Table of Contents 1 SYSTEM OVERVIEW GENERAL ARRANGEMENT AND OPERATION INSTALLATION MECHANICAL INSTALLATION 7

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1 2016 TECHNICAL DOCUMENTATION WILHELMSEN SHIPS SERVICE MARINE CHEMICALS - WATER SOLUTIONS WILHELMSEN SHIPS SERVICE AS Strandveien 20, N-1324 Lysaker, Norway

2 Table of Contents 1 SYSTEM OVERVIEW GENERAL ARRANGEMENT AND OPERATION INSTALLATION MECHANICAL INSTALLATION ELECTRICAL INSTALLATION..8 4 START UP AND COMMISSIONING GENERAL MAINTENANCE SPARE PARTS GENERAL SPARE PARTS LIST.11 7 FAILURE ANALYSIS APPENDIX A - ADDITIONAL DRAWINGS l Page

3 LIST OF ABBREVIATIONS BSP BW BWT Fig. ppm PID PTFE PVDF SS Std. WSS British Standard Pipe Boiler Water Boiler Water Treatment Figure Parts per million Proportional Integral Derivative Polytetrafluoroethylene Polyvinylidene Fluoride Stainless Steel Standard Wilhelmsen Ships Service 2 l Page

4 1 SYSTEM OVERVIEW The Aquaguard BW chemical dosing system is designed to provide cost effective and controlled delivery of your boiler treatment chemicals and protect the boiler system from the damaging effects of corrosion and scale formation. Controlled dosing can be initiated in a number of ways: a. By signal from modulating feed pumps (Analog) b. By signal from On/Off feed pumps (Digital) c. Manual/Continuous dosing d. Timer controlled dosing Options 1 & 2 will provide dosing control that is proportional to water consumption. By using this method combined with manual adjustment of the dosing pump stroke, the correct chemical treatment reserve can be established in the boiler water system. Kindly refer to the Pump Manuals for the mode selection and operation. 3 l Page

2 GENERAL ARRANGEMENT AND OPERATION The general arrangement of the entire Boiler Water Treatment system is as shown in Fig.

2) which is linked to the required number of chemical dosing pumps located on the respective chemical drum bunds (Fig. 3). A Prominent Gamma X (Fig.

The treatment chemicals are normally injected into the suction side of the boiler feed line through PVDF or stainless steel injection fittings (Fig. 6).

5 2 GENERAL ARRANGEMENT AND OPERATION The general arrangement of the entire Boiler Water Treatment system is as shown in Fig. 1. Fig. 1 - Typical Installation Arrangement for the Aquaguard BW Dosing Unit The Aquaguard BW is of robust construction and consists of the control unit (Fig. 2) which is linked to the required number of chemical dosing pumps located on the respective chemical drum bunds (Fig. 3). A Prominent Gamma X (Fig. 4) dosing pump is configured as the master controller with 1 or 2 Prominent Beta pumps (Fig. 5) (depending on the treatment programme) slaved to the master dosing pump. The treatment chemicals are normally injected into the suction side of the boiler feed line through PVDF or stainless steel injection fittings (Fig. 6). The dosing pumps can be operated in the Analog, On/Off (Digital) or Manual mode. In case of Analog mode of operation, the dosing is controlled by an external Analog signal like the modulating feed valve position. In the On/Off digital control mode, the dosing action is controlled by an external contact or switch like the feedwater level, etc. In the Manual mode of operation, the dosing parameters can be manually set as required. Please refer to Chapter 4 for the Start Up and Commissioning procedures. Also refer to Gamma X and Beta Dosing Pump manuals for detailed information on dosing pumps. 4 l Page

6 Fig. 2 Aquaguard BW Controller Fig. 3 Aquaguard BW Dosing Pumps and Chemical Drum Bunds Fig. 4 Gamma X Dosing Pump (Master) Fig. 5 Beta Dosing Pump (Slave) 5 l Page

7 Fig. 6 Typical Injection Point Fig. 7 Signal Cable to External 4-20 ma or On/Off Source Fig. 8 Suction Lance with Level Switch Fig. 9 Double Walled Dosing Line 6 l Page

8 3 INSTALLATION Supply Checklist: Item No. Item Description WSS Part No. Quantity 1 2 Aquaguard BW Control unit - 3 Pump Unit * ( or ) Aquaguard BW Control unit - 2 Pump Unit * ( or ) * * 3 Beta Dosing Pump 1602 PVT* or 2* 4 Gamma X 1602 PVT Dosing Pump Suction Assembly 6x4mm PVC with Level Switch or 3* 7 SS Injection Fittings - Hot water injector 200 C (6x4mm) or 3* 8 Signal Control Cable 5m (5m or 10m to be used) Signal Control Cable 10m (5m or 10m to be used) mm PTFE dosing line (double walled per metre) or Drum Bund with Pump Stand or 3* 12 Spares Pack for Beta and Gamma X Dosing Pump 1602PVT * Depending on number of treatment chemicals 3.1 MECHANICAL INSTALLATION Mount the controller on a suitable support or bulkhead using the pre-fitted anti-vibration mountings. Ensure that the cabinet is suitably earthed Position chemical bunds close to the control unit and mount the dosing pumps onto the pump flanges Plug in control wiring and power plugs into the dosing pumps Place the chemical drums into their respective bunds, insert suction lances and plug in level switch controllers in to front of dosing pumps For each chemical in use, fit a ½ BSP female valve fitting (injection point) into the suction side of the feed water line. It is advised to have a minimum distance of 0.3m between the injection points Run and secure chemical dosing lines from the dosing pumps and fit to the relevant injection points using Stainless Steel injection fittings. Trim the injection quill to fit the length of the valve. 7 l Page

3.2 ELECTRICAL INSTALLATION 3.2.1 Earthing Ensure that the control unit is properly earthed. 3.2.2 Power Supply Connect the power supply directly to the fused terminal located in the left hand corner of the control cabinet.

3 Signal Supply When using signal control, connect control wiring to the source (Analog or Digital) as per wiring diagram in Appendix A and plug the other end of the signal cable to the underside of

9 3.2 ELECTRICAL INSTALLATION Earthing Ensure that the control unit is properly earthed Power Supply Connect the power supply directly to the fused terminal located in the left hand corner of the control cabinet. Ensure electrical supply is isolated before connection. Kindly refer to the wiring diagram in Appendix A Signal Supply When using signal control, connect control wiring to the source (Analog or Digital) as per wiring diagram in Appendix A and plug the other end of the signal cable to the underside of the Gamma X dosing pump Signal Cable and Connections Signal/control cable is required for an Analog/Proportional dosing based on the feedwater flow rate or ON/OFF (digital) dosing based on a digital input. Please refer to Section 9.2 in Gamma X dosing pump manual for further information on signal cable connections Signal Cable with plug and loose wires: Brown, Black, Blue, White & Grey Analog control proportional to feedwater flow rate: Pump run enable & manual: Black & Brown cables must be enabled/joined. Analog Control: Select Analog control function in Gamma X dosing pump. Cable connection: Blue and Black-Brown (enabled/joined). Note: For External Contact/Digital/ON-OFF control, use white and Black-Brown (enabled/joined) cables and select the Contact operating mode in Gamma X dosing pump. 8 l Page

4 START UP AND COMMISSIONING Inspect the system to confirm that the installation is complete and that all pipework and connections are secure.

10 4 START UP AND COMMISSIONING Inspect the system to confirm that the installation is complete and that all pipework and connections are secure. Check that drums of treatment products are available and in place in the bunds underneath the chemical dosing pumps. 4.1 Confirm that the Earth connection is fitted correctly. 4.2 Power On - Switch on the main isolating switch and note that the Power On indicator illuminates. 4.3 Dosing Lines - Open any of the isolating valves at the dosing points and ensure that all dosing line locking compression nuts are tight and free of leaks. 4.4 Signal Connections - Confirm that the signal wiring from the feed pump control unit is connected as in wiring diagrams in Appendix A. 4.5 Prime Chemical Dosing Pumps - A chemical pump will not operate reliably if there is air present in the pump head or in the pump valves. Priming is the process of displacing all air with liquid so that the pump can develop full discharge pressure and flow. In all cases priming is achieved by running the pump at maximum output against reduced back pressure to clear any trapped air. The backpressure in the pump discharge line may be relieved using a valve installed in the head of the pump; refer to the manufactures instructions located in the rear of this manual on how to prime the dosing pumps. Turn individual pump control switches to Prime position and observe until chemical dosing is achieved Fig. 7 Priming and Run Condition 4.6 Run Condition - When dosing pumps are primed, turn control switches to Run position. Check that control cables from the controller to the dosing pumps are fitted. Set the Gamma X dosing pump to Analog control mode and the pumps will now dose chemicals in proportion to feed water flow. It is advised to set pump stroke at 50% then fine tune in line with boiler and condensate water test results. 9 l Page

11 5 GENERAL MAINTENANCE 5.1 Routine Attention - The display panel and pump alarms should be checked on a daily basis for alarms and these should be dealt with for example replace empty chemical treatment drums. Please refer to the instruction charts placed adjacent to the Control Unit and the Dosing Pumps. 5.2 The condition of the dosing lines and injection points should be inspected to detect any signs of leakage. The dosing pumps should also be inspected for any signs of faults or leakage. 5.3 The Nalfleet Aquaguard BW Dosing System requires very little routine maintenance apart from procedures relating to the dosing pumps. 5.4 It is recommended that dosing pumps are serviced annually with the installation of the appropriate spare parts for which refer to the Spare Parts list. For further information regarding the dosing pumps please refer to the pump manufacturer s manuals. 10 l Page

12 6 SPARE PARTS 6.1 GENERAL SPARE PARTS LIST No. Aquaguard BW Spares Item Description WSS Part No. 1 Replacement Aquaguard BW Control Unit 3 Pump Unit Replacement Aquaguard BW Control Unit 2 Pump Unit Beta Dosing Pump 1602 PVT Spares Pack for Beta and Gamma X Dosing Pump 1602PVT Gamma X 1602PVT Dosing Pump Suction Assembly 6x4mm PVC with Level Switch Signal Control Cable 5m (5m or 10m to be used) Signal Control Cable 10m (5m or 10m to be used) mm PTFE dosing line (double walled per metre) SS Injection Fitting - Hot water injector 200 C (6x4mm) Drum Bund with Pump Stand l Page

13 7 FAILURE ANALYSIS Note: In case of non-availability of the external field signal (analog/digital), the dosing unit can be operated in manual mode of operation. In Gamma X pump, the mode of operation can be changed from Analog to Manual mode. In Beta pump the manual operation can be performed by changing the setting from EXTERN to individual manual setting with the help of the multifunctional switch on the Beta pump. No. Cause Action Consequence/Effect 1 No power to controller or dosing pumps Check power supply and fuses Failure of Boiler Water Treatment System 2 Low chemical levels by test results 3 High chemical levels by test results 4 Signal Control Gamma X dosing pump in fail mode 5 Low chemical level alarm 6 Empty chemical drum alarm Check that chemical drums are not empty Check that control function is working Check that dosing pumps are primed Check for leaks in dosing lines Increase stroke of relevant dosing pump Check that control function is working Check that dosing pumps are primed Decrease stroke of relevant dosing pump Check that signal cable is connected; check for pump failure; if required set the dosing pumps to manual mode of operation. Replace the chemical drum with a filled one before the chemical drum get empty. In case the chemical drum is filled, check that the float switch in the suction lance is functioning properly. Replace the chemical drum with a filled one. In case the chemical drum is filled, check that the float switch in the suction lance is functioning properly. 7 Improper Earthing Proper earthing should be made available Under-dosing of chemical and desired chemical dosing effects could not be achieved Over-dosing and wastage of chemicals and desired dosing effects may not be achieved Required dosing results cannot be achieved and nonavailability of field signals for signal based/proportional dosing Warning signal for indication on the dosing pump Dosing pump stops and the dosing action is halted. Indication on the control unit. Possibility of leakage current and possible damage to electronic equipments in the control unit 12 l Page

14 8 Communication failure between Gamma X and Beta pumps Beta pump can be set to manual mode of operation 9 Pump Failure Dosing pump to be diagnosed for faults and errors 10 Faulty float switch on Replace the suction lance suction lance 11 Failure of automatic control function due to non-availability of the external analog/digital signal with a new one The dosing pump(s) can be operated in manual mode by adjusting the dosing pump parameters as required Synchronization of chemical dosing strokes between the dosing pumps is lost. For every x strokes of the master Gamma X pump, slave Beta pump does not have x dosing strokes Respective dosing action cannot be achieved Pump stops in case of faulty chemical drum empty alarm Check for the availability of the external signal on the control unit; refer to the wiring diagram (Appendix A - Section C). 13 l Page

15 8 Appendix A - Additional Drawings a. External view of the Control Unit: 14 l Page

16 b. Internal view of the Control Unit 15 l Page

17 c. Wiring Diagram 16 l Page

18 d. Pump Stand and Drum Bund General Arrangement 17 l Page

The Vario motor-driven pump series from ProMinent Adaptable to a wide range of applications VARIO METERING PUMP

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