PURCHASER : CHINA MERCHANTS HEAVY INDUSTRY (JIANGSU) CO.,LTD. OIT DOC NO : FPS-WM-14 071-F03 SUB. P.O. NO : CMHI(JS)-151-1-CG-051 / CMHI(JS)-151-2-CG-051
DOC TITLE
: HI-FOG OPERATION &
PROJECT
: DRILLING ASSIST TENDER BARGE
MAINTENANCE MANUAL
HULL NO.
: CMHI(JS)-151-1 / CMHI(JS)-151-2
EDITION
OWNER
: MERMAID DRILLING LIMITED
MANU./SUPP. : MARIOFF / OAKWELL
SYSTEM
: HI-FOG WATER MIST SYSTEM
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Hi-Fog SPU System Operation & Maintenance Manual P31000_D
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Total Flooding Protection (English Languages)
REVISION DATA
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PREPARED BY
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CHECKED BY
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APPROVAD BY
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00 10-Dec-14
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Steven Chn
MANUFACTURER: Marioff Corporation Oy • Plaza Business park Halo Äyritie 24, 01510 Vantaa, Finland Tel. +358 (0)9 870 851 • Fax +358 (0)9 8708 5399 • www.marioff.com AUTHORIZED DISTRIBUTOR: Oakwell International Trading (Shanghai) Co., Ltd./ Room403, Building H, Huaxin Science and Technology Park, 142 Tian Lin Road,Shanghai 200233, China Tel:+86-21-64325985 • Fax:+86-21-64696073 • www.oakwell.com.sg
SPU Operating and Maintenance Manual
Document code / revision: P31000 D Publishing date: 09 Jun 2014
Published by Marioff Corporation Oy © 2014 all rights reserved Plaza Business Park Halo Äyritie 24 01511 Vantaa Finland Tel. +358 (0)10 6880 000 Fax +358 (0)10 6880 010 http://www.marioff.com In case of discrepancy between the original English document and the translated document, the English text prevails. All rights reserved. Marioff Corporation Oy reserves the right to change or modify the information given in this document, including technical details, without notice. Reproduction of any part of this document without the express written permission of Marioff Corporation Oy is prohibited. HI-FOG® and Marioff® are registered trademarks of Marioff Corporation Oy. Marioff is part of UTC Building & Industrial Systems, a unit of United Technologies Corp. (NYSE:UTX), which provides high technology products and services to the building and aerospace industries worldwide. More information on Marioff group companies, agents/distributors and references can be found at www.marioff.com.
CAUTION HI-FOG® systems comprise mechanical components that employ high pressure for water pressurization. HI-FOG® system installation embraces high-pressure testing of discharge tubing. Care must be taken to ensure that all relevant safety procedures are followed during installation to the satisfaction of the authority having jurisdiction and that only competent personnel, appropriately trained and certified, are permitted to install, test, commission and service the system. Marioff group companies and their respective affiliates, officers, employees and representatives shall have no liability whatsoever for the compliance by third parties to the present manual or to any applicable safety procedures.
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Table of Contents
Table of Contents 1. Introduction .................................................................................7 1.1 More information...............................................................7 2. Warnings and cautions ..............................................................8 3. General SPU description............................................................10 3.1 Unit description .................................................................10 3.1.1 Main parts ......................................................................10 3.1.2 Starter cabinet ...............................................................13 3.2 Operating description........................................................14 4. Operating instructions ...............................................................15 4.1 System in stand-by mode .................................................15 4.2 Start ..................................................................................15 4.2.1 Automatic start...............................................................15 4.2.2 Manual start - remote.....................................................15 4.2.3 Manual start - local ........................................................15 4.3 Pump unit in operation......................................................16 4.4 System stop and reset ......................................................16 4.5 Clearing up after system operation...................................17 5. Maintenance ................................................................................18 5.1 Inspection and maintenance frequencies .........................18 5.2 Inspection and maintenance procedures..........................19 5.2.1 Check all valve positions ...............................................19 5.2.2 Check the stand-by pressure and pump........................19 5.2.3 Check electric supply, test lamps ..................................19 5.2.4 Visually inspect the pump unit and its fittings ................19 5.2.5 Check oil level of the pumps..........................................20 5.2.6 Check drive chains and flexible coupling .......................20 5.2.7 Check air pressure regulator and empty water lock ......21 5.2.8 Check water filter and separator....................................22 5.2.9 Test run the unit.............................................................24 5.2.10 Check pump unit batteries and charger.......................24 5.2.11 Check the setting values of pressure and flow switches and transducers .......................................................25 5.2.12 Test the unit in accordance with service instructions...25 5.2.13 Check breather cap filter..............................................25 5.2.14 Replace suction hoses (BSPU) ...................................25 5.2.15 Change pump oil (every 2 years or 200 hours) ...........25 6. Troubleshooting..........................................................................27 6.1 General faults ...................................................................27 6.1.1 Unit will not start ............................................................27 6.1.2 Unit will not stop.............................................................27 6.1.3 Unit starts unintentionally...............................................27 6.1.4 Water accumulators released unintentionally (if fitted) ..28 6.1.5 Stabilisation phase not completed .................................28 6.1.6 Stand-by pump striking frequently .................................28
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6.1.7 Fuses blown...................................................................29 6.2 Alarms...............................................................................29 6.2.1 Nitrogen pressure low (if connected to water accumulator unit) .................................29 6.2.2 Battery charger fault ......................................................29 6.2.3 230VAC control voltage fault .........................................29 6.2.4 Earth fault (24VDC) .......................................................30 6.2.5 Circuit breaker released.................................................30 6.2.6 Out of water ...................................................................30 6.2.7 Pump unit fault...............................................................30 6.2.8 Compressed air low pressure fault (if applicable) ..........30 6.2.9 Inlet/Outlet valve closed (if applicable) ..........................30 6.2.10 Line voltage fault (if applicable) ...................................30 6.2.11 Other faults ..................................................................31 A. Appendix - Spare parts ..............................................................33
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1. Introduction This manual describes how to operate and maintain the HI-FOG® Sprinkler Pump Unit (SPU). This manual describes the SPU at a general level and the illustrations in this manual may not reflect exactly the SPU model or version supplied. The diagrams and parts lists supplied with each unit are specific for the supplied unit. Any changes made to the supplied and installed system or its equipment are allowed only with the written consent from Marioff Corporation.
NOTICE! Always refer to project documentation for details of your installation.
1.1 More information Refer to the project-specific documentation as well as to the documents listed below for more information.
Marioff diagrams and drawings • Hydraulic diagrams and parts lists for the supplied unit • Electric diagrams and parts lists for the supplied unit • Dimensional drawing for the supplied unit
Marioff Technical Data Sheets and Manuals • Data sheets for specific units as applicable • Marioff water specification DOC0002101 • Marioff pressurized air specification K0006983 • Standard HI-FOG® SPU gearbox chain and coupling change TE1002 • Inhibitor pump assembly K0007347 • Safety valve sets for SPU and MSPU K0008018 and Special safety valve sets K0008040 • Marioff Installation manuals P32010 (Land applications) and DOC0004462 (Marine applications)
Third-party documents • High pressure plunger pump operating instructions • Stand-by pump operating and maintenance instructions • Fire detection system operating instructions
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2. Warnings and cautions Warnings give information about possible hazards for the users of the SPU system. Cautions give information about possible system hazards. Make sure that all mechanical and electrical assemblies and parts of the SPU system are used with care and inspected regularly. Make sure that the personnel using the system are • instructed in the proper use and care • aware of the performance limitations • aware and observe all warnings and cautions described in this manual
Warnings The HI-FOG® SPU produces high-pressure water when operating. To avoid injury to personnel and/or damage to equipment always follow the safety procedures described in this manual and required by local and/or national authorities.
WARNING! HAZARDOUS VOLTAGE WILL CAUSE DEATH OR SERIOUS INJURY.
Only qualified personnel are permitted to perform electrical work on the SPU. Check local safety regulations. Electrical cabinets may have several power supplies and voltages. Before starting electrical work, isolate each power supply.
Cautions Water used with the HI-FOG® system must be the equivalent of a potable supply. In all cases the input water must be fed through a < 100 μm filter and the chloride concentration MUST not exceed 50 ppm (= 50 mg/l). Under no circumstances add suppression additives to the stored water supply. Only appropriately trained personnel are permitted to work on, test and service the SPU, the sprinkler system and its associated equipment. When in doubt, contact Marioff representative.
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Check, test and service the SPU in accordance with the instructions in this manual.
NOTICE! Failure to check, test and service the SPU in accordance with the instructions given in this manual can jeopardize the reliable operation of the system.
Only use spare parts that are manufactured, supplied, or recommended by Marioff. If the SPU is switched off for any reason, take adequate fire precautions, according to your safety procedures, to cover the period that the SPU is out of operation. NOTICE! If the system includes a water cylinder accumulator, it will be released if the SPU main switch is turned off, when the system is activated. Before carrying out any service, testing or maintenance work, remove the plug from the accumulator release valve to avoid unintentional release. Remember to replace the plug.
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3. General SPU description 3.1 Unit description The HI-FOG® Sprinkler Pump Unit (SPU) is designed to supply high-pressure water to a HI-FOG® water mist distribution system used for fire protection. It is used with singlefluid, single-pipe type HI-FOG® sprinkler systems that use water, in the form of a fine mist, as the fire suppressant. The HI-FOG® Boosted Sprinkler Pump Unit (BSPU) has similar functionality as the standard SPU but it provides larger flow per one motor. It is typically used in marine applications (machinery spaces).
3.1.1 Main parts The SPU has the following main parts: • One or more pump modules (the number depends on the SPU installed, refer to the system specifications). Each pump module has one 3-phase electric motor, two plunger pumps and two unloaders. • An electric control and monitoring system (relay) • A break-water tank NOTICE: Units may also be supplied without a break-water tank. • A separator (optional) and filter in the inlet from the water feeding system • A pneumatic stand-by pump There can be either one or two power supplies to the SPU. If the system includes two power supplies, the switching between them is done automatically. A feed pump or hydrophore supplies fresh water to the SPU. In addition to the fresh water inlet the SPU may be connected to a fire main or another water source for redundancy. BSPU has the same basic components as the standard SPU. There are some small differences, for example BSPU has suction hoses from tank to pumps whereas SPU has pipes. In addition, BSPU has a wider frame than SPU.
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Refer to the figure below for SPU main parts (SPU 05+1 used as an example).
Starter cabinet Air inlet Break-water tank Gearbox
Stand-by pump Test valve Overflow outlet
Safety valve Pump
Electric motor
Mounting frame Breather cap High pressure water outlet Water inlet Water filter Redundancy water feed inlet (optional) Separator (optional)
Separator drain
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SPU Operating and Maintenance Manual The following figure illustrates Boosted SPU design (BSPU 05+1 used as an example).
Starter cabinet Air inlet Break-water tank Gearbox
Stand-by pump Test valve Overflow outlet
Safety valve
Pump
Electric motor
Mounting frame Breather cap High pressure water outlet Water inlet Water filter Redundancy water feed inlet (optional) Separator (optional)
Separator drain
Arrangements vary per model. Refer to labels.
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3.1.2 Starter cabinet The illustration shows the SPU08 starter cabinet. Starter cabinet monitors, operates, and controls the SPU. The starter cabinet has the following manual operations and selections available (numbers in brackets correspond to those in the figure): • Manual start motor 1-X (X: depends on the unit size) (M1-MX) • Lamp test (1) • System reset (2) • 230 VAC control voltage fault (3) • Battery charger fault (4) • Earth fault 24 VDC (5) • Out of water (6) • Control system on (7) The following is added for land applications: • Inlet/outlet valve closed (8) • Voltage metering selection (9) • Line voltage fault (10) • Compressed air low pressure (11) • Circuit breaker released (12) The following is added for marine applications: • Pump unit fault (8) • Main supply on (13) • Emergency supply on (14)
NOTICE! The starter cabinet layout is only an example and the cabinet configuration varies depending on the pump unit size and project. See project documentation for details of the installed system and refer to labels on lamps/ switches.
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3.2 Operating description Stand-by mode = Normal mode when the system is on. In normal use the system must always be in the stand-by mode. Operating mode = The system is activated. Stabilisation mode = The system is returning from activation to stand-by mode. Off = The system is shut down for maintenance or repair. A pressure of 25 bar (or other system specific set value) is maintained in the system when it is in the stand-by mode. A fire causes the heat-sensitive bulbs on one or more sprinklers to break. Alternatively, section valves open and water starts to flow from the released spray heads. The flow monitor detects the flow and starts the SPU. A pressure switch starts the SPU if the flow monitor malfunctions. You can also start the SPU manually, either locally by turning the start switch(es) on the starter cabinet, or remotely by sending a start signal to the starter cabinet. When the SPU is activated, the pump modules automatically start in sequence. A few seconds delay between each start reduces electric peak loads. If the flow of water required is less than the output of the unit, the unloader valves open and route extra water back to the break tank. High-pressure water is now fed to the HI-FOG® system forming a fire suppression mist. After the SPU has been stopped it must be reset. The stabilisation phase takes a few minutes, during which the system pressure drops to the stand-by level and then the unit returns to the stand-by mode.
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4. Operating instructions 4.1 System in stand-by mode In normal use the system must be in the stand-by mode. The system is in the stand-by mode when: • the SPU is connected to the electric supply and the main power switch is on • working air is supplied to the stand-by pump and the pump is operational • the system pressure is within the set limits • the control system is operational • the piping is sound and tight (see Marioff Installation manuals P32010 and DOC0004462)
4.2 Start 4.2.1 Automatic start The SPU will automatically start to operate if it detects a water flow and/or if the water pressure drops below a preset value (typically 17 bar) for more than preset time (typically 10 - 20 seconds) (depending on the system size). The redundant motor, if supplied, will automatically start if one of the motors does not start or stops operating. To stop the unit press and hold the Reset button for one (1) second. Make sure that there is no fire before you stop the unit. If there is still flow in the system after the reset period the unit will restart (see chapter 4.4). Isolate the sections where there is flow.
4.2.2 Manual start - remote Press the Emergency start button on the remote control panel (if provided) to start the SPU. Press the Emergency start button a second time to stop the pump. You must reset the unit after this. Refer to chapter 4.4.
4.2.3 Manual start - local Set the pump activation switches in the pump unit control cabinet to the ”1” position to switch the pumps on. To stop the pumps, set the switches to ”A” position. You must reset the pumps after this. Refer to chapter 4.4.
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NOTICE! Starting the pump with the pump activation switches will override all other protection. Before carrying out a local manual start, check that no fault alarms are on.
4.3 Pump unit in operation When the pump unit has received a start signal it will maintain the required pressure and flow in the system until a reset signal is given or the pump runs out of water. The low level switch in the break tank prevents the unit from starting when there is not enough water, or stops the motors to prevent them from running dry. When the redundancy source of water (if applicable) has been connected and/or the break tank has been refilled, the pumps will restart automatically. If the “HI-FOG activated” mode is on and the pressure drops below a preset value (typically 30 bar) for preset time (typically 15 seconds), or if there is a power cut, or if the motors cannot be started for some other reason, a signal is automatically given to release the water accumulator unit (if fitted).
4.4 System stop and reset Step 1. Before you stop the unit, make sure that there is no fire. Step 2. Make sure that any released sprinklers/spray heads are isolated and the section valves are closed so that there is no flow into the HI-FOG® system. Step 3. Press and hold down for one (1) second the Reset button on the pump unit or, if fitted, on the release or mimic panels. The pump motors stop (if started automatically), the stabilisation valve opens (decreasing the system pressure) and the alarms clear.
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The stabilisation valve will close when the pressure in the system drops to a preset value (typically 22 bar). After that, the stand-by pump in the pump unit automatically increases the pressure in the system to the stand-by pressure (typically 25 bar). Restart is prevented during the stabilisation period. When the reset phase is completed the pump unit automatically switches to the stand-by mode. You can also stop the water discharge from the SPU by closing the ball valve located on the unit, but this is only recommended in the case of unintentional release. This action will not stop the motors. Standard vessel systems will not reset properly unless the system pressure has reached 130 bar. The pump unit must be run until the pressure has risen above this point before resetting the system by pressing the Reset button for one second.
Reset after a “Manual emergency start” (Manual start - remote): Step 1. To shut down the pump, press the same Emergency start button that was used to start the system. Step 2. Run the pump unit until the system pressure reaches 130 bar, after which you can reset the system by pressing the Reset button for one second.
4.5 Clearing up after system operation If sea water or a similar redundancy source was used, you must flush the complete system with fresh water.
Step 1. Empty the break water tank of redundancy water via the drain valve. Step 2. Manually run the pump for a period long enough to remove all the redundancy water from the pump unit, the break water tank and/or the system piping. Step 3. Change the water filter cartridge.
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5. Maintenance 5.1 Inspection and maintenance frequencies This chapter describes the minimum requirements for maintenance routines of the SPU. Always check the project-specific documentation for SPU and system level maintenance routines and their frequencies. In addition to the information in the table below, note the following: • Other maintenance frequencies may be specified in local laws and regulations or in customer-specific system specifications. • Refer to the third-party manufacturer’s instructions (as delivered with the system) for more information. Chapter
Action
Weekly
Monthly
Annually
5.2.1
Check all valve positions
x
x
x
x
5.2.2
Check the stand-by pressure and pump
x
x
x
x
5.2.3
Check electric supply, test lamps
x
x
x
x
5.2.4
Visually inspect the pump unit and its fittings
x
x
x
x
5.2.5
Check oil level of the pumps
x
x
x
5.2.6
Check drive chains and flexible coupling
x
x
5.2.7
Check air pressure regulator and empty water lock
x
x
5.2.8
Check water filter and separator
x
x
5.2.9
Test run the unit
x
x
5.2.10
Check pump unit batteries and charger
x
5.2.11
Check the setting values of pressure and flow switches and transducers
x
5.2.12
Test the unit in accordance with service instructions
x
5.2.13
Check breather cap filter
x
5.2.14
Replace suction hoses (BSPU)
x
5.2.15
Change pump oil (every 2 years or 200 hours)
x
x
Every 5 years
x
*
x
x x
x
*other frequencies may be specified in local laws and regulations or in the system-specific instructions
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5.2 Inspection and maintenance procedures This chapter describes how to carry out the inspections and maintenance listed in the above table. Treat as urgent, the notification of any factors liable to have a detrimental effect on the performance of the pump unit or the HI-FOG® system.
5.2.1 Check all valve positions In stand-by and operating modes the valves must be in the following positions.
Open valves • outlet valve to the sprinkler system • fresh water supply valve • air inlet to the stand-by pump
Closed valves • test valve • sea-water / redundancy water valve • drain valve
5.2.2 Check the stand-by pressure and pump Check that the stand-by pressure in the system is set to the correct level (25 bar, if not otherwise stated) and ensure the stand-by pump does not start running too often (if it does it indicates that there is leakage in the system). A faulty stand-by pump must be replaced with a new one. For maintenance and overhaul refer to the manufacturer’s operating and maintenance instructions.
5.2.3 Check electric supply, test lamps Make sure that the SPU is receiving power. Press the Lamp test button in the starter cabinet. All signal lights in the starter cabinet should be lit. Change any faulty light bulbs.
5.2.4 Visually inspect the pump unit and its fittings Check that there is no water or air leaking from the system.
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Check that all fittings are tight. Report all abnormal wear and tear, damage, etc.
5.2.5 Check oil level of the pumps The optimal oil level is at the mid-level of the sight glass. If it is below this level, add more oil. See figure below.
The oil color should be clear golden brown. If the oil is dirty, cloudy or grey when the unit is in the stand-by mode, change the oil.
NOTICE! The oil appears cloudy when the unit is in the operation mode.
See the manufacturer’s pump operating instructions. See also examples of recommended pump oil types in chapter “Change pump oil (every 2 years or 200 hours)” on page 25.
5.2.6 Check drive chains and flexible coupling
NOTICE! Switch the unit off before checking the drive chains and coupling. Turn the main switch off and secure it before removing the cover.
The drive chains are self-lubricated, which means that they do not need to be greased. To indicate this, there is a notification sticker attached to the gearbox with the following text: Notice! Do not use grease. This roller chain is self-lubricated.
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However, if the drive chains are not maintenance-free (in older pump units) and there is no notification sticker, the drive chains must be well greased. If the chain is dry or rusty, grease the chain using Shell Gadus S3 Wirerope T or an equivalent molybdenum-graphite based grease with heat resistance up to +200°C and good adhesion capability. Check also the condition of the flexible couplings. A slight amount of wear is normal - if any signs of excessive wearing are shown, change the coupling.
The chain and coupling can be changed by removing the pump module (make sure that the pump unit is off before starting this job). Four items of Marioff tool M12080 are needed. See Technical data sheet TE1002 “Standard HI-FOG® SPU Gearbox chain and coupling change”.
5.2.7 Check air pressure regulator and empty water lock Check for leakages and make sure that the stand-by pressure is maintained at 25 bar (or other system specific set value).
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5.2.8 Check water filter and separator Replace the filter annually or if it is dirty. Follow the steps below.
Step 1. Close the water intake valve. Step 2. Open the drain plugs and allow the water to drain out. Step 3. Open the filter cover and pull out the filter cartridge and check it visually. Change filter if contaminated. Step 4. Check the bypass valve. If it is open, the upper extension spring is not around the upper guide sleeve. The valve must be closed. Refer to “How to reset the bypass valve” on page 23.
Step 5. Reinstall or replace the filter cartridge. Step 6. Close the drain plugs and filter cover. Step 7. When filling the unit via the filter, loose the air bleeding screw to bleed air from the filter. Step 8. Carefully open the water intake valve. Step 9. After filling the unit, tighten the air bleeding screw. NOTICE: On some models the filter tube is glued to the cover, i.e. it opens at the filter base.
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How to reset the bypass valve If the bypass valve is closed the extension spring will be positioned around the upper guide sleeve. If the bypass valve has opened, the extension spring will not be around the upper guide sleeve. It must be repositioned. To reset the bypass valve:
Step 1. Remove locking wire from bypass screws. Step 2. Loosen the bypass screws. Step 3. Remove the upper extension spring. Step 4. Tighten the bypass screws. Step 5. Install the locking wire. Step 6. Reinstall the upper extension spring around the upper guide sleeve. Step 7. Visually examine the separator (if fitted). Ensure that the purging orifice at the bottom of the separator is open.
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5.2.9 Test run the unit Step 1. Start the pump unit locally, remotely or automatically. Vary the way of starting occasionally to ensure that all the starting modes work. When testing locally, the pressure start is tested by closing the air supply to the stand-by pump and fully opening the test valve. The flow switch start is tested by slowly opening the test valve so the pressure does not drop below 17 bar (or the set value). NOTICE! Starting the pump with the manual switches on the starter cabinet will override all protections. Make sure that there is water and that no fault alarms are on. NOTICE! If a water accumulator unit is fitted, remove the plug from the solenoid release valve or close the gas cylinder valves to prevent unintentional release. Remember to reset the accumulator unit after testing.
Step 2. Make sure that the unit starts to supply water at full working pressure after a short delay. Step 3. Make sure that all motors and pumps are running (except the redundancy module, if supplied). Step 4. If the redundancy module is supplied, test it by opening the control fuse (F x.1) of one of the running motors. Step 5. Reset the unit after testing by pressing the Reset button (close test valve and open outlet valve if opened/closed). Step 6. Check that the pressure in the system returns to the 25 bar stand-by pressure after a few minutes. Step 7. Check that the whole system is reset and operational.
5.2.10 Check pump unit batteries and charger Ensure the charger output voltage is 27.3 - 27.7 V at the battery. Check the battery capacity with a suitable charge condition meter. The batteries must be replaced every five (5) years, or more often if the battery is faulty, or the unit is subjected to vibration, large temperature variations or other severe environmental conditions. Note that especially high ambient temperature reduces the battery life time.
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5.2.11 Check the setting values of pressure and flow switches and transducers Check the settings of pressure switches, transducers and flow switch. If the switching points have changed regarding the set point, adjust the point to original.
5.2.12 Test the unit in accordance with service instructions It is recommended that testing is carried out by a Marioff authorised service engineer. Contact Marioff for more information.
5.2.13 Check breather cap filter Check the breather cap filter on top of the break water tank. Replace every five years or if it is dirty.
5.2.14 Replace suction hoses (BSPU) Replace the suction hoses (from tank to pumps) every 5 years to prevent minor cracks that are difficult to detect.
5.2.15 Change pump oil (every 2 years or 200 hours) Also refer to paragraph “Check drive chains and flexible coupling” on page 20 and the Speck-Triplex-Plunger pump operating instructions. The oil must be changed every 2 years or after 200 running hours, whichever comes first. With new systems the initial oil must be changed after 50 running hours (or 2 years), whichever comes first. Use an ISO VG 220 or SAE 90 class gear oil. Oil quantity is 0,9 litres per pump.
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Sight glass
BSPU - detailed pump view
SPU - detailed pump view
Some recommendations for pump oil: • ARAL Getriebeöl EP 85W-90 • ARAL Degol BG 220 • BP Energear 90 • BP Energol GR-XP 220 • CASTROL EP 90 • CASTROL ALPHA SP 220 • CASTROL ALPHA MW 220 • ESSO GEAR OIL GX 85W-90 • ESSO GEAR OIL GP-D 85W-90 • SPARTAN EP 220 • Mobilube GX 85W-90-A • Mobilgear 630 • Shell SPIRAX GX SAE 80W-90 • NESTE GEAR EP 80W-90
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6. Troubleshooting This chapter lists the possible fault situations and their remedies. If the problem you are facing is not listed here, contact Marioff immediately. When contacting Marioff in troubleshooting situations, have the following information available: • the project number of the installed system • the serial number of the pump unit • detailed description of the fault situation (what was done before the fault situation occured and what happened during the fault situation)
6.1 General faults This chapter lists the possible general SPU faults.
6.1.1 Unit will not start Possible reason: No electric supply. Solution: Connect supply. Check if the main fuses in the main switchboard have blown. Check if the starter cabinet main switch is open or the main circuit breaker has released. Possible reason: No control voltage. Solution: Connect supply. Check control voltage fuse of auxiliary voltage transformer. Possible reason: No water. Solution: Ensure feed water availability. Possible reason: Stabilisation phase is on (Pump unit reset light on the starter cabinet is on). Solution: Wait for completion of stabilisation phase or start the pump unit manually.
6.1.2 Unit will not stop Possible reason: Pressure has not exceeded 130 bar in the system or/and the emergency start is still activated. Solution: Run the unit until the pressure reaches 130 bar and then reset the unit (see chapter 4.4.) or/and deactivate the emergency start.
6.1.3 Unit starts unintentionally Possible reason: Pressure switch is faulty or incorrectly adjusted.
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Solution: Adjust or replace pressure switch (must be correctly adjusted, contact Marioff). Possible reason: Flow switch is faulty or incorrectly adjusted. Solution: Adjust or replace flow switch (must be correctly adjusted, contact Marioff). Possible reason: Small leakage in the system. Solution: Ensure system is tight. Possible reason: False start signal. Solution: Check system wiring and signals. Possible reason: System pressure drops due to system leakage or stand-by pump problem. Solution: Ensure system is tight. Check air supply to stand-by pump. Check stand-by pump (refer to manufacturer’s instructions) and replace if faulty.
6.1.4 Water accumulators released unintentionally (if fitted) Possible reason: Operational fault caused by • opening main switch (control voltage still on, start signal active, pressure decreasing --> water accumulator released) • test valve kept open so that pressure stays below 30 bar (or set value) for more than 15 seconds (or set value) Solution: The water accumulator will release if the start signal is on and the pressure stays below 30 bar (or set value) for more than 15 seconds (or set value). Before testing or servicing the unit the water accumulator solenoid valve should be disconnected. Possible reason: Pressure switch faulty or incorrectly adjusted. Solution: Adjust or replace pressure switch (must be correctly adjusted, contact Marioff).
6.1.5 Stabilisation phase not completed The stabilisation will not start before the system pressure has reached 130 bar. The pump unit must be run until the pressure has risen above 130 bar before resetting the system is possible. Possible reason: Pressure switch faulty or incorrectly adjusted. Solution: Adjust or replace pressure switch (must be correctly adjusted, contact Marioff). Possible reason: Stabilisation valve is faulty. Solution: Replace valve.
6.1.6 Stand-by pump striking frequently Possible reason: Small leakage in the system.
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Solution: Ensure system is tight. Possible reason: Stand-by pump is faulty. Solution: Replace stand-by pump. Possible reason: Air trapped on the pump inlet side. Solution: Bleed air from the bleeding pipe by opening the nut and letting the air out of the pipe.
6.1.7 Fuses blown Possible reason: Establish reason for disengaged fuses and rectify. Solution: If problem rectified or reason not found, reconnect. If problem persists, contact Marioff.
6.2 Alarms This chapter lists the SPU system alarms.
6.2.1 Nitrogen pressure low (if connected to water accumulator unit) Possible reason: Pressure in one or more nitrogen cylinders below alarm set value. Solution: Refill/replace nitrogen cylinder(s). Possible reason: Alarm circuit cut. Solution: Reconnect.
6.2.2 Battery charger fault Possible reason: No power supply to the charger or unit. Solution: Reconnect supply. Possible reason: Charger is faulty. Solution: Replace charger.
6.2.3 230VAC control voltage fault Possible reason: No voltage in transformer T 0.3. Solution: Check power supply and fuse. Possible reason: Transformer is faulty. Solution: Replace transformer.
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6.2.4 Earth fault (24VDC) Possible reason: + or - of the 24VDC control in contact with ground. Solution: Find the contact point (for example, by opening fuses and disconnecting panels) that causes earth fault and rectify.
6.2.5 Circuit breaker released Possible reason: Overload or short circuit in electric coupling. Solution: If problem rectified or reason not found, reconnect. If problem persists, contact Marioff.
6.2.6 Out of water Possible reason: Water in break tank below “low level” (or feed water pressure low in unit without tank). Solution: Make sure there is a feed water supply. Possible reason: Tank low level switch faulty or stuck; cable fault. Solution: Rectify or replace. NOTICE: If this happens in an emergency and it is certain that all valves to fresh water supply are open, switch over to the redundant water source (sea water or equivalent).
6.2.7 Pump unit fault Possible reason: Common alarm given in combination with one of the above. Solution: See above.
6.2.8 Compressed air low pressure fault (if applicable) Possible reason: Compressor fault. Solution: Check compressor; replace if faulty. Check compressed air supply. If supply in order, check pressure switch and cables.
6.2.9 Inlet/Outlet valve closed (if applicable) Possible reason: The valve is not fully open, thus it sets an alarm. Solution: Check that both valves are fully open.
6.2.10 Line voltage fault (if applicable) This fault is a signal to a third-party system.
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Possible reason: Main supply voltage fault. Solution: Check the system for low voltage, excess voltage, or asymmetric phases. Check phase monitor relay.
6.2.11 Other faults Possible reason: Reason cannot be found. Solution: Contact Marioff for assistance or advice. Note that some faults are automatically remedied and the fault information is lost. In some cases the faults are sent to a third-party system before the automatic remedy takes place and possibly the fault alarm is visible in the third-party system but not in the SPU anymore. In those events the third-party system needs to be checked according to the manufacturers’ instructions.
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A. Appendix - Spare parts Description
Type Code
Stock Code
Pump (SPU)
NP25/41-140 right
E02052
Pump (SPU)
NP25/41-140 left
E02050
Pump (SPU)
NP25/50-140 right
E02056
Pump (SPU)
NP25/50-140 left
E02055
Pump (BSPU)
NP25/60-140 right
M-0005964
Pump (BSPU)
NP25/60-140 left
M-0005963
Pump (BSPU)
NP25/70-140 left
M-0005961
Pump (BSPU)
NP25/70-140 right
M-0005962
Seal set for pump models NP25/41-140 and NP25/50-140
Manuf.ref. 14.0884
G40130.1
Pump valve kit for pump models NP25/41-140 and NP25/50-140
Manuf.ref. 14.0397
G40135
Seal set for pump models NP25/60-140 and NP25/70-140
Manuf.ref. 14.0655
V-0006475
Pump valve kit for pump models NP25/60-140 and NP25/70-140
Manuf.ref. 14.0654
V-0006474
Pump oil
EP SAE80W-90
L53005
Unloader
UL262/2
D51023
Seal set for unloader UL262/2
Manuf.ref. 14.0554
G40011
Hose assembly
28L90-R-28LA-270AY
A-0006099
Electric motor
See nameplate
Voltage, frequency, power
Drive chain (self-lubricated)
10 B-2 L42 5/8
E04097.1
Drive clutch (green)
42/64 SH green
E04019
Drive chain spare part set*
V31161 (for motor type 160L) V31181 (for motor type 180L)
Pump support sleeve**
M12080
Pressure switch (monitoring)
PN3001 0-250 Bar
M23064.A
Pressure switch (release signal)
PN5001 0-250 Bar
M23065.A
Float switch
A01090 Besta
M22125.1
Water filter cartridge
100 μm
E32005 (height: 425 ± 0,5) E32006 (height: 212 ± 0,5)
Breather cap filter
BFP7G10W1.0
E05085
Breather cap filter cartridge Flow monitor
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E05086 SID10ADBFPKG/ US-100-I PF
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Stand-by pump Trojan
Trojan type-J, 11:1
E40040
10108KP TROJAN-J AIR SIDE
G40090
10138KH/11 TROJAN-J WET
G40095
Air regulator unit
FRC-1/4
E41015
Stabilization valve NS-12
SVM 12-ANN-S12/12-10-0
D01535
Seal set for Trojan stand-by pump
Repair kit for stabilization valve NS-12***
V11070.A
Seal set for stabilization valve NS-12***
V10101.A
Safety valve set (for SPU)****
V-0002671 (for SPU01-02) V-0002672 (for SPU03) V-0002681 (for SPU04 V-0002683 (for SPU05-06) V-0002684 (for SPU07-08) V-0003548 (for SPU09)
Safety valve spare part assembly**** (for SPU/ BSPU)
D-0005755
Electric spare parts (such as contactors, circuit breakers, relays etc.)*****
*Drive chain spare part sets include clutch flex element, clutch, roller chain, sprocket wheel and other needed parts. **You need 4 pieces of pump support sleeves to pull the pump out when replacing the drive chain. Pump support sleeves are not included in drive chain spare part sets V31161 and V31181. ***See Marioff Spare part and maintenance drawing DMOVSE000862. ****See Marioff Technical data sheet K0008018. *****Electrical components may vary considerably depending on the project. See projectspecific part list for electric spare parts.
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Marioff Corporation Oy
Protecting people, property and business continuity
Head Office Marioff Corporation Oy Plaza Business Park Halo Äyritie 24, P.O. Box 1002
Information on Marioff group companies, agents/distributors and references can be found at www.marioff.com.
01511 Vantaa
Marioff Corporation Oy reserves the right to change or modify the information given in this document, including
Finland
technical details, without notice. HI-FOG® and Marioff® are registered trademarks of Marioff Corporation Oy. Marioff is part of UTC Building & Industrial Systems, a unit of United Technologies Corp. (NYSE:UTX).
Tel. +358 (0)10 6880 000 Fax +358 (0)10 6880 010 Email:
[email protected]
All rights reserved. Reproduction of any part of this document without the express written permission of Marioff Corporation Oy is prohibited.
