FluidAqua Mobil FAM-200

Transcription

1 FluidAqua Mobil FAM-200 Mechanical and Electrical Erection Instructions English Doc.: c en / Siemens (PG)

2 Trademarks The trademarks of other companies are exclusively used for the products of those companies. Copyright 2007 by HYDAC Filtertechnik GmbH all rights reserved All rights reserved. This manual may not be reproduced in part or whole without the explicit written agreement from HYDAC Filtertechnik. Contraventions are liable to compensation. Exclusion of liability However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors. The content of the manual is checked regularly. Any corrections required will be incorporated in subsequent editions. We welcome any suggestions for improvements. Technical specifications are subject to change without notice. All details are subject to technical modifications. HYDAC FILTERTECHNIK GmbH Industriegebiet D Sulzbach/Saar, Germany Germany Tel.: ++49 (0) 6897 / Fax: ++49 (0) 6897 / HYDAC Filtertechnik GmbH en Page 2

3 Content Content... 3 Foreword... 4 Customer Service... 5 Modifications to the Product... 5 Warranty Erection Safety Guidelines General Manoeuvring Loads Prevention of Falling Accidents Fire and Explosion Hazard Welding Work Applicable Rules and Regulations (selection; not purported to be exhaustive) Operation Safety Guidelines General Safety Instructions General Instructions Safety Regulations Mechanical Erection Scope of Erection Resources Preconditions to Erection Description of Erection Check/Inspection of the Packing Removal of the Packing Checking the Unit for Completeness and Damage in Transit Transportation of the Unit to the Installation Site Setting up the Oil Purification Unit Installation of the piping connection to the Oil Purification Unit Suction port connection (Inlet) Return line connection (outlet) Retransfer pump connection (Inlet retransfer Pump) Water connection Drainage oil collection vessel and fine filter Electrical Installation Remaining Work Steps HYDAC Filtertechnik GmbH en Page 3

4 Foreword For you, as owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its installation. It is intended to help you become acquainted with the proper/designated use of the product and use it properly. You should keep it in the vicinity of the product so it is always at your fingertips. Sometimes the information contained in this documentation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting-edge. Consequently, there might be deviations in technical details, illustrations and dimensions. In these cases we go to every effort to keep your documentation current by sending you updates. But we need your help. Please make sure that you incorporate the updates in your documentation and that non-current sections are removed. If you discover errors while reading the documentation or have suggestions or other useful information, please don t hesitate to contact us: HYDAC Filtertechnik GmbH Dept.: SFVI, Techn. Documentation P. O. Box Sulzbach / Saar, Germany Fax: ++49 (0) filtersysteme@hydac.com The editor would welcome your involvement. Putting experience into practice HYDAC Filtertechnik GmbH en Page 4

5 Customer Service If you have any questions, suggestions, or encounter any problems of a technical nature, please contact: When contacting us, please always include the model/type designation and article no. / serial no. / firmware version of the product: Fax: ++49 (0) filtersysteme@hydac.com Modifications to the Product We would like to point out that changes to the product (e.g. purchasing options, etc.) may result in the information in the operating instructions no longer being completely accurate or sufficient. When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative. Please notify us immediately of any modifications made to the product whether by you or a third party. Warranty For the warranty provided by us, please refer to the General Conditions of Sale and Delivery of HYDAC Filtertechnik GmbH. They are available at: Legal information. HYDAC Filtertechnik GmbH en Page 5

6 ... And now for a few tips on using this documentation. The following example shows you how you can access the information you are looking for quick and easy. WHAT do I want to know? WHERE can I find the information I m looking for? The documentation is subdivided into chapters and sections. 1. Look for the table of contents. 2. Skim the boldfaced section headings. HOW can I find the section and page I m looking for? Page through the operating instructions, keeping your eyes focussed on the lower right corner. As soon as you see the page number you are looking for, stop paging. The chapter heading is featured in the upper right corner of each page. Product description Page no. Edition date of chapter/section The documentation number/edition and index are featured in the lower left corner of each page and on the cover sheet of the instructions. This information features the following format: MontA Product a en Documentation no. Index The documentation no. is a part no. which is used to order the instructions. The index is increased every time the instructions are revised or changed. Please note that the method described above of locating specific information does not release you from carefully reading the entire manual prior to starting the unit up for the first time and carefully rereading the manual at regular intervals later on. HYDAC Filtertechnik GmbH en Page 6

7 1 Erection Safety Guidelines 1.1 General The proper protective clothing and gear is to be worn at all times when performing work (helmet, protective footwear, closely fitting work clothes). Long hair is not to be worn loosely, no loose clothing or jewellery including rings are to be worn. A hazard is posed by these items be uncaught or pulled in during drilling work etc. The regulations and instructions of the supplier are to also be followed in addition to the safety, set-up, installation and commissioning instructions included herein. Adherence is to be maintained to pertinent national and local regulations in effect at the installation site of the hydraulic power unit. 1.2 Manoeuvring Loads Individual components and assemblies are to be carefully attached and secured to hoisting gear during erection and installation work. The lifting eyes provided for this purpose are to be used and the ropes to be guided in such a manner so that facility parts or projecting piping components are not damaged. Only suitable, intact, properly functioning hoisting gear and load suspension devices possessing a sufficient rated load-bearing capacity are to be used. Under no circumstances is work to be performed beneath suspended loads, in other words they are to be kept clear of at all times. 1.3 Prevention of Falling Accidents When performing erection work at elevated levels, only safety-tested climbing equipment and working platforms are to be used. Under no circumstances may machinery components be used for climbing up. When working at extremely high levels, safety belts etc. are to be worn. All handles, steps, railings, platforms, landings, and ladders etc. are to be kept clean and free of snow and ice. 1.4 Fire and Explosion Hazard Welding, blow-torch and sanding work may not be performed unless express permission is given. Fire or explosion hazard may be present. Smoking and open fires are only permitted in designated areas. 1.5 Welding Work Additional welding work on the hydraulic unit is not allowed. HYDAC Filtertechnik GmbH en Page 7

8 1.6 Applicable Rules and Regulations (selection; not purported to be exhaustive) Accident Prevention Regulations Safety Rules and Regulations of the Trade Association of the Iron and Steel Industry Safety Regulations Applicable to Crane Operators and Painting/Coating Personnel Safety Marking Regulations VGB 125 DIN 4888 Parts 1-3 Fire Prevention Regulations Environmental Protection Regulations Working Hours Regulations Law Pertaining to the Protection of Working Youth Maternity Protection Act First aid to be administered in the event of accidents HYDAC Filtertechnik GmbH en Page 8

9 2 Operation Safety Guidelines 2.1 General Safety Instructions The design of the Oil Purification Unit is based on the latest state of technology. A reliable function is only guaranteed when observing all instructions, adjustments and ratings. As the unit is pressure producing and all used components are subject to fluid and gas pressure the unit may become dangerous if subjected to inexpert handling or if untrained personnel are used for operation, maintenance or service. Warning against inexpert or unforeseen use! To guarantee safe operation the following items have to be observed: 2.2 General Instructions As long as the Oil Purification Unit is subject to hydraulic pressure or electric voltage no interference is allowed. Hydraulic units are only to be operated through trained personnel. All security devices have regularly to be checked concerning their good condition. Adjustment of pressure relief valves of the installed pumps is not allowed. Security devices are not allowed to be removed, to be made ineffective or to be ignored due to risk of accidents. This operation and maintenance instruction is only valid for the HYDAC scope of supply. For all parts not belonging to our scope of supplies please consider the instructions of the corresponding manufacturer. 2.3 Safety Regulations The following regulations applies in European countries. For non-european countries see the local valid regulations. Low-Voltage Directive (73/23/EEC): In effect since: 1 January 1997 National (German) law: Equipment Safety Law (GSG) 1st Ordinance to the Equipment Safety Law (1. GSGV) Simple Pressure Vessels Directive (87/404/EEC): In effect since: 1 July 1992 National (German) law: Equipment Safety Law (GSG) 6th Ordinance to the Equipment Safety Law (6. GSGV) Machinery Directive (98/37/EC; revised directive, currently proposed): In effect since: 1 January 1995 National (German) law: Equipment Safety Law (GSG) 9th Ordinance to the Equipment Safety Law (9. GSGV) Pressure Vessels Directive (97/23/EC): In effect since: 29 May 2002 National (German) law: Equipment Safety Law (GSG) 14th Ordinance to the Equipment Safety Law (14. GSGV) HYDAC Filtertechnik GmbH en Page 9

10 EMC Directive (89/336/EEC): In effect since: 1 January 1996 National (German) law: Electromagnetic Compatibility Act (EMVG) Occupational Safety Directive (89/391/EEC): In effect since: 21 August 1996 National (German) law: Occupational Safety Act (ArbSchG) HYDAC Filtertechnik GmbH en Page 10

11 3 Mechanical Erection 3.1 Scope of Erection This section provides a brief overview of the work steps to be performed when installing and setting up the Oil Purification Unit. Check/Inspection of the Packing Removal of the Packing Checking the Unit for Completeness and Damage in Transit Transportation of the Unit to the Installation Site Setting up the Oil Purification Unit Installation of the Piping Electrical Installation Remaining Work Steps 3.2 Resources This section provides a brief overview of the equipment, tools and workers required to install and set up the Oil Purification Unit. - Lifting devices possessing a minimum load-bearing capacity of 2 metric tons - Crane - adjustable spreader beam (minimum 1800mm, preferably self-adjustable), - lift slings/ropes with hooks - Tools and equipment to perform installation work, i.e. installation of pipe work (e.g. 1 set of open-end wrenches and screwdrivers in the standard sizes, etc.) Siemens technicians or personnel trained by Siemens, at minimum the following: - 1 electrician - 1 mechanic 3.3 Preconditions to Erection This section provides a brief overview of the measures to be initiated in order to provide for smooth installation of the Oil Purification Unit. The work steps described in this manual are to be performed by properly trained and certified personnel of Siemens, or by skilled personnel which is trained and certified. Availability of the skilled personnel required for installation (e.g. welders, electricians, mechanics, etc.) Provision of the requisite equipment and tools for installation and setup work (hoisting gear, block and tackle, welding equipment, etc.) Provision of the requisite equipment and tools for installation work HYDAC Filtertechnik GmbH en Page 11

12 Preparation of the installation site for the installation work Cleaning of the installation surfaces on the Oil Purification Unit and the components to be mounted (e.g. screwed pipe fittings) Warning: The Oil Purification Unit does not feature corrosion protection appropriate for out-door or long term storage. The following applies in particular: No storage out in the open May only be stored in dry (indoor) areas. In the event that the packing has been is damaged or removed, the unit is to be installed as soon as possible. 3.4 Description of Erection This section provides a detailed listing in chronological order of the work steps to be performed in installing and setting up the Oil Purification Unit Check/Inspection of the Packing Check/inspect the packing for damage. In the event that damage is detected => repair the packing in an expert manner. Don t remove the packing until shortly before the unit is to be installed Removal of the Packing First remove the lid and upper part of the packing. Then remove the side panels of the packing. Remove the protective film from the unit Checking the Unit for Completeness and Damage in Transit Check the unit and the components supplied loosely for damage. In the event that damage is detected => notify erection management immediately for deciding on how to proceed further. Check the consignment (the unit and the components supplied loosely) for completeness on the basis of the packing specification. In the event that the consignment is incomplete => notify erection management immediately for deciding on how to proceed further Warning: After being unpacked, the Oil Purification Unit is to be transported to the installation site as quickly as possible. HYDAC Filtertechnik GmbH en Page 12

13 3.4.4 Transportation of the Unit to the Installation Site The following is required for transportation of the unit: Lifting devices possessing a minimum load-bearing capacity of 2 metric tons Crane adjustable spreader beam (minimum 1735 mm, preferably self-adjustable), 4 lift slings/ropes with hooks The spreader beam has to be designed in such a manner so that it is ensured that the 4 load-bearing slings/ropes are always in a vertical position after they are inserted into the lifting lugs on the Oil Purification Unit (cf. figure 1 and Transportation guidelines on following page). Figure 1: lifting eyes Fasten the load-bearing slings/ropes to the of the adjustable spreader beam and with the hooks to the lifting eyes of the Oil Purification Unit. Make sure that no components (e.g. piping sections, pumps, electrical control cabinet) are squeezed or damaged by the slings/ropes. Adjust the adjustable spreader beam Slowly lift the unit up a few centimetres. Check to see that the slings/ropes are securely fastened to the ring bolts. Make sure when lifting the unit that no components (e.g. piping sections) are squeezed or damaged. Slowly lift the unit to the conveying height. Convey the unit and the components supplied loosely to the installation site. Warning: Adhere to the guidelines pertaining to the movement of loads. Only use adjustable spreader beam (Traverse) as shown on following picture. HYDAC Filtertechnik GmbH en Page 13

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15 3.4.5 Setting up the Oil Purification Unit The Oil Purification Unit is to be set up/installed on a concrete foundation. The entire structure has to rest flush/level on the foundation for structural strength reasons. Setup and installation of the Oil Purification Unit at the installation site: Set the unit down at the installation site. Align the unit in accordance with the respective Siemens drawing => Note the required access area: Figure 2: Required access area Using the 4 mounting brackets on the base frame of the Oil Purification Unit, the unit is fixed with the supplied 4 anchor bolts (Fischer FAZ 12/20 A2, Art. No.: 93031). Figure 3: Mounting bracket Drill the holes in the foundation (hole diameter: 12 mm, drilled hole depth: min. 100 mm). HYDAC Filtertechnik GmbH en Page 15

16 Push the bolts through the mounting brackets. Before driving in, the hexagon nut must be brought into the optimal installation position (the bolt projects by 2 to 3 mm). Figure 4: Push through Installation of anchor bolts Mount the base frame to the foundation with a maximum torque of 60Nm Installation of the piping connection to the Oil Purification Unit During setup and installation, make sure to maintain as much cleanliness as possible so that no dirt is allowed to enter the Oil Purification Unit. The cover caps at the connector/linkage points may not be removed until the piping is installed. The piping has to be laid/installed so that no pressure is exerted on it Check whether the pipe work has been laid/installed so that no pressure is exerted on it or so it is not subjected to any tension => Connections must be made without strain or stresses to the Oil Purification Units piping. The nominal size of the connected piping, must be at least as large as the inlet port size of the Oil Purification Unit in order to prevent an high pressure loss. Mounting of the piping sections is to be done as follows: Retransfer pump Figure 5: Piping connections to Oil Purification Unit Drainage Oil Collection Vessel G1 G1 HYDAC Filtertechnik GmbH en Page 16

17 Suction port connection (Inlet) Remove the cover cap of the inlet flanged ball valve (MAV 93 AA251). Make sure the piping is as level and straight as possible in order to avoid pressure losses along the piping. The maximum allowable suction pressure is -0,4 bar. Make sure that the tank connection is always below the fluid level. Connect the piping with an appropriate flange with seal to the flanged ball valve (DIN EN DN80 PN16). Screw the nuts tight with a maximum torque of 80Nm Return line connection (outlet) Remove the cover cap of the return line flange. Make sure the piping is as level and straight as possible in order to avoid pressure losses along the piping. Make sure that the tank connection is always below the fluid level. Connect the piping with an appropriate flange with seal to the flanged ball valve (DIN EN DN80 PN16). Screw the nuts tight with a maximum torque of 80Nm Retransfer pump connection (Inlet retransfer Pump) The supplied oil retransfer pump (MAV86 AP001) must be connected to the Inlet retransfer pump. Only use the supplied Pump KF4/125 Remove the cover cap of the flanged ball valve (MAV 93 AA263). Make sure the piping is as level and straight as possible in order to avoid pressure losses along the piping. Make sure that the tank connection is always below the fluid level. Connect the piping with an appropriate flange with seal to the flanged ball valve (DIN EN DN80 PN16). Screw the nuts tight with a maximum torque of 80Nm.. Also referer to the Installation Instruction of the Pump manufacturer Kracht (attached) Water connection The unit is supplied with an automatic water supply for the watering vacuum pump, the water supply must be connected according to all relevant national and provincial regulations. Point of connection: female G1 thread, maximum torque of 310 Nm. Conditions for the water connection: Cold water until max. 30 C Working pressure: min. 1,5 bar / 150 kpa HYDAC Filtertechnik GmbH en Page 17

18 max. 16 bar / 1600 kpa The Unit is equipped with a backflow preventer and a filter combination. The backflow preventer is installed to prevent possible backflow of contaminated water into the water main. It opens when the pressure exceeds 1,5 bar ( 150 kpa). Figure 6: Setting outlet pressure (pressure after filter unit): To avoid a heavy trouble in the tank of the vacuum pump, the pressure must be reduced. Set the outlet pressure according to the operating instruction Honeywell (attached): Outlet pressure max. 5 bar (500 kpa) Drainage oil collection vessel and fine filter Connect the drain piping to the oil drain line. Point of connection: female G1 thread, maximum torque of 310 Nm Electrical Installation Laying and connecting the electric lines/cables between the electrical control cabinet of the Oil Purification Unit and the terminal box of the electric control system of the overall facility in accordance with the respective Siemens drawings. Laying and connecting the electric lines/cables between the electrical control cabinet of the Oil Purification Unit and the retransfer pump. For the connection to the Oil Purification Unit und the retransfer pump please refer to HYDAC circuit diagram drawing no Warning: Electrical installation of the unit may only be performed by properly trained and certified personnel. The electrical installation work between the Oil Purification Unit and the electrical control system of the overall facility forms part of the scope of delivery of Siemens AG Remaining Work Steps Clean the installation site and the Oil Purification Unit including the pipe work after completing the installation work. HYDAC Filtertechnik GmbH en Page 18