4 CONTROL PANEL 12 ... The Bilgewater Membrane Separator (BMS) ... the 15ppm Bilge Separator system,

Bilgewater Membrane SeparatorBMS350, BMS500, BMS1000, BMS2000, and BMS2500Installation, Operation & Maintenance

Bilgewater Membrane Separator

Part Number: 95-0018

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Page 3: Bilgewater Membrane Separator - Village MarineBMS)_2012.pdf ·  · 2017-06-143.4 CONTROL PANEL 12 ... The Bilgewater Membrane Separator (BMS) ... the 15ppm Bilge Separator system,

TABLE OF CONTENTS

iii VMT - v. JUNE 2010

1.0 INTRODUCTION 5

1.1 UNPACKING AND HANDLING 6

1.2 PERFORMANCE SPECIFICATIONS 6

1.3 PHYSICAL CHARACTERISTICS 6

1.4 UTILITY REQUIREMENTS 6

1.5 ENVIROMENTAL REQUIREMENTS 7

2.0 INSTALLATION 8

2.1 LOCATION FOR BMS 8

2.2 TO INSTALL THE BMS 8

2.3 TO CONNECT THE ELECTRICAL 9

3.0 GENERAL THEORY OF OPERATION 11

3.1 THEORY OF OPERATION 11

3.2 OPERATIONAL DESCRIPTION 12

3.3 OIL DISCHARGE MODE 12

3.4 CONTROL PANEL 12

3.5 CONTROLS AND INSTRUMENTATION 13

4.0 OPERATION 17

4.1 TO START THE BMS 18

4.2 NORMAL OPERATION 18

4.3 TO SHUT DOWN UNIT 19

4.4 MAINTENANCE SHUTDOWN 21

5.0 MAINTENANCE 22

5.1 PUMP MOTOR LUBRICATION 22

5.2 CLEANING THE BMS UNIT 24

5.3 FILTER BAG REPLACEMENT 25

5.4 MEMBRANE CLEANING 25

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TABLE OF CONTENTS

iv VMT - v. JUNE 2010

5.5 MEMBRANE REPLACEMENT 27

5.6 SYSTEM PROLONGED SHUTDOWN 27

6.0 DISASSEMBLY AND REPAIR 30

6.1 SCOPE 30

6.2 SEPARATION MEDIA REPLACEMENT 30

6.3 LEVEL CONTROL RELAY REPLACEMENT 30

7.0 TROUBLESHOOTING 32

7.1 RESETTING SYSTEM GLOBE VALVES 34

8.0 DRAWINGS AND DIAGRAMS 36

9.1 SPARES AND CONSUMABLES 45

9.2 SPARES-OIL CONTENT MONITOR (SMART CELL-BILGE) 45

10.0 MANUFACTURER’S LITERATURE 65

10.1 SMART CELL- BILGE- INSTRUCTION MANUAL 65

10.2 CENTRIFUGAL PUMP MANUAL 65

10.3 PROGRESSIVE CAVITY PUMP SPARE PARTS 65

10.4 CERTIFICATES 65

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INSTALLATION

5 VMT - v. JUNE 2010

1.0 INTRODUCTION SYSTEM DESCRIPTION

Parker Racor Village Marine Tec’s (VMT) Bilgewater Membrane Separators (BMS) have been designed to meet the International Maritime Organization (IMO) resolution MEPC107(49). (Guidelines and Specifications for Pollution Prevention Equipment for Machinery Space Bilges of Ships) as incorporated into 46 CFR 162.050. The VMT units are an advanced three -stage system capable of handling the complete range of oils that might be carried on board a commercial marine vessel.

HOW TO USE YOUR MANUAL This User Guide & Reference Manual contains important information about the safe operation and maintenance of your Bilgewater Membrane Separator unit. We advise you to please read through the entire User Guide & Reference Manual carefully to ensure you familiarize yourself with the operation of your BMS system and follow the recommendations within the manual, to help make your water purification experience trouble-free and enjoyable.

SAFETY WARNINGS Throughout this User Guide & Reference Manual you will see many important statements or labels indicated on the product with the following words:

Indicates a strong possibility of severe personal injury or death if warning instructions are ignored.

Indicates hazards or unsafe practices of product may cause minor personal injury or may cause property damage.

NOTE: Text specifies useful information.

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INSTALLATION

6 VMT - v. JUNE 2010

1.1 UNPACKING AND HANDLING The Bilgewater Membrane Separator (BMS) is shipped pre-assembled. There are no special instructions towards unpacking and handling of the watermaker system. Inspect the BMS unit to verify it was not damaged in transit. Be sure to mark and record all hose locations for reference, if disconnection of hoses becomes necessary. DO NOT EXPOSE THE BILGEWATER MEMBRANE SEPARATOR UNIT TO FREEZING TEMPERATURES WITHOUT PROPER STEPS TO TREAT THE UNIT FOR SUB-FREEZING TEMPERATURES.

1.2 PERFORMANCE SPECIFICATIONS

Parameter Specification

Model Number: BMS350-2500

Raw water temperature range: 34-113 F (1-45C) Raw water inlet pressure: 20 PSI MAX

Maximum bilge/oily water inlet pressure: 0 psi(1)

Minimum product water production(2)

: 1.5-11 GPM / .35-2.5 m3/hr (Respectively)

Maximum inlet oil concentration (for continuous operation): 100%

Oil discharge cycle duration: Variable

Table 1.1 - Performance Characteristics

(1) Water production will be directly affected by the amount of back pressure on the system process pump. Excessive or convoluted, piping configurations may reduce unit production below minimum requirements. If this is the case it might be necessary to adjust GV3 (product pressure control valve) by opening it slightly. Please refer to table 4.2 in section 4.2 for normal operating parameters.

1.3 PHYSICAL CHARACTERISTICS Refer to PAGE 46 for weight and dimensions of the BMS.

1.4 UTILITY REQUIREMENTS Refer to the Piping and Instrumentation Diagram (P&ID) in Section 9.0: DRAWINGS AND DIAGRAMS

for interconnection properties. Refer to the nameplate attached on control box top for power requirements.

Utility Design Pressure

Minimum Design Pressure

Maximum

Oily Water Inlet -20 FT/-6 meters 0

Effluent Discharge 0 45 PSI / 310 KPa

Unit Drain N/A N/A

Fresh/Flush Water Supply(1)

10 PSI / 69 KPa 15 PSI / 103 KPa

Oil Discharge(1)

0 20 PSI / 138 KPa

Table 1.2 - Utility Requirement

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INSTALLATION

7 VMT - v. JUNE 2010

1.5 ENVIROMENTAL REQUIREMENTS

Parameter Specifications Ambient Temperature Range 34-113F (1-45C)

Pitch: 22 (6 sec cycle)

Roll: 22 (12 sec cycle)

Table 1.3 - Nominal Operating Conditions

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INSTALLATION

8 VMT - v. JUNE 2010

2.0 INSTALLATION

2.1 LOCATION FOR BMS

Village Marine Tec. recommends installing the BMS unit in the ship, as low as possible. To minimize the amount of external piping, the BMS should be installed as close to the ship’s Oily Waste Holding Tank and overboard discharge connection.

Figure 1: Recommended Installation Location

The unit must be mounted no higher than 20 ft / 6 meters above the bilge water intake. The BMS unit should not be installed below the Bilge. If there are any questions about the installation, please contact VMT for technical assistance.

2.2 TO INSTALL THE BMS Every installation is unique, the mounting instructions are provided for guidance only. It is recommended that you use your own discretion as to the exact method of mounting and placement of any mounting bolt holes.

Step 1: Place the BMS unit in an appropriate location and drill a minimum of four (4) holes, one through each of the four stanchion bottom support plate. When drilling holes, always check to make sure that the drill bit will not pass through to any component of the separator, or cause any other kind of damage to the mounting area. Mount the BMS unit securely making sure that the four base stanchions are continuously supported.

Step 2: Refer to the system drawings in Section 9.0: DRAWINGS AND DIAGRAMS for the connection

requirements. Make the following plumbing connections to the piping interfaces: A FOOT VALVE AND STRAINER MUST BE INSTALLED BY THE CONSUMER TO PREVENT FOREIGN MATERIAL OBSTRUCTING AND CLOGGING THE BMS. FAILURE TO INSTALL A FOOT VALVE WITH A SUITABLE STRAINER MAY VOID THE BMS SYSTEM WARRANTY.

Connect the oily water inlet line to the check valve located on the left side of the unit when facing the control panel (see Table 1.2 for raw water utility requirements). The inlet piping should at least equal in size to the inlet connection size. A foot valve and strainer must be installed at the end of the inlet piping where it takes suction from the bilge. INLET AND DISCHARGE INTERCONNECTING LINES SHOULD BE CONSTRUCTED OF SUITABLE MATERIAL. PLASTIC MATERIALS SUCH AS PVC MAY NOT BE SUITABLE DUE TO THEIR

WATERLINEWATERLINE

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INSTALLATION

9 VMT - v. JUNE 2010

INCOMPATIBILITY WITH CERTAIN FUELS AND OILS.

NOTE: Verify all piping connections are airtight. Excessive air in solution with the clean water effluent results in erroneous high oil content readings. A) Connect the clean water discharge (SOV-2) to a 3 way manual recirculate valve (3-way ball valve).

The clean water discharge connection is ¾” HB and is located in the back side of the BMS (when facing the control panel). Connect one side of the 3-way ball valve to your desired connection for overboard discharge. The overboard discharge port may be located above or below the waterline provided that there is no back pressure. Connect the other side of the 3-way ball valve back to the bilge.

NOTE: For future inspection purposes on board ship, a sampling point should be provided in a vertical section of the water effluent piping as close as is practicable to the 15ppm Bilge Separator outlet. A manual re-circulate valve MUST be installed per MEPC107(49), after and adjacent to the overboard outlet of the stopping device (SOV2-clean water discharge solenoid valve) to enable the 15ppm Bilge Separator system, including the 15ppm Bilge Alarm and the automatic stopping device, to be tested with the overboard discharge closed. (See P&ID 21001 in Drawings and Diagrams) B) Connect the oil discharge to an unobstructed ¾” line that is connected to the top of the oily waste

storage tank. The oil discharge connection is ¾" HB and is located on the back side of the unit (when facing the control panel) near the top.

NOTE: If the discharge of water into the waste oil tank is unacceptable, a line must be installed to

manually divert the oil discharge link back to the bilge when cleaning.

C) Connect a fresh water source to the ¾" flush water supply line. This connection is ¾" HB and is

connected at the Fresh Water Solenoid Valve (SOV1).

NOTE: Verify that the fresh water supply flow rate corresponds to and does not exceed the rated capacity of the BMS unit, this can be done using a ball valve to throttle the feed flow. (e.g. if you have a BMS-500 which is rated for 2.2 gpm/ .5m

3/hr make sure the feed flow does not exceed 2.2

gpm). Also it is VERY IMPORTANT that the fresh water inlet pressure does not exceed 15 psi, and therefore a pressure regulator MUST be installed to control the inlet pressure to the acceptable limits. Failure to do this will result in malfunction of the feed pump.

D) Connect the recirculation line (SOV3) to an unobstructed ¾” line that is connected back to the bilge. SOV3 will open when the oil content is above 15ppm at which point all effluent will be directed back to the bilge.

E) Connect the flush line (SOV4) to an unobstructed ¾” line that is connected back to the bilge. The

flush line is ¾” HB and is located on the back side of the unit (when facing the control panel) near the bottom.

F) Connect all drains back to bilge. DO NOT CONNECT THE SYSTEM DRAIN LINES TO THE CLEAN WATER EFFLUENT PIPING AS WATER DRAINED FROM THE SEPARATOR MAY HAVE RESIDUAL OIL LEVELS GREATER THAN 15 PPM.

DO NOT START UP UNIT WITHOUT FIRST THOUROUGHLY REVIEWING SECTIONS 4.0 AND 7.1 FOR UNIT START UP. FAILURE TO DO SO MAY RESULT IN IMPROPER INSTALLATION AND POSSIBLY DAMAGE THE UNIT.

2.3 TO CONNECT THE ELECTRICAL

TURN OFF ALL ELECTRICAL POWER FOR USE WITH THE BMS UNIT PRIOR TO CONNECTING TO THE BMS POWER SOURCE. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONS HANDLING THE UNIT.

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INSTALLATION

10 VMT - v. JUNE 2010

NOTE: Adhere to all electrical codes and regulations governing the installation and wiring of electrical equipment. Typical codes specify the type and size of conduit, wire diameter, and class or wire insulation depending upon the amperage and environment.

NOTE: The power supply should always be of greater service rating than the requirements of the BMS

unit. This will assure proper voltage even if power supply voltage is slightly less than required. Never connect the BMS unit to a line that services another electrical device. THE BMS UNIT SHOULD HAVE ITS OWN INDEPENDENT POWER SUPPLY.

Step 1: Connect the correct voltage/power supply to the power cord provided. Step 2: Connect a suitable ground to the BMS unit skid (as determined by the specifics of your installation).

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GENERAL THEORY

11 VMT - v. JUNE 2010

3.0 GENERAL THEORY OF OPERATION

3.1 THEORY OF OPERATION

The VMT units are an advanced three -stage system capable of handling the complete range of oils that might be carried on board a commercial marine vessel. STAGE 1: The first or Separator stage consists of a coalescing tank described below: Oil and water do not mix easily. Given enough time to elapse, a static mixture of oil and water will almost separate on its own. There are special proprietary filtration polymers that VMT employs which have strong affinities for oil. The design and construction of the VMT BMS takes maximum advantage of both of these principles in order to reduce effluent oil concentrations in the overboard discharged water to less than 15 parts per million (ppm). To minimize oily and water mixing or agitation, the feed pump is placed on the downstream side of the coalescing tank. This minimizes the agitation on the inlet stream which reduces emulsified oil (i.e. suspended in the water as a solution) amounts, increasing the overall 1

ST stage efficiency of the VMT

separation process. Upon entering the Separator Stage, the oily water enters a large diameter first-pass chamber, reducing its stream velocity. Decelerating the oily water stream is critical; it maximizes the amount of time for gravity separation to take place. The slower the stream velocity, the longer the oily water will be in contact with the VMT filtration media. The first-pass chamber is filled with specially designed proprietary polyethylene rings that have a high surface-area-to-weight ratio. As the oily water flows along the surface of the polyethylene rings, small droplets will adhere to its surface. When enough has collected, the oil droplets’ natural buoyancy will cause them to release and float to the separator top, when enough oil collects at the top, the unit automatically back-flushes the accumulated oil out of the unit and into a waste holding tank. STAGE 2: Prior to exiting the coalescing tank, the reduced concentration oily water mixture passes through a polishing chamber. This chamber is completely filled with tightly packed polypropylene beads that are designed to remove any remaining free oil from the effluent stream. This unique design ensures the effluent discharge is less than 15 ppm of free oil. STAGE 3: Under IMO resolution MEPC107 (49), all Bilgewater Membrane Separators must be able to handle the complete range of oils that might be carried on board ship, whether they are free oils or in emulsion. The coalescing tank is effective in separating free oils but is unable to handle emulsions, which is why the (Third) stage of the BMS was specifically designed to treat emulsions by incorporating advanced VMT membrane technology. The effluent from the Separator stage coalescing tank is pressurized by the feed pump for processing through the Parker bag filter supplying the process pump with a positive suction head pressure. The bag filter removes suspended solids and oil droplets of approximately 5 microns and larger from the flow. This semi cleaned effluent is supplied to the process pump for processing by the VMT membrane. The process pump increases the effluent pressure and drives the emulsions along the surface of the membrane at high velocity. Water, salts, detergents, and other trace contaminants are forced through the membrane by back pressure created by the process pump and the system operating pressure control valves while emulsified oils are rejected. All processed water is continuously monitored by an MEPC107 (49) approved Oil Content Meter (Smart Cell) before the water is discharged overboard. If the oil content exceeds 15 ppm, this “bad” water will automatically be redirected to the vessel’s bilge beginning the process again. The reject water (concentrate) from the Membrane or third stage is automatically redirected within the VMT BMS to the inlet of the bag filter for reprocessing through the filter and membrane.

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GENERAL THEORY

12 VMT - v. JUNE 2010

3.2 OPERATIONAL DESCRIPTION The oily water is sucked out of the bilge through a Purchaser supplied foot valve. This valve strains out large particles and objects accumulated in the bilge. The oily water stream then flows through a check valve and into the separator. Upon reducing the oily water stream velocity, it enters the first-pass chamber taking up approximately ½ of the total volume of the separator. The chamber is capped with a removable metal retaining screen that is designed to contain the polymer separation media. It is in this chamber that the bulk of the oil separation takes place. After flowing vertically down through the first pass chamber, the oily water stream passes through a second retaining screen into the second-pass chamber. This chamber contains tiny polymer beads designed to remove any residual oil from the water stream. To optimize oil separation and meet the IMO requirements of MEPC107 (49), the effluent from the separator is passed through an UF membrane. This ensures all effluent is below 15ppm whether it is in emulsion or not.

Figure 2: System Diagram

3.3 OIL DISCHARGE MODE When enough oil collects at the top of the separator, a liquid level monitoring assembly automatically reconfigures the system and begins discharging oil to the ship supplied Oily Waste Holding Tank. The actual process is as follows: The oil discharge process is initiated when enough oil has accumulated to cover the entire length of the longest of the three level probes. A signal is sent to secure the system pump, shut the clean water discharge valve and open the fresh water valve. Fresh water then flows into the unit through the bottom and forces the oil out through the oil discharge piping. When sufficient oil has been discharged to enable the water to contact the shortest liquid probes, the automatic flush mode secures and the system returns to its normal configuration. Note: The level probes will interpret air at the top of the tank the same as oil, and initiate the oil discharge mode to purge the air.

3.4 CONTROL PANEL The BMS is equipped with a centralized control panel for monitoring of all important unit functions and operating parameters. The specific control switches and status (indicating) lights utilized are as follows:

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GENERAL THEORY

13 VMT - v. JUNE 2010

CONTROL SWITCHES

(1) ON/OFF CONTROL SWITCH

Controls the operation (ON/OFF) of the entire system. Placing the switch in the "OFF" position prevents all operation of the system regardless of the position of all other switches.

(2) MANUAL FUNCTION SWITCH

Three position switch that controls manual flush, for separator and membranes. (TANK FILL/OFF/SEPARATOR FLUSH)

(A) TANK FILL

Immediately reconfigures system and activates oil discharge mode regardless of oil level. Unit will remain in oil discharge mode as long as the switch is placed in the “OFF” position. Used to prime system at start up. Afterwards this is used to manually flush the coalescing tank.

(B) MEMBRANE FLUSH

Immediately reconfigures system and activates separator flush. Unit will continue to flush until switch is placed in the “OFF” position.

(3) OPERATION SWITCH

Three position switch that controls normal, and membrane cleaning operations. (RUN/OFF/CLEAN) (A) RUN

Activates BMS normal operating mode, effluent water discharge/ recirculation, oil discharge, and self flushing cycles are all automated in normal operation.

(B) CLEAN

Activates membrane self clean mode. Clean mode will continue to run until the temperature switch senses high water temperature (>120

0F) or the mode control switch is placed to

either “OFF” or “RUN” positions.

STATUS (INDICATING LIGHTS)

(4) CLEAN WATER DISCHARGE LIGHT

GREEN light illuminates whenever the unit is operating in its normal mode and is discharging clean effluent.

(5) OIL DISCHARGE LIGHT

GREEN light illuminates whenever the unit is operating in the Oil Discharge mode and is discharging either oil or fresh water.

(6) POWER ON LIGHT

RED light illuminates whenever the unit is receiving the power necessary for operation. This light will illuminate regardless of whether the unit is actually operating.

(7) ALARM 1 LIGHT

RED light illuminates whenever OCM detects high oil content above 15ppm.

(8) ALARM 2 LIGHT

RED light illuminates whenever PSW1 detects low pressure upstream of the process pump indicating filter replacement may be required.

(9) ALARM 3 LIGHT

RED light illuminates whenever PSW2 detects lower than normal product pressure indicating membrane cleaning and possible membrane replacement may be required. The light will also illuminate when the temperature switch located downstream of the process pump exceeds 120

oF.

3.5 CONTROLS AND INSTRUMENTATION The following table describes the function of the components.

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GENERAL THEORY

14 VMT - v. JUNE 2010

CALL OUT DESCRIPTION FUNCTION

P1 Suction Pump Provides suction pressure necessary to provide adequate effluent flow.

P2 Boost Pump Boosts the pressure and flow for proper processing through the membrane

PG1 Vacuum and Pressure Guage

Monitors separator section pressure (vacuum pressure during normal operations and positive pressure during flushing)

PG2 Feed Pump (P1) Discharge Pressure Guage

Monitors Pump 1 discharge pressure

PG3 Process pump (P2) Suction Pressure Guage

Monitors Pump 2 suction pressure

PG4 Process Pump (P2) Discharge Pressure Guage

Monitors Pump 2 discharge pressure

PG5 Product Pressure Guage

Monitors product pressure

PRV1 Feed Pump (P1) Discharge Pressure Relief Valve

Relieves excess pressure during normal operations

PRV2 Process Pump (P2) Discharge Pressure Relief Valve

Relieves excess pressure during normal operations

SOV1 Flush Water Supply Valve

Normally closed solenoid operated valve that is open during flushing operations and closed during normal operations

SOV2 Clean Water Discharge Valve

Normally closed solenoid operated valve that directs treated water overboard

SOV3 Dirty Water Recirculation Valve

Normally closed solenoid operated valve that opens and redirects water to bilge when oil content is greater than 15 ppm

SOV4 Flush Water Discharge Valve

Normally closed solenoid operated valve that is open during flushing operations and closed during normal operations

CV1 Oily Water Inlet Check Valve

Prevents back flow from the unit into the bilge during fresh water flushing (e.g. during oil discharge mode)

CV2 Oil Discharge Check Valve

Prevents back flow into the unit from the oily waste system during normal operations

PSW1 P2 suction pressure switch

Deactivates normal operation when low suction pressure upstream of P2 is detected signifying filter replacement or cleaning may be needed.

PSW2 Product Pressure Switch

Deactivates normal operation when high discharge pressure of P2 ( >90psig ) is detected.

TSW High temperature switch.

Deactivates normal operation when high temperature not adequate for proper membrane operation is detected

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GENERAL THEORY

15 VMT - v. JUNE 2010

OCM Oil Content Monitor Monitors discharge oil concentrations and automatically diverts effluent to bilge when oil concentration is greater than 15 ppm

V2 Drain Valve Manual ball valve used to drain the Separator for maintenance

V6 Drain Valve Manual ball valve used to drain the Filter for maintenance

V7 Drain Valve Manual ball valve used to drain the membrane for maintenance

GV1 Globe Valve Manually set globe valve used to regulate reject pressure

GV2 Globe Valve Manually set globe valve used to regulate flush line pressure when in flush mode.

GV3 Globe Valve Manually set globe valve used to regulate product discharge pressure

Table 3.1 - Factors Affecting Permeate Quality

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GENERAL THEORY

16 VMT - v. JUNE 2010

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OPERATION

17 VMT - v. JUNE 2010

4.0 OPERATION

Operating Chart. This Chart should be referenced when reading all of the following:

Operating Chart Section

Pre Start up Normal Operation Maintenance

Tank fill Run Mode

Oil discharge Recirculation

Separator Flush

Membrane Clean

OCM Flush/

calibrate

Ma

nu

al

Va

lve

s

V1 OPEN CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED

V2 CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED

V3 OPEN CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED

V4 OPEN CLOSED CLOSED CLOSED CLOSED OPEN CLOSED

V5 CLOSED CLOSED CLOSED CLOSED CLOSED OPEN CLOSED

V6 CLOSED CLOSED CLOSED CLOSED CLOSED OPEN CLOSED

V7 CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED

V8 OPEN CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED

V9 CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED OPEN

GV1

LEAVE ALL AT FACTORY SETTINGS GV2

GV3

Au

tom

ati

c

Va

lve

s

SOV1 OPEN CLOSED OPEN CLOSED OPEN CLOSED CLOSED

SOV2 CLOSED OPEN CLOSED CLOSED CLOSED CLOSED CLOSED

SOV3 CLOSED CLOSED CLOSED OPEN CLOSED CLOSED CLOSED

SOV4 CLOSED CLOSED CLOSED CLOSED OPEN CLOSED CLOSED

Pu

mp

Feed Pump ON* ON OFF ON ON OFF OFF

Process pump OFF ON ON ON ON ON OFF

Sw

itc

he

s

Power ON ON ON ON ON ON ON

Operation switch

OFF RUN RUN RUN ON/OFF CLEAN OFF OFF/RUN/ CLEAN

Manual function switch

Tank fill OFF OFF OFF Separator

Flush OFF OFF

Tank fill / OFF

/ Separator flush

Lig

hts

Power ON ON ON ON ON ON ON

Alarm 1 OFF OFF OFF OFF OFF OFF OFF

Alarm 2 OFF OFF OFF ON OFF OFF OFF

Alarm 3 OFF OFF OFF OFF OFF OFF OFF

Clean Water Discharge

OFF ON OFF OFF OFF OFF OFF

Oil Discharge OFF OFF ON OFF OFF OFF OFF

* Pump will be on only during pre start up for a short time allowing unit to prime properly

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OPERATION

18 VMT - v. JUNE 2010

4.1 TO START THE BMS NOTE: For the initial start-up, verify to first complete the system installation in accordance with Section

2.0: INSTALLATION.

4.1.1 Tank Fill

Step 1: Put all manual ball valves in the position shown on chart. V1,V3, V4 and V8 are all open. All others

closed. Step 2: Turn Power switch on. Verify the POWER ON light illuminates.

Step 3: Place the MANUAL FUNCTION SWITCH in the TANK FILL position. (Make sure clean water supply

corresponds and does not exceed the rated capacity of the unit.) Step 4: Allow the Separator to fill. Once V3 begins to bleed, shut off valve. Then observe V4 and make sure a

full stream is flowing then shut off valve. Repeat for V8 then V1. NOTE: Feed pump will be on for about 45 sec once V4 has been closed. PRV 1 may be triggered

momentarily once PG1 reaches 30 psi. This is normal during initial start up. Feed pump will not turn on again after initial start up. If the feed pump needs to be turned on again to fill the unit turn the unit off completely, this will reset the unit and will allow for initial start up conditions. (Make sure all gauges read zero before turning on unit.)

Step 5: Once valves are closed turn MANUAL FUNCTION SWITCH to the OFF position. System control

valves will need to be verified and possibly adjusted if they have been moved during shipping and storage. Please refer to section 7.0 before starting unit.

Step 8: Verify motor rotation is clockwise when looking from motor end. To do this put the OPERATION

SWITCH in the AUTO position for a couple seconds, enough to view motor rotation then place back in the OFF position.

4.2 NORMAL OPERATION

4.2.1 Normal Operation (below 15 ppm) NOTE: Normal Operation is completely automated. As long as the MANUAL FUNCTION SWITCH is in

the RUN position it will run for 30 min after which the system will automatically run a system flush for 10min. It will do this continuously and uninterrupted unless the oil probe senses oil and needs to run the oil discharge mode. After which the system will return to normal operation. All while in the RUN position.

Step 1: Put all manual ball valves in the position shown on chart. All ball valves should be closed. Step 2: Put the MANUAL FUNCTION SWITCH in the OFF position

Step 3: Put the OPERATION SWITCH in the RUN position

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Step 4: Inspect unit for proper operation. Check all gauges and record pressure. The following data sheet shows the pressure ranges for normal operation.

NOTE: On initial start up the unit might take a few minutes to stabilize, allow about 5 min before

recording data.

Pressure Gage description Gauge ID pressure range actual reading

Tank section pressure PG1 -30 to 2 PSI (-206 to 13.8

KPa)

P1 discharge pressure PG2 10-25 PSI (103-172 KPa)

P2 suction pressure PG3 10-25 PSI (35-172 KPa)

P2 discharge pressure PG4 70-90 PSI (482-620 KPa)

Product pressure PG5 30-60 PSI (206-414 KPa)

Table 4.2 – SYSTEM OPERATING PARAMETERS If all pressure readings read within the recommended pressure ranges unit is now operational. The water discharge light will be illuminated and the system will begin discharging overboard as long as

the ppm is <15ppm P1 and P2 are both running NOTE: If system parameters are not as recommended, system globe valves may have been moved

during transit. In this case please refer to section 7.1 for instructions on how to reset system valves.

4.2.2 Normal Operation Oil Discharge

When the Oil Sensing Probe (OSP) sees enough oil to discharge it will automatically do the following: 1. Shut off Feed Pump P1 2. Open SOV1 3. Close SOV2 and SOV3 4. The oil discharge light will illuminate 5. When all oil is discharged to the slop tank and the OSP sees clean water it will revert back to

normal operation. 6. Note: process pump P2 will continue running during this cycle.

4.2.3 Normal Operation (Over 15 ppm) Recirculation to Bilge

When the “Oil Content Monitor” (OCM) reads over 15 ppm the following happens automatically to prevent oil from being discharged overboard. 1. SOV2 (effluent discharge overboard) closes and SOV3 (recirculation to bilge) opens. 2. The overboard discharge light will go out. 3. Everything else remains the same as in normal operation

4.3 TO SHUT DOWN UNIT

NOTE: A system flush should be done prior to every shut down. This ensures that the membranes sit in

clean water and prevents premature fouling. If membranes are allowed to completely dry they may be ruined.

Step 1: Place the OPERATION SWITCH in the OFF position.

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Step 2: Put the MANUAL FUNCTION SWITCH in the MEMBRANE FLUSH position. Step 3: Allow flush cycle to run for approximately15-30 minutes. This ensures all oil is flushed out and only clean

water remains in the system. This flush cycle may need to be run longer depending on last shut down. Verify by observing the water discharged from the flush line (SOV4) and make sure water is clear and not cloudy (white).

Step 4: Place OPERATION SWITCH in the OFF position.

Step 5: System is ready for shut down. Place the MANUAL FUNCTION SWITCH &OPERATION SWITCH in

the OFF positions. Step 6: Turn Power ON Switch in OFF position. Step 7: Verify power on Light is off

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4.4 MAINTENANCE SHUTDOWN

This procedure should be used if any system connections must be broken or the separator itself must be opened for maintenance.

Step 1: Perform shut down procedure as described in section 4.3

WATER DRAINED FROM THE SEPARATOR MAY HAVE RESIDUAL OIL LEVEL OF GREATER THAN 15 PPM. DO NOT DISCHARGE OVERBOARD IF WATER IS GREATER THAN 15 PPM. IT IS RECOMMENDED THAT THIS WATER BE DIRECTED BACK TO THE BILGE.

Step 2: Connect the BMS drain to a dedicated holding tank or bilge (if not connected during initial installation). NOTE: If holding tank is at level or above the BMS, use a boost pump to complete the system drain. NOTE: This procedure incorporates a gravity drain of the separator that will remove most, but not all of

the water from the separator.

Step 3: Once the BMS has been flushed and turned off, open drain valves V2, V6, V7 and V9 Step 4: When no more water flows from the drain connection, shut the drain valves.

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MAINTENANCE

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5.0 MAINTENANCE

5.1 PUMP MOTOR LUBRICATION

NOTE: Motors should be re-lubricated at least once a year.

Step 1: Locate the grease fittings near the motor shaft. Wipe the fitting clean. Step 2: Remove filler and drain plugs. Free drain hole of any hard grease if present (use a wire if necessary). Step 3: Add 2-3 strokes of grease using a low pressure grease gun (see Table 5.2 for grease type). Injecting

grease too quickly can cause untimely bearing malfunction. Inject grease slowly for approximately 1 minute.

Location Type

Pump Motor Chevron SRI Grease - NGLI 2 ExxonMobil PolyrexEM Grease Shell Oil Dolium R - NGLI 2 Texaco Premium RB

Table 5.2 - Motor and HP Pump Lubrication Requirements.

DO NOT mix grease types. Keep consistent the grade and type of grease used for motor. Also, keep the grease CLEAN.

Step 4: If the motor is equipped with a motor drain plug, replace the drain plug (if removed) and start BMS unit.

Let BMS to run motor for approximately 20 minutes. Step 5: Secure the BMS unit, wipe off any of the drained grease and replace the fill and drain plugs, as

required. The motor is now ready to resume operation.

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COMMENT/DISCREPANCY REPORT

Village Marine Tec Bilgewater Membrane Separator Model BMS ______

Plant No: Date: Log Task No: Time: System Affected: Technician : Comment/Discrepancy: Corrective Action: Action Taken: Date Completed:

Printed Name:

Signature:

Figure 5.1 - Sample Discrepancy Report

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5.2 CLEANING THE BMS UNIT

5.2.1 BMS Separator Flush

The coalescer tank media is cleaned by an upward flow of fresh water each time the oil discharge cycle starts. However if conditions have led to heavy loading of oil in the tank, extra cleaning can be done by running the oil discharge cycle manually for extra time or with hot water.

NOTE: If the discharge of water into the waste oil tank is unacceptable, a line must be installed to

manually divert the oil discharge link back to the bilge when flushing.

Step 1: Stop the system by placing the MANUAL FUNCTION SWITCH & OPERATION SWITCH in the OFF

positions. Step 2: Place the MANUAL FUNCTION SWITCH in the TANK FILL position. This will initiate oil discharge

mode. If hot water 100F –150F (37C-65C) is available, it can be used for maximum cleaning. Step 3: Allow the system to remain in oil discharge mode for approximately 20-30 minutes.

5.2.2 Membrane Flush

NOTE: The membrane will be automatically flushed by the system every 30 minutes for about 10 min. However it is recommended that a manual flush be performed before every system shutdown, membrane cleaning and every 2 weeks to ensure prolonged membrane life.

Step 1: Stop the system by placing the MANUAL FUNCTION SWITCH AND OPERATIONAL SWITCH in the

OFF positions.

Step 2: Place the MANUAL FUNCTION SWITCH in the SEPARATOR FLUSH position. This will start the

membrane flush cycle. If hot water 100F –115F (37C-46C) is available, it should be utilized for best results.

Step 3: Allow the system to remain in flush mode for approximately 20-30 minutes. Observe the water from the

flush to bilge outlet and make sure the water coming out is not cloudy (white) but clear. Step 4: Place MANUAL FUNCTION SWITCH in the OFF position.

5.2.3 OCM Flush

NOTE: It is recommended that the OCM flush procedure be performed at least once a week, to prevent the OCM monitor from getting dirty and potentially reading false positives causing the system to remain in recirculation mode.

Step 1: On the OCM Smart-Cell use the DOWN and UP keys to view the menu options.

Step 2: Scroll down to “Diagnostics” then press the ENTER key.

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Step 3: Select “View disp PPM” and press ENTER. This will open the clean water solenoid valve and allow

fresh water into the monitor. Be sure to open V9 to allow the clean water to drain. The PPM reading will be displayed during flushing. This reading should be less than 2 ppm.

Step 4: Allow the SMART-CELL to flush for about 1-2 minutes then close V9 and press the Enter Key twice to leave the diagnostics screen, set the clean water solenoid valve back to sample and return to the operation screen. (Please refer to Bilge Alarm instruction manual sec 4.7 and 5.1 for further assistance and recommended maintenance).

5.3 FILTER BAG REPLACEMENT

Refer to Pipe and Instrumentation diagram (PID) drawing in section 8 for referenced valves. WHEN TO REPLACE

The Process filters require replacing when the differential pressure reaches10 PSI (69 KPa) between the inlet and outlet of the filter housing (Use PG2 and PG3 to determine this difference).

NOTE: If the system shuts down on its own check to see if Alarm 1 is illuminated. If it is, put the

MANUAL FUNCTION SWITCH in the MEMBRANE FLUSH position and determine DP. If DP is

>10psi the filter needs to be replaced.

FILTER REPLACEMENT PROCEDURE

Step 1: Place THE POWER switch in OFF position. Step 2: Verify the power on light is off. Step 3: Open valve V6 and drain the filter housing. Verify drain is connected back to bilge. Step 4: Once the filter housing is drained unscrew the filter housing from its cap which is bolted to the unit. Step 5: Locate cover O-ring and set aside for reassembly. Step 6: Install new filter element. Make sure filter gasket is firmly seated onto the step of the top of the filter before

reassembling. Step 7: Place cover O-ring back on top of housing and screw housing back to its cap. Step 5: Close the process filter drain valve V6. Step 6: Refill the system as described in section 4.1

5.4 MEMBRANE CLEANING

WHEN TO CLEAN

VMT’s BMS system employs an automatic system flush every 30 min for 10 min. This is an effective means of protecting the membrane from fouling. However the membranes may become fouled by mineral scale, biological matter and grime. These deposits build up and cause a loss in processed water production, a loss of processed water quality, or both. The membranes require cleaning when the product pressure (PG5) falls below 30 psi. Alarm 3 will illuminate when the product pressure is to low signifying membrane cleaning or replacement is required.

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5.4.1 PREPARATION FOR CLEANING

The Membranes are cleaned in place. No disassembly of components is required.

Step 1: Shut the system down per section 4.3, skip steps 5 and 6. Step 2: Once the unit flush has concluded, a batch of detergent should be applied. Pour the recommended

amount of cleaning detergent (as given below) into the process filter housing’s cleaning canister and add water until cleaning canister is almost full (mix into solution). Open the process filter’s drain valve (V6) followed by the cleaning valve (V5) to allow for the cleaning detergent to be drawn into the process filter by vacuum.

RECOMMENDED QTY TO BE USED PER CLEANING CYCLE (IN QUARTS/LITERS)

MODEL CLEANER 1 CLEANER 2 CHLORINE BLEACH

BMS350-500 0.5 0.5 0.5

BMS1000 0.75 0.75 0.75

BMS2000 1.5 1.5 1.5

BMS-2500 1.5 1.5 1.5

Cleaner 1 is an alkaline type detergent and should be used when fouling of the membrane is due to fair soot, (fine carbon particles), oil and/or organics.

NOTE: It is recommended to keep the PH of any alkaline cleaning mixture between 10 and 12.

Cleaner 2 is an acidic type cleaner and should be used when fouling of the membrane is due to the water hardness and metallic scale (rusty pipes). Always try cleaner 1 first, if this does not work then cleaner 2 is recommended to see if the problem is corrected.

NOTE: When using these acidic compounds keep the PH level over 2

NOTE: Chlorine bleach is to be strictly used only when biological fouling has occurred and must be

used in the recommended amounts and NEVER allowed to soak or circulate for over ten minutes. Typical indications are bad odor, process water discolored to light green, or it can be blackish.

Step 3: Once the Cleaning Canister is emptied of detergent, immediately close the cleaning valve (V5) and process

filter drain valve (V6) as to minimize any air into the system. Step 4: Start the cleaning cycle by opening V4 and placing the OPERATION SWITCH in the CLEAN position.

Within the first 10 seconds purge the process filter of any air by opening and closing V4. Then shut off valve.

Step 5: Allow cycle to run for 30 minutes or until the temperature switch (TSW) shuts the system down due to

high membrane temperature (50 0C).

NOTE: If cleaning with chlorine bleach, DO NOT repeat this cycle and DO NOT soak.

Step 6: Place OPERATION SWITCH in the OFF position. Allow membranes to soak for a minimum of 4 hours.

Overnight would be best. Then run membrane flush to remove detergent from the system. See 5.2.2 Step 7: Once the system has been flushed and if the cleaned water production has not recovered within 40% of

initial start up production repeat cycle with a second and last circulation cycle if needed. A successful recovery can be noted by observing the product pressure (PG5) once the unit is in normal operation. Normal system product pressure (as read by PG5) should be within 45-70 psi. If no pressure increase, is observed then, try a second batch of cleaner 1. If this does not work, repeat the membrane cleaning procedure with cleaner 2. If all else fails, run a quick cleaning cycle with chlorine bleach, using only the

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recommended amount and be sure not to let the cleaning cycle run for more than 10 min and do not soak.

NOTE: If cleaning with chlorine bleach, DO NOT repeat this cycle and DO NOT soak.

Step 8: Ensure that the system has been flushed thoroughly otherwise on start up the smart cell will register

higher PPM’s and re-circulate to bilge until the detergent is fully removed. Step 9: After cleaning, the process filter may need to be replaced with a new filter if the differential pressure is over

10 Psi. (see filter bag replacement 5.3)

5.5 MEMBRANE REPLACEMENT

WHEN TO REPLACE

When the membrane cleaning procedure no longer revives the membrane to within 40 % of their fresh water start up production it may be time to replace the membrane. Again this can be noted by observing the product pressure (PG5). When the product pressure drops below 30 psi, its typically due to fouling of the membrane. In this case Alarm 3 will illuminate indicating membrane cleaning or replacement may be required. Commence cleaning of the membrane per section 5.4. Always try cleaner number 1 first and see if the product pressure (PG5 increases). When effective you will see and increase of about 20-30 psi. If cleaner 1 does not work the membrane may be fouled due to water hardness and metallic scale (rusty pipes), in this case try cleaner 2. Chlorine bleach is a last resort and must be used in the recommended amounts and NEVER allowed to re-circulate for more than 10 min. If after cleaning with

all three chemicals the system product pressure does not increase than it is time to replace the membrane. MEMBRANE REPLACEMENT PROCEDURE

Step 1: Perform membrane flush per section 5.2.2 unless already done due to membrane cleaning. Step 2: Verify system power is off by placing the POWER SWITCH in the OFF position. Step 3: Open V7 to drain membrane housing. Step 4: Once the membrane housing is completely drained disconnect the two unions connecting the piping

directly below the membrane housing to allow for membrane housing disassembly. Step 5: Unscrew membrane housing from its cap which is bolted to the unit. Step 6: Locate cover O-ring and set aside for reassembly. Step 7: Remove membrane by simply pulling it out from the housing. It may be necessary to turn the housing

upside down and tap the bottom of the housing to force the membrane out. Step 5: Inspect new membrane making sure all O-rings are in place. See section 8 (drawings and diagrams) Step 6: Install new membrane into housing making sure membrane reaches the bottom of the housing. Step 7: Place cover O-ring back on top of housing and screw housing back to its cap. Step 5: Close the membrane housing drain valve V7 Step 6: Refill the system as described in section 4.1

5.6 SYSTEM PROLONGED SHUTDOWN The waste oil is an excellent breeding ground for bacteria. During shutdowns of more than three days, the BMS should be flushed in accordance with section 5.2 to prevent bacteria from forming. For extended durations of shutdowns or storage periods (greater than 3 weeks), the BMS should be flushed and cleaned in accordance with section 5.2 and 5.4. After which the unit shall be sterilized as described below.

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NOTE: If the discharge of water into the waste oil tank is unacceptable, a line must be installed to

manually divert the oil discharge link back to the bilge when cleaning.

Step 1: Perform a normal cleaning as outlined in sections 5.2 and 5.4 Step 2: Repeat section 5.4.1 except on step 2 replace the cleaning detergent with the preserving solution as

outlined below.

Model Teaspoons/ml of Chlorine

Mixed in Pints/Liters of water

BMS350 1/ 4.9 2/.95

BMS1000 1/ 4.9 1/.47

BMS2000 2/ 9.8 2/.95

BMS2500 3/ 14.7 3/1.42

Step 3: Start preserving cycle (same as cleaning cycle). Allow the circulation cycle to operate for approximately 5-10 minutes to fully penetrate the membrane surfaces. NOTE: DO NOT allow clean cycle to run for more than 10 min when using chlorine.

Step 4: Stop the preserving cycle by placing the OPERATION SWITCH in the OFF position.

Step 5: Unit can now be shut down by placing the POWER SWITCH in the OFF position.

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DISASSEMBLY AND REPAIR

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6.0 DISASSEMBLY AND REPAIR

6.1 SCOPE

This section provides instructions for removal, disassembly and repair of the Village Marine Tec Models BMS Bilgewater Membrane Separator and its components.

6.2 SEPARATION MEDIA REPLACEMENT

In normal and proper operation, the media will not require replacement. Periodic thorough cleaning can

be done by flushing with hot water (up to 150F). If media replacement is required due to special circumstances, then remove top hat and remove separation screen to remove media.

6.3 LEVEL CONTROL RELAY REPLACEMENT

Step 1: Turn off system by placing the POWER ON switch in the OFF position. Verify Power on light turns off.

Step 2: Place new level control relay in 11 pin plug. Make sure relay’s manufacturing print is right side up and

readable. Step 3: Open relay compartment containing dip switches. (See Below)

Step 4: set switch 1 to on (up position) and switch 2 to off (down position).

Step 5: Turn system power switch on. Verify power on light is illuminated. Step 6: Verify green LED is illuminated in the level control relay.

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Step 7: Make sure that the tank is full of water and that the probes are immersed. Press the “teach” pushbutton at the front of the controller for approximately 2 seconds, until the green LED turns OFF. The controller will now auto-adjust itself according to the resistance of the measuring liquid.

NOTE: If the resistance of the liquid is outside the maximum range handled by the controller, the green LED will flash quickly for a period of 2 seconds, indicating a wrong teach-in. If this occurs it probably means that the tank is full of oil. Flush the Tank per section 5.2.1 until only water is discharged.

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TROUBLESHOOTING

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7.0 TROUBLESHOOTING This section is designed to guide the operator of the Village Marine Tec Bilgewater Membrane Separator units in locating the probable cause of the most frequently encountered problems. This section can only be a guide to solving potential problems with the RO unit and cannot contain all possible malfunctions, nor can it contain all possible ways to determine the cause of a malfunction. The best troubleshooting tool is the knowledge of the plant gained through

experience. Any condition not covered in this section may be resolved by contacting any Village Marine Tec Service Department. Preliminary procedures: 1. Always check for loose connections or broken wires when checking electrical parts. Checking for continuity and

solid contact can prevent hours of wasted effort. 2. Always inspect and test equipment or apparatus for probable cause of malfunction before performing

replacement. When using the troubleshooting guide on the following pages read all the probable causes before taking any action. Use good common sense and then use the probable cause that most likely fits the given situation.

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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Feed Pump Repeatedly Trips or Relief Valve Opens

Closed outlet valve Open outlet valve.

Pump short circuit Replace damaged wiring.

System Won't Enter Flush Mode

Foreign material on level probe(s)

Remove level probe(s) and wipe

clean

Liquid level control relay short circuit

Check probe insulation and/or

replace relay

Oil leaking past Oil Discharge check Troubleshoot valve. Replace if

valve, CV2 necessary

System in Continuous Oil Discharge Mode

Foreign material on level probe(s)

Remove level probe(s) and wipe

clean.

Liquid level control relay short circuit

Check probe insulation and/or

replace relay.

Clean Water Valve stuck open

Troubleshoot valve. Replace if

necessary.

Air leak in incoming lines Fix leak, can usually tell if this is the case by verifying proper P1 suction.

Reduced System Flow

Clogged foot valve

Inspect foot valve and remove any

foreign matter

Pumps clogged

Open pump casing and remove

foreign matter. (stator may be sucked in, remove pump head and adjust stator.

Pumps damaged

Troubleshoot pump. Replace if

necessary

membrane fouled

Run Membrane flush/clean and see if

system flow increases, inspect membrane and replace if necessary

system won't start RUN mode PSW-1 reads low suction pressure at P2

Run Membrane flush for 1-2 minutes then try Run Mode again

System frequently in recirculation mode

High oil content in reject loop Run Membrane Flush Cycle for 30 min

Dirty Oil content Monitor Run OCM flush Cycle, per section 5.2.3

P2 won't start Thermal overloads tripped Reset

System won't start any mode PLC not in run mode

Check PLC and ensure switch in PLC unit is in Run and not in Stop

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System gauges read zero or will not meet design requirements

Feed pump stator has been sucked in and feed pump is clogged

Disassemble pump housing and remove black stator. Check for damaged seals and replace if necessary. Reassemble pump. Verify the clean water inlet pressure does not exceed 20 psi or the rated water flow rate capacity of the unit.

Pressure does not rise even though pressure control valves GV1, GV2 or GV3 are fully closed

Pressure control valve seal might be worn out.

Disassemble pressure control valve and check seal for damage. Replace if necessary.

Table 7.1: Trouble shooting table

7.1 RESETTING SYSTEM GLOBE VALVES

System valves (globe valves), should NOT in any circumstance be moved from factory settings. If however

system operating parameters such as recommended in table 4.2 of section 4.2.2 cannot be maintained then it is highly possible that system globe valves have accidentally been moved and need to be reset. Below are instructions on how to reset system globe valves.

NOTE: Verify that pressure regulator has been installed at the fresh water inlet connection (SOV-1) and set to 15 psi.

Step 1: Make sure system is full of water, if not fill system per section 4.1 Step 2: Once you are sure the system is full of water, place the MANUAL FUNCTION SWITCH & OPERATION

SWITCH in the OFF positions.

Step 3: Leave the POWER ON switch in the ON position. Verify power light is illuminated.

Step 4: Locate GV1, GV2 and GV3. See Drawings and Diagrams (PID and system general arrangement). Step 5: Close the three globe valves fully. Step 6: Start by opening GV1 half way. Step 7: Then open GV3 1 full turn no more, this valve is usually mostly closed when set correctly if this valve is open

more than ½ way it needs to be closed and GV1 adjusted instead. Step 8: Now place OPERATION SWITCH in the RUN position.

Step 9: Observe PG2 and PG4. Ensure the pressure as read from PG4 never goes over 100 psi. Step 10: Start closing GV3 slowly. PG4 will begin to rise and PG2 will decrease. Stop closing GV3 when PG4

reaches 75-80 psi. (If you notice that PG2 and PG3 are both reading 0 while PG4 and PG5 are both lower than design parameters as recommended in table 4.2 of section 4.2.2, system may not have enough water in reject loop. Close GV3 fully (DO NOT OVERTIGHTEN VALVE) and observe PG2, and PG4. Pressure will

begin to rise rapidly. Once PG2 passes 20 psi begin opening GV3 slowly until PG2 reads 15-20 psi and PG4 reads 65-90 psi ). PG4 at this point may be within parameters, above parameters or below parameters. At this point you will need to adjust GV1 as well.

The best way to do this would be to perform the adjustments using GV3 to try and obtain your parameters,

keeping in mind that GV3 is mainly closed (Never all the way but mostly. Adjustments to this valve should

be minor to set recommended parameters as per table 4.2 of section 4.2.2.). If you cannot obtain the required parameters by adjusting GV3 then adjust GV1 accordingly depending on what you need. For example if while setting GV3 you can only obtain the parameters correctly as read by PG2, and PG3 but you cannot obtain the required pressure needed to meet the parameters of PG4 and PG5 then you will need to Close GV1 in order to increase the pressure as read by PG4. Then attempt to regulate the system parameters again using GV3. If the opposite is observed where you have too much pressure in PG4 then

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open GV1 slightly and attempt to regulate the system parameters again using GV3. Repeat this as needed to obtain the required parameters.

NOTE: If you open GV1, PG2 will rise and PG4 will decrease. If you close GV1, PG2 will decrease and PG4

will increase. This should only be used for fine tuning when necessary. Use GV3 and/or GV2 to do most of the adjusting.

Once the system is running correctly in run mode, GV2 will now have to be reset to ensure flush mode will

work properly. Step 11: Place OPERATION SWITCH in the OFF position.

Step 12: Locate GV2 and open valve 1 full turn. (valve should be fully closed before opening 1 full turn) Step 13: Place MANUAL FUNCTION SWITCH in the FLUSH position.

Step 13: Begin closing GV2 slowly as you observe PG2 and PG4. Stop closing valve when PG4 reaches 60-90

PSI. PG2 should read 10-20 PSI. Step 14 Since GV1 has already been set there should be no need to reset this valve. System adjustments

should be done using only GV2. NOTE: Should you have trouble adjusting valves, verify that the feed pump is working properly by opening

V3. A steady stream should be observed, you will notice the stream is pressurized which is a good sign. If you observe pulsation or a non-pressurized stream the feed pump stator might be out of place. Turn system completely off and ensure system clean water feed pressure does not exceed 20 psi, and verify that a pressure regulator is installed. Verify that the clean water feed flow rate does not exceed the unit’s rated capacity. Once this is verified disassemble pump, pull stator out of pump housing and place back in the correct place. Restart unit per section 4.1.

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8.0 DRAWINGS AND DIAGRAMS

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37 VMT - v. JUNE 2010

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DRAWINGS AND DIAGRAMS

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39 VMT - v. JUNE 2010

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40 VMT - v. JUNE 2010

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41 VMT - v. JUNE 2010

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DRAWINGS AND DIAGRAMS

42 VMT - v. JUNE 2010

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DRAWINGS AND DIAGRAMS

43 VMT - v. JUNE 2010

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DRAWINGS AND DIAGRAMS

44 VMT - v. JUNE 2010

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45 VMT - v. JUNE 2010

9.0 PARTS REFERENCE

9.1 SPARES AND CONSUMABLES

Description Part No.

Membrane Element all models 33-3003

Process filter 5 micron all models 33-0057

media fill kit (model BMS350 and BMS500) 90-5026

media fill kit (model BMS1000) 90-5028

media fill kit (model BMS2000 and BMS2500) 90-5029

Process filter and Membrane housing cover seal O-ring 33-0082

Switch, 3-pos 20-0029

Switch, 2-pos 20-0028

Light, Indicator, Green 20-3004

Light, Indicator, Red 20-3006

Light, Incandescent (110 VAC) 20-0505

Relay level control 110 VAC/50-60 20-0296

PLC preloaded with Code 70-5030

Cleaner 1 - 5 LB (Alkaline Type) 85-0042

Cleaner 2 - 5 LB (Acid Type) 85-0043

Preservative - 5 LB 85-0044

Cleaner 1 - 1 LB (Alkaline Type) 85-0036

Cleaner 2 - 1 LB (Acid Type) 85-0037

Preservative - 1 LB 85-0038

Process pump seal kit (Models BMS350-1000) 70-5029

Process pump seal kit (Models BMS2000-2500) 70-5044

Solenoid valve, ¾” FNPT 60-0121

Din connector, 20-5038

9.2 SPARES-OIL CONTENT MONITOR (SMART CELL-BILGE)

NOTE: At yearly intervals (or when necessary) the wiper ring on the manual clean assembly should be replaced.

This can be ordered from VMT directly as part no. 70-5031.

When ordering spares, it is important to supply details of the type of monitor, serial number of monitor, part number of each

spare required, its description and any other relevant information.

Description Part No.

Cell wiper ring 70-5031

Fuse 1.25A 70-5032

Smart Cell 70-5033

Smart Bilge PCB Assy (115) 70-5035

Membrane overlay 70-5036

LCD display module 70-5038

Smart Bilge Download Cable 70-5039

Solenoid Valve (115V) 70-5040

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47 VMT - v. JUNE 2010

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48 VMT - v. JUNE 2010

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PARTS REFERENCE

49 VMT - v. JUNE 2010

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PARTS REFERENCE

50 VMT - v. JUNE 2010

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51 VMT - v. JUNE 2010

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52 VMT - v. JUNE 2010

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PARTS REFERENCE

53 VMT - v. JUNE 2010

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PARTS REFERENCE

54 VMT - v. JUNE 2010

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PARTS REFERENCE

55 VMT - v. JUNE 2010

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PARTS REFERENCE

56 VMT - v. JUNE 2010

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PARTS REFERENCE

57 VMT - v. JUNE 2010

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58 VMT - v. JUNE 2010

P

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59 VMT - v. JUNE 2010

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60 VMT - v. JUNE 2010

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61 VMT - v. JUNE 2010

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62 VMT - v. JUNE 2010

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PARTS REFERENCE

63 VMT - v. JUNE 2010

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PARTS REFERENCE

64 VMT - v. JUNE 2010

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65 VMT - v. JUNE 2010

10.0 MANUFACTURER’S LITERATURE

10.1 SMART CELL- BILGE- INSTRUCTION MANUAL

10.2 CENTRIFUGAL PUMP MANUAL

10.3 PROGRESSIVE CAVITY PUMP SPARE PARTS

10.4 CERTIFICATES

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67 VMT - v. JUNE 2010

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68 VMT - v. JUNE 2010

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69 VMT - v. JUNE 2010

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70 VMT - v. JUNE 2010

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71 VMT - v. JUNE 2010

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74 VMT - v. JUNE 2010

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75 VMT - v. JUNE 2010

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76 VMT - v. JUNE 2010

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77 VMT - v. JUNE 2010

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78 VMT - v. JUNE 2010

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79 VMT - v. JUNE 2010

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80 VMT - v. JUNE 2010

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81 VMT - v. JUNE 2010

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82 VMT - v. JUNE 2010

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83 VMT - v. JUNE 2010

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84 VMT - v. JUNE 2010

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85 VMT - v. JUNE 2010

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86 VMT - v. JUNE 2010

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92 VMT - v. JUNE 2010

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93 VMT - v. JUNE 2010

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94 VMT - v. JUNE 2010

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95 VMT - v. JUNE 2010

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96 VMT - v. JUNE 2010

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106 VMT - v. JUNE 2010

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