OS35 Rev 2 OIL WATER S st - Ultraspin · DRAFT INSTALLATION, OPERATING AND MAINTENANCE MANUAL OS35...

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INSTALLATION, OPERATING AND

MAINTENANCE MANUAL

OS35

OIL WATER SEPARATOR

Page 1 of 115

Rev 2

1st May 2014

Document Details

Equipment : Oil Water Separation System

Model : OS35

Document Title : Installation, Operating and Maintenance Manual

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IMPORTANT NOTES TO BE READ BEFORE COMMENCING ANY WORK

Important notes to be read before commencing any work

Safety:

Before attempting to undertake installation, maintenance or repair work of any nature, the persons concerned should be alerted to the nature of the risks involved when working in a situation of a potentially hazardous nature. As it is not possible to cover every aspect of safety in a single article, care has been taken in preparation of the following notes, which should serve as a general guide to the most common situations likely to be encountered. It is necessary to point out that neither Ultraspin nor any of its associates can accept responsibility for any form of personal injury, however caused. Therefore, every care should be taken to observe the normal rules of safety.

Approvals:

The manual is intended as a guide only. If required, site-specific drawings, Council, Water, Electricity Authority and Government approval and professional advice shall be obtained prior to installing the equipment mentioned in this manual.

Warning:

Certain instructions and advice carry this tag. This information should NOT be ignored or damage to equipment or personnel could result.

Warranty:

The data is based on tests and experience which Ultraspin believes are reliable and is supplied for information services only. Ultraspin disclaims any liability for damage or injury which results from the use of the enclosed data and nothing contained therein shall constitute a guarantee, warranty or representation (including free from patent liability) by Ultraspin with respect to the data, the product described, or its suitability for any specific purpose, even if that purpose is known to Ultraspin.

Patents:

Ultraspin has patented features of the skimmer, hydrocyclone and processes covered in this literature. Processes or products in this manual should not be used without the prior written consent of Ultraspin.

Update:

Data subject to correction and update without notice

Copyright:

Ultraspin Technology Pty Ltd © 2007-2014; All rights reserved

Design:

This manual is not a design guide. It does not provide a substitute for careful planning and a considered site design drawing prepared by qualified and experienced people. If there is any uncertainty with design, the service of competent design engineers experienced in oily water and local requirements should be sought. If needed Ultraspin can provide a list of recommended designers.

Pictures:

All pictures in this manual are for illustration only and do not necessarily represent current products.

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Contents IMPORTANT NOTES TO BE READ BEFORE COMMENCING ANY WORK ............................................................................

A GENERAL INFORMATION .............................................................................................................................

A.1 SUPPLIER DETAILS ......................................................................................................................................

B GENERAL DESCRIPTION ............................................................................................................................ 10

B.1 TYPICAL SYSTEMS .................................................................................................................................... 10

B.2 PRINCIPLES OF OPERATION ....................................................................................................................... 12

B.2.1 How Does the Ultraspin Separator Work? ...................................................................................... 12

B.2.2 Why Is It Such A Powerful Separator? ............................................................................................ 12

B.3 TYPICAL DESCRIPTION OF OPERATION ....................................................................................................... 13

B.4 TYPICAL SCOPE OF SUPPLY ....................................................................................................................... 15

B.5 AVAILABLE OPTIONS .................................................................................................................................. 17

B.6 FUNCTIONAL DESCRIPTION OF KEY ITEMS .................................................................................................. 18

B.6.1 Oil Skimmer and Hose ..................................................................................................................... 18

B.6.2 Collection Pit Level Switch .............................................................................................................. 18

B.6.3 Back-Up Strainer ............................................................................................................................. 18

B.6.4 Air-Operated Diaphragm Pump ....................................................................................................... 18

B.6.5 Ultraspin Oil Separator .................................................................................................................... 18

B.6.6 Pneumatic Control Circuit ................................................................................................................ 19

B.6.7 Recycle/Discharge Function ............................................................................................................ 19

B.6.8 Decant Tank .................................................................................................................................... 20

C DATA SUMMARY.......................................................................................................................................... 21

C.1.1 Ultraspin Separator .......................................................................................................................... 21

C.1.2 Back-Up Strainer ............................................................................................................................. 22

C.1.3 Float Level Switch ........................................................................................................................... 23

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D LIFTING AND HANDLING ............................................................................................................................ 24

D.1 ULTRASPIN SEPARATOR ............................................................................................................................ 24

D.2 DECANT TANK ........................................................................................................................................... 24

D.3 SPECIAL LIFTING EQUIPMENT..................................................................................................................... 24

D.4 TYPICAL EQUIPMENT WEIGHTS .................................................................................................................. 25

E CORROSION PROTECTION ........................................................................................................................ 26

E.1 SYSTEM USED .......................................................................................................................................... 26

E.2 METHOD OF REPAIR .................................................................................................................................. 27

F STORAGE OF EQUIPMENT ......................................................................................................................... 28

F.1 PRIOR TO INSTALLATION ............................................................................................................................ 28

F.2 FOR EXTENDED SHUT-DOWN .................................................................................................................... 28

G DRAWINGS SCHEDULE .............................................................................................................................. 29

H INSTRUMENT LIST (WITH CALIBRATION RANGES AND SET POINTS) ................................................ 36

I SPARE PARTS LIST ..................................................................................................................................... 37

I.1 COMMISSIONING SPARES .......................................................................................................................... 37

I.2 OPERATION AND MAINTENANCE SPARES (2 YEARS) .................................................................................... 38

I.3 CAPITAL SPARES ...................................................................................................................................... 39

J INSTALLATION INSTRUCTIONS................................................................................................................. 40

J.1 SERVICES REQUIRED PRIOR TO INSTALLATION ........................................................................................... 40

J.2 UNDERGROUND PITS ................................................................................................................................. 41

J.2.1 Collection Pit .................................................................................................................................... 41

J.3 ULTRASPIN SEPARATOR INSTALLATION....................................................................................................... 43

J.3.1 Safe Maintenance Access ............................................................................................................... 43

J.3.2 Procedure for Installing a Stand-Alone Ultraspin Separator and Decant Tank ............................... 44

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J.3.3 Procedure for Installing an Ultraspin Separator with Integral Skid Base ........................................ 46

J.3.4 Procedure for Installing an Ultraspin Separator Units with Integral Galvanised Bund .................... 47

J.4 LEVEL SWITCH INSTALLATION .................................................................................................................... 48

J.4.2 Level Switch Connections ............................................................................................................... 48

J.5 EXTERNAL PROCESS CONNECTIONS TO/FROM ULTRASPIN SEPARATOR SKID ............................................... 50

J.5.1 Pneumatic Connection to Separator Pump – ½” BSP (f) Screwed Connection .............................. 50

J.5.2 Effluent inlet – 1½” BSP (f) Screwed Connection ........................................................................... 50

J.5.3 Treated Water Outlet – 1” BSP (m) Screwed Connection ............................................................... 51

J.5.4 Oily Reject Line from Separator to Decant Tank – ½” ID Flexible Hose ......................................... 52

J.5.5 Decant Tank Outlet Return to Collection Pit – 2” NB PVC (Class 12) ............................................ 53

J.5.6 Sample Points – ½” Hosetail ........................................................................................................... 53

J.6 INSTALLATION CHECKLIST .......................................................................................................................... 54

J.7 CLEANING AND FLUSHING OF EQUIPMENT AFTER INSTALLATION ................................................................... 54

J.8 COMMISSIONING ....................................................................................................................................... 55

J.8.1 Introduction ...................................................................................................................................... 55

J.8.2 Equipment Check ............................................................................................................................ 55

J.8.3 Pneumatic Air Supply ...................................................................................................................... 55

J.8.4 Effluent Feed Supply ....................................................................................................................... 55

J.8.5 Piping and Valving ........................................................................................................................... 56

J.8.6 Separator Pump Priming ................................................................................................................. 56

J.8.7 Decant Tank .................................................................................................................................... 56

J.8.8 Recycle/Discharge Function ............................................................................................................ 56

J.8.9 Adjustment of Pneumatic Timer ...................................................................................................... 57

J.8.10 Pre Start-up Checks ........................................................................................................................ 58

J.8.11 Checking the Pump Operation ........................................................................................................ 58

J.8.12 Starting the System ......................................................................................................................... 58

J.8.13 Stopping the System ....................................................................................................................... 58

J.8.14 System Checks ................................................................................................................................ 58

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J.8.15 Fine Tuning ...................................................................................................................................... 59

K OPERATING INSTRUCTIONS AND INFORMATION .................................................................................. 60

K.1 GENERAL .................................................................................................................................................. 60

K.2 OPERATION OF ULTRASPIN SEPARATOR ..................................................................................................... 60

K.2.1 Adjusting the Separator Filter-Regulator ......................................................................................... 60

K.2.2 Automatic Recycle Start .................................................................................................................. 61

K.2.3 Manual Start .................................................................................................................................... 62

K.3 DAILY OPERATIONAL CHECK SHEET ........................................................................................................... 63

K.4 WEEKLY OPERATIONAL CHECKS ................................................................................................................ 63

K.5 CHECKING FOR CORRECT SEPARATOR FLOWS ........................................................................................... 64

K.6 DEALING WITH EMERGENCY SITUATIONS .................................................................................................... 65

K.6.1 Stopping the Ultraspin Separator Pump .......................................................................................... 65

K.6.2 Oil Spills ........................................................................................................................................... 65

K.7 RECOMMENDED OIL AND GREASE TEST METHOD ....................................................................................... 66

K.8 SAMPLING PROCEDURE ............................................................................................................................. 67

K.8.1 Caution – look after yourself! ........................................................................................................... 67

K.8.2 The Process Sample Point .............................................................................................................. 68

K.8.3 The Sample Piping and Valves ....................................................................................................... 70

K.8.4 The Sampling Jar ............................................................................................................................ 70

K.8.5 Sample Collection Technique .......................................................................................................... 72

K.8.6 Number of Samples and dividing the sample in the Laboratory...................................................... 74

K.8.7 Sampling with Ultraspin systems ..................................................................................................... 75

K.8.8 Composite Samples ........................................................................................................................ 75

K.8.9 Sample Preservation ....................................................................................................................... 76

L FACTORS AFFECTING OIL WATER SEPARATION PERFORMANCE ..................................................... 78

M MAINTENANCE INSTRUCTIONS AND PROCEDURES ............................................................................. 79

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M.1 OPERATIONAL MAINTENANCE .................................................................................................................... 79

M.1.1 Back-Up Strainer Cleaning .............................................................................................................. 79

M.1.2 Leak Checking ................................................................................................................................. 79

M.1.3 Air Diaphragm Pump Maintenance ................................................................................................. 80

M.1.4 Ultraspin Separator Reject Holes Cleaning ..................................................................................... 80

M.1.5 Separator Seals ............................................................................................................................... 80

M.1.6 Recycle/Discharge Valve ................................................................................................................. 81

M.1.7 Liner Removal ................................................................................................................................. 82

M.1.8 Decant Tank .................................................................................................................................... 84

M.2 SCHEDULED MAINTENANCE ....................................................................................................................... 85

M.2.1 Training for Maintenance Personnel ............................................................................................... 85

M.2.2 Specialised Labour Required .......................................................................................................... 85

M.2.3 Access Procedures .......................................................................................................................... 85

M.2.4 Special Tools for Maintenance ........................................................................................................ 85

M.2.5 List of Consumables Required ........................................................................................................ 85

M.3 TROUBLESHOOTING MATRIX ...................................................................................................................... 86

M.3.1 Ultraspin Separator .......................................................................................................................... 86

N HAZARD ANALYSIS ..................................................................................................................................... 90

N.1 GENERAL HAZARDS .................................................................................................................................. 90

N.2 PROPRIETARY EQUIPMENT HAZARD ........................................................................................................... 91

N.2.1 General ............................................................................................................................................ 91

N.2.2 Unauthorized Use ............................................................................................................................ 91

N.2.3 General Safety Procedures ............................................................................................................. 91

N.3 PERSONAL PROTECTIVE EQUIPMENT REQUIRED ......................................................................................... 92

N.1 OPERATING NOISE LEVEL OF ULTRASPIN OS SEPARATOR .......................................................................... 93

O AVAILABLE OPTIONS ................................................................................................................................. 94

O.1 AERATION TANK ........................................................................................................................................ 94

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O.2 OIL STORAGE AND WATER DECANT TANK FACT SHEET............................................................................... 97

O.3 DESANDER MODULE .................................................................................................................................. 99

O.4 MANUAL CONTROL .................................................................................................................................. 102

O.4.1 Summary ....................................................................................................................................... 102

O.5 SEMI-AUTO OPERATION (SYDNEY WATER KIT) ......................................................................................... 104

O.5.1 Summary ....................................................................................................................................... 104

O.6 OS45 SEPARATOR (HIGHER FLOW SEPARATOR) ...................................................................................... 106

P PROPRIETARY EQUIPMENT DETAIL....................................................................................................... 107

P.1 PUMP MANUAL ........................................................................................................................................ 107

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A GENERAL INFORMATION

A.1 SUPPLIER DETAILS

Ultraspin Contact Details

Supplier: Ultraspin Technology

Address: 46 Wadhurst Drive, Boronia VIC 3155

Telephone (B/H): (03) 9800 1100

Fax: (03) 9800 1661

Engineering Contact: Engineering Manager

Email: [email protected]

Sales Contact: Sales Engineer


Service Contact: Service Manager


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B GENERAL DESCRIPTION

The Ultraspin “system” is made up of several items of equipment. This section describes typical items of

equipment used in a typical system.

B.1 TYPICAL SYSTEMS

Figure B1: Auto Recycle

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Figure B2: Auto Recycle with Spill Pit

Note that these are typical arrangement drawings only and may not represent specific installations

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B.2 PRINCIPLES OF OPERATION

B.2.1 How Does the Ultraspin Separator Work?

The heart of the Ultraspin system is the Ultraspin

separator itself.

The Ultraspin Separator works on a very simple

principle. The oily water is pumped tangentially into

the large diameter end of the separator. This initiates

a spinning vortex. This spinning vortex is accelerated

as it moves down the tapered separation tube

flinging the heavier water to the outside walls while

the lighter oil moves to the centre. The separated oil

is removed via a hole in the separator end-face, and

the treated water is discharged out the other end of

the tube.

B.2.2 Why Is It Such A Powerful Separator?

Unlike plate-pack-style separators the Ultraspin

Separator does not rely on weak gravity forces for

separation. The centrifugal force generated inside

the vortex of the Ultraspin Separator is of the order

of 1,000 times the force of gravity. With such force

even emulsified oil droplets can be separated.

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B.3 TYPICAL DESCRIPTION OF OPERATION

Contaminated oily waste water drains to a main oily water collection pit. A level switch in this pit indicates when

the high level mark is reached, so that the Ultraspin oily water treatment system can activate automatically.

The oily water treatment system takes its feed from the surface of the pit. There are several major advantages

of this:

• The pit is more “flood-proof”, as skimming prevents oil build-up in the pit. If the pit should accidentally

flood, due to power failure or similar, any oil spillage to the surrounding area will be minimized.

• Improvement to the water discharge quality by reducing dissolved oil components, as the system

removes free-floating oil every time the system operates.

The oily water is fed to the Ultraspin separator via a debris strainer basket. This strainer helps protect all

downstream pumps and equipment from debris that may cause blockage or high cleaning requirements.

This Ultraspin system uses an air diaphragm pump, and the pump selected is a low-shear design as it does not

emulsify the oil in the water and make separation difficult.

• Self priming

• Solids tolerant

The oily water is pumped to the Ultraspin separator, which uses high centrifugal force to separate oil droplets

from the water. There are no moving parts and no items to clean, so this is a major advantage over other oily

water treatment systems.

The concentrated oil-rich water stream from the top of the Ultraspin Separator flows to the 650 litre Decant

Tank. There is no pressure in this flowing stream as it enters the Decant Tank. The oil and water mixture enters

the tank via a vented settling pipe. Due to the settling time and the tank design, oil collects at the top of the

tank. Internal piping automatically drains the water from the tank. The contaminated water component is

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decanted and returned to the pit for re-treatment. As more oil enters the tank the oil layer thickens and, because

oil is lighter than water, the top of the oil layer rises. This separated oil floats to the top of the tank and is then

collected.

The pneumatic controls logic for the operation of the Ultraspin Separator is provided by a pneumatic valve

linked to the level switch, which controls the operation for separator stop/start and the recycle discharge valve

operation.

Treated water is recycled for an initial period of time to ensure that high separation efficiency is achieved on

system start-up. After the preset recycle time, the separator diverts to discharge (and the treated water stream

is directed to the discharge point).

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B.4 TYPICAL SCOPE OF SUPPLY

An Ultraspin system may contain some or all of the following components.

Floating Oil Skimmer

• Removes free-floating oil

• Allows any dissolved oil in the water to liberate

• Avoids build-up of stagnant, smelly oil layers inside

the pit

• Pit is “flood-proof”. If the pit should accidentally flood,

any oil spillage will be minimised

Skimmer Suction Hose

• Suction-rated

• Mechanically strong

Back-Up Strainer

• Protects reject and underflow from blockages

• Typical size: 3 mm openings (sizes may vary)

• Quality stainless steel construction

Air Diaphragm Pump

• Operational simplicity

• Self-priming

• Solids tolerant to 6mm particles

• Efficient air diaphragm configuration (creating less slip

and oil emulsification)

• Rated for hazardous area use

Ultraspin Oil Separator

• Small diameter/high oil separation efficiency

• Removes oil droplets

• Separation efficiency increases with increasing flow

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Recycle Feature

• Removes oil before discharge

• Enables very high system efficiencies via multiple

passes

• Enables system “tuning” to suit difficult situations

(increased recycle time)

• System can be adjusted if future discharge

regulations increase (increases recycle time)

Decant Tank

• 1,100 L Poly Tank

• PVC internal piping

• Automatically drains excess water back to the effluent

pit

• Accumulates and overflows excess “waste oil” for

disposal

Level Switch for Oil Collection Pit

• High/Low water level control

• Pneumatic operation for use in Class 1, Zone 0

hazardous areas

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B.5 AVAILABLE OPTIONS

The emphasis with Ultraspin Separators is on a total packaged system approach. The following options are

available on OS Separators:

• Aeration Tank: Used to remove volatile and dissolved hydrocarbons from the treated water exiting the

separator (refer to section M.1).

• Desander Module: Provides an additional level of separation by using a solids separator to remove

solids and oil-wet solids (post-deoiler) (refer to section M.2)

• Galvanised Skid: Allows the Ultraspin system to be mounted in a single-lift skid-mounted arrangement

to reduce installation time on site and keep equipment within a packaged space (refer to section M.3)

• Galvanised Bund: Provides the added security to contain spills from the equipment and tanks (refer to

section M.4)

• Manual Control: This is a base model and has no level control, recycle or automatic operation. This

requires the operator to start and stop the separator using the compressed air inlet isolation valve.

• Waste Oil Tank: Collects and stores separated “dry” oil from the decant tank, prior to disposal.

• High Oil Kit: This add-on is used when there are large amounts of oil to be skimmed from the collection

source upon start-up. The operation requires the operator to start the system and then switch to

automatic operation (refer to section M.5)

• Viton Kit: The pump and all seals are fitted out with viton seals in lieu of nitrile. This is used where

large amounts of hydrocarbon are present and could cause a problem with material compatibility.

• High/ High Pneumatic Control: Provides additional alarm for the operator to warn against the

collection pit overfilling.

• Semi-Auto Operation: Used within the Sydney Metro area to comply with local regulations, where the

operator must start the system after a pit inspection (refer to section M.6).

• Underground Mining Specific Pump: For underground mining applications, a non-aluminium (non-

sparking) pump can be provided in lieu of the standard air-operated diaphragm pump.

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B.6 FUNCTIONAL DESCRIPTION OF KEY ITEMS

B.6.1 Oil Skimmer and Hose

For a functional description please refer to the separate skimmer module in Section N.

B.6.2 Collection Pit Level Switch

The level switch floats and rods rise and fall in accordance with the water level in the collection pit. As

the water level rises the level switch ball floats rise and actuate the pneumatic controls to start the

Ultraspin Separator. Conversely, the system shuts off when the water level drops below the set point.

B.6.3 Back-Up Strainer

The effluent is then drawn through a debris strainer on the separator skid, which removes large debris

and particles.

The inlet strainer should be regularly monitored and cleaned. The system should have water quality

checked regularly (see Section 7.0).

B.6.4 Air-Operated Diaphragm Pump

A low-shear air diaphragm pump provides the pressure to drive the fluid through the Ultraspin

separator. For a functional description and other matters related to the pump, please refer to Section N.

B.6.5 Ultraspin Oil Separator

The pumped pressure is used to create the required vortex and spinning flow to create separation. The

treated water is discharged from the end of the Ultraspin separator. The separated oil (with some

water) is sent to a decant tank.

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An air compressor (typically supplied by others) is required to provide compressed air to the Ultraspin

Separator. The air compressor capacity should be selected to provide 42 scfm of free air at a maximum

pressure of 100 psi (800 kPa).

Compressed air is used to operate the diaphragm pump, as well as actuating the 3-way recycle/

discharge valve and other control logic.

B.6.6 Pneumatic Control Circuit

The pneumatic control circuit provides the means by which the system can start and stop. A level

switch in the oil collection pit provides the start signal for the Ultraspin Separator.

The control sequence for the system start and recycle modes is contained within the pneumatic control

circuit. Pneumatic pilot valves and timers are used to control the process, in order to allow ease of

operation. The Ultraspin separator runs in response to the collection pit water level. The unit also has a

local isolation valve (mounted on the filter-regulator) to turn the unit off as required.

B.6.7 Recycle/Discharge Function

The recycle function allows the treated water to be initially returned back to the collection source and

undergo another treatment cycle. This is recommended where there is a high oil load at the collection

point. The recycle period (depending on the size of the collection pit) has been factory set to thirty (30)

minutes (however this may be adjusted during commissioning by the Ultraspin engineer, depending on

the size of the pit, oil load into the collection pit and water flow into the pit).

During this time there will be no discharge of treated water from the system, with the only flow from the

system being the oil rich stream that flows to the oil collection tank. After the set recycle time, the

system will automatically divert from recycle to discharge, and treated water will be allowed to flow to

the discharge point. Again, the advantage of the recycle system is evident during high oil load in the

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collection pit, as this feature ensures that water is never discharged from the system without undergoing

several passes to reduce the initial oil content.

Once the preset recycle time has expired, the 3-way ball valve will actuate to allow treated water to be

discharged from the system. The system will continue to discharge until the collection pit has been

pumped down to a low level and the level switch deactivates (that is, the separator switches OFF).

Each time the system restarts, the recycle timer will recommence and treated water will be recycled

until the recycle time has expired again.

The ¼-turn 3-way ball valve is actuated via a mechanical pneumatic timer, which is adjustable and

contained within the small enclosure on the side of the separator tube.

Important Note:

In recycle mode the system will return treated water back to the collection pit and will not discharge

water to sewer.

B.6.8 Decant Tank

For a full functional description of the decant tank, please refer to Section N.

The oil and water mixture enters the tank via a vented settling pipe. Due to the settling time and the tank

design, oil collects at the top of the tank. Oil will accumulate on the surface and will flow over the

overflow nozzle once the height of the oil/water mixture has reached the equivalent height of the water

column in the overflow pipe. Water is decanted from the tank and returned to the dirty water effluent

source for further treatment. This pipe must have a sloping fall to the balance tank.

Oil can be removed using a pump-out hose via the large removable lid on top of the tank. A

concentrated oil outlet is offered as an option. When fitted, it drains off concentrated oil, thus

maintaining a constant oil layer and, therefore, preventing the tank from ever becoming full with oil.

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C DATA SUMMARY

C.1.1 Ultraspin Separator

OIL SEPARATOR MODEL: OS35

PE

RF

OR

MA

NC

E S

PE

CIF

ICA

TIO

NS

Application Treatment of Water Containing Oil

Nominal Flow rate (L/h) 3,500

Operating Temperature Range (°C) 2 to 45

Fluid pH Range 5 to 9

Max. Discharge Treated Water Pressure (kPa) 150

Max. Discharge Oil Pressure (kPa) 50

Control Operation Fully Pneumatic

Air Quality Clean, Filtered Compressed Air

Air Usage at 450 kPa (scfm) 20

Typical. Compressor Capacity (scfm)* 29

Recycle Timer 0-90 min (set at 30 min)

Required Compressed Air Inlet Pressure 800 kPa

Compressed Air Supply Pipe Size (min) 1” OD Tube

Pump Type Low Shear, Pneumatic Double Diaphragm

1½”

Typical Oily Water Reject Ratio Ratio of Overflow to Feed

6.5 %

Typical Reject Orifice Size (mm) 4.5

Strainer Sizes PMB-2 (7m3/h capacity)

Max. Inlet Particle Size (Through Strainer) 3 mm

Separator Units 1x M28 Deoiler Module

Sample Points ½” Inlet and Outlet Point

Pressure Indication Inlet Air and Pump Discharge Pressure Gauges

Location Classification Rated for Indoor or Outdoor Use

Hazardous Area Classification Class 1, Zone 2

Max Free Hydrocarbons layer in pit per start up 230 L (90 Min Recycle)

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*NOTE: Figures quoted are for an 80% efficient piston compressor with a 100% duty cycle (running all the time).

When selecting a new compressor, or appraising the suitability of an existing one, the efficiency, type, duty

cycle and general operating demands of the compressor need to be considered. The best source of information

in this regard is a compressor vendor or manufacturer.

C.1.2 Back-Up Strainer

BACK-UP STRAINER

SP

EC

IFIC

AT

ION

S Model BFL-1

Shipping Weight (kg) 32

Filter Housing Materials of Construction Stainless Steel (Grade: 316 SS)

Strainer Basket Rating 3mm Perforated Screen

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C.1.3 Float Level Switch

LEVEL SWITCH

MODEL: L1

PE

RF

OR

MA

NC

E S

PE

CIF

ICA

TIO

NS

Application Level Monitoring for Oil Water Separator

Operating Temperature Range (°C) 2 to 70

Fluid pH Range 5 to 11

Low Level From Control Box (mm) 950

High Level From Control Box (mm) 650

Difference Between High and Low Level (mm) 300

Minimum Working Depth (mm) 500

Control Operation Fully Pneumatic

Air Quality Clean, Filtered Compressed Air

Max Air Usage at 450 kPa (scfm) 2

Location Classification Water Resistant for In Pit Use

Hazardous Area Classification Class 1, Zone 0

PH

YS

ICA

L C

HA

RA

CT

ER

IST

ICS

Level Switch Box Length (mm) 230

Level Switch Box Width (mm) 210

Level Switch Box Height (mm) 150

Level Switch Box Materials Stainless Steel (Grade 304)

Required Level Switch Box Fastening M10 Dynabolts (SS 316)

High / Low Level Rod Materials Stainless Steel (Grade 304)

High /Low Level Float Materials Polypropylene

Float Diameter 6”

Float Buoyancy 2 kgf

Typical Shipping Weight (kg) 5.5

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D LIFTING AND HANDLING

D.1 ULTRASPIN SEPARATOR

The Ultraspin Separator is mounted on a folded stainless steel skid base, with all equipment contained

within the skid. Once unpackaged, the Ultraspin Separator can be moved into position (with the aid of a

lifting device) and then manually manoeuvred into position.

D.2 DECANT TANK

The Decant Tank is a purpose-modified plastic tank, weighing less than 20 kg. As there are no lifting

devices required for this tank, it can be manoeuvred into position manually.

D.3 SPECIAL LIFTING EQUIPMENT

The following lifting equipment will be used to position and move the equipment component items.

Item Equipment Name Configuration Special Lifting Equipment

Required

1 Oil Skimmer and Hose Separate Items Lift into position by hand

2 Ultraspin Separator Separate Item Lift into position with a hand-

trolley

3 Decant Tank Separate Item Lift into position by hand

4 Level Switch Separate Item Lift into position by hand

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D.4 TYPICAL EQUIPMENT WEIGHTS

Item Equipment Name Configuration Weight (kg)

1 Oil Skimmer and Hose Separate Items 10 kg ea

2 Ultraspin Separator Separate Item 40 kg

3 Decant Tank Separate Item 15 kg

4 Level Switch Separate Item 5 kg

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E CORROSION PROTECTION

E.1 SYSTEM USED

Item No. Major Item Surface Parent Material Surface Protection

Details

1 Oil Skimmer Stainless steel (Grade: 316L) None required

2 Oil Skimmer (skimmer hose) PVC with galvanised steel spiral wound wire

None required

3 Strainer Stainless steel (Grade: 316L) None required

4 Separator Pump Anodised aluminium None required

5 Ultraspin Separator (skid base) Stainless steel (Grade: 316L) None required

6 Ultraspin Separator (separator shell) Stainless steel (Grade: 316L) None required

7 Ultraspin Separator (inlet and outlet manifolds and piping)

Stainless steel (Grade: 316L) None required

8 Ultraspin Separator (reject stream) Oil-resistant nitrile hose (UV stabilised) None required

9 Ultraspin Separator (3-way valve and sample valves)


10 Ultraspin Separator (pressure gauges) Stainless steel (Grade: 316L) None required

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11 Ultraspin Separator (pneumatic circuit) Aluminium body with stainless steel wetted parts

None required

12 Ultraspin Separator (clamps and brackets)


13 Decant Tank Medium density polyethylene None required

14 Level Switch Stainless steel (Grade: 316L), with brass and aluminium internal components

None required

E.2 METHOD OF REPAIR

• The method of repair will be to use touch-up paint to the same specification as that listed in the above

table for all painted surfaces.

• There is no surface repair for stainless steel equipment items

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F STORAGE OF EQUIPMENT

F.1 PRIOR TO INSTALLATION

The Ultraspin Separator (with Oil Skimmer and Hose) will be transported to site and stored in cardboard

boxes, with the Separator box securely nailed to a timber pallet. The decant tank is stored on a pallet

and shrink-wrapped with plastic film.

Where a galvanised skid or bund is used, the equipment items will be located on the bund and stretch-

wrapped with plastic film.

All of the equipment items can be stored indefinitely in a clean, dry location until such time that installation

is commenced.

F.2 FOR EXTENDED SHUT-DOWN

All equipment items are weather-proof and can be stored in their installed position outdoors and exposed

to the sun.

Specific equipment items are rated to the following specifications:

• 3-way valve and pneumatic actuator on recycle valve is rated to IP67

• Collection pit level switch is rated to IP66

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G DRAWINGS SCHEDULE

Number Description

I-P-0203-01 Typical Process Flow Diagram for OS Separator

I-P-0054-01 Installation Schematic for OS Separator

OS-A-0020-01 OS35 Separator General Arrangement Drawing

OSD-TANK-03 1,100 L Oil Storage and Decant Tank General Arrangement

OS-A-0090-01 L1 Level Switch General Arrangement Drawing

I-A-0107-05 Auto-Recycle Control Pneumatic Schematic

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H INSTRUMENT LIST (WITH CALIBRATION RANGES AND SET POINTS)

Item No.

Instrument Number

Instrument Instrument Make and

Model Contact

Type Setting Range

1 LSLH-01

Level Switch (Ball Float Type) – Low/High Level in Main Oily Water Collection Pit

Make: Ultraspin Ball Float Level Switch Model: L1

N/A

Float height can be set at installation. Distance b/w high and low ball floats is set at 300mm

N/A

2 PI-01 Pressure Gauge on Separator Inlet

Make: Tek-land Instruments Model: 1/4" BSP (f) Bottom Entry 0 to 600 kPag, 2½” Dial

- 0 to 600 kPa N/A

3 PI-02 Pressure Gauge on Separator Outlet

Make: Tek-land Instruments Model: 1/4" BSP (f) Bottom Entry 0 to 600 kPag, 2½” Dial

- 0 to 600 kPa N/A

4 PI-03 Pressure Gauge on Pneumatic Filter-Regulator

Make: SMC Model: 1/8" BSP Rear Entry 0 to 1000 kPag, 1” Dial

- 0 to 1000 kPa N/A

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I SPARE PARTS LIST

I.1 COMMISSIONING SPARES

Typical spares required for commission are listed below:

Item Part No. Description Option Required Quantity

1 ORN013 O-ring 334 (nitrile 70) Base 1 ea

2 ORN014 O-ring 335 (nitrile 70) Base 1 ea

3 TLS069 BSM spanner 4 inch (aluminium) Base 1 ea

4 TLS208 Lower Removal Tool Base 1 ea

5 PNC010 Air hose Ø10mm OD x 100 metre roll (black LDPE) Base .15 ea

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I.2 OPERATION AND MAINTENANCE SPARES (2 YEARS)

Typical maintenance spares for 2 years are shown below:

Item Part No. Description Option Required Quantity

1 SUBSK026 Sub-Assembly for Main Bellows for S1 Skimmer (Stainless) 1 ea

2 INT035 Pressure gauge 0-600 kPa 1/4 inch BSP (m) rear entry Ø63 mm face liquid filled (316 SS/brass)

Base Unit 1 ea

3 LVL008 Level switch pneumatic components (Ultraspin L1 Level Switch)

Auto/Recycling 1 ea

4 ORN001 O-ring 1 inch BSM round (viton 70) 1 ea

5 ORN017 Flat faced seal 4 inch BSM (viton) Base Unit 1 ea

6 ORN005 O-ring 1-1/2 inch BSM round (viton 70) 1 ea

7 ORN013 O-ring 334 (nitrile 70) Base Unit 1 ea

8 ORN014 O-ring 335 (nitrile 70) Base Unit 1 ea

9 ORN041 O-ring for BFL-1 strainer housing (viton) 1 ea

10 PMP015 Air side repair kit (air shuttle valve) to suit 1-1/2 inch pneumatic ARO pump

1 ea

11 PMP016 Wet side repair kit (diaphragms and balls) to suit 1-1/2 inch pneumatic ARO pump

1 ea

12 PNC020 Filter element for SMC AW-30 filter-regulator, 40 micron 1 ea

13 PNC021 Bowl assembly for SMC AF/AW-30 filter-regulator N.O 1 ea

14 PNC022 Bowl O-ring for SMC AW-30 filter-regulator 1 ea

15 PNC031 Coalescing oil filter (modular micro-mist) 1/4 inch BSP with manual drain

1 ea

16 SUBOS004 Sub-Assembly for 3-Way Valve, L-Port Ball Valve 3/4 inch BSP (f) (OS35 Separators)

Auto/Recycling 1 ea

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I.3 CAPITAL SPARES

Item Part No. Description Option Qty / Equipment

1 SK-A-

0030-08 S1 Skimmer Hose (3 metre) MK2.0

1 ea

2 SUBOS003 Sub-Assembly for Pneumatic Timer for OS35 and OS70 Auto-Recycle

1 ea

3 SUBOS004 Sub-Assembly for 3-Way Valve, L-Port Ball Valve 3/4 inch BSP (f) (OS35 Separators)

1 ea

4 SUBOS012 Sub-Assembly for Auto-Recycle Pneumatic Filter Regulator Assembly (OS35 Separator)

1 ea

5 PMP002 Pump 1-1/2 inch ARO diaphragm pump - with muffler (nitrile/aluminium)

1 ea

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J INSTALLATION INSTRUCTIONS

Important Note:

Compliance with procedures and instructions in this guide is necessary for proper installation. Failure

to comply may cause compliance or operational problems. National, state, location and company

construction codes and environmental regulations should be consulted to ensure compliance.

Prior to installation of the Ultraspin equipment, all appropriate approvals, permits, licences and

agreements must be obtained from the relevant Government authorities.

The following is a typical guide to the recommended method of preparing the site and for correct

installation of separator. Sites and client requirements may vary from what is described here.

J.1 SERVICES REQUIRED PRIOR TO INSTALLATION

Please ensure that the following services are available and functional before installing the Oil Separator:

• Compressed air (supplied via a ½” OD line as clean, dry air at a pressure of 8 Bar) to supply air to

the separator skid pneumatic take-off point.

• Concrete plinth with bunded walls (or other location to secure the separation skid), as per the

details in skid general arrangement drawing.

• Drainage from all areas to the main oily water collection pond.

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J.2 UNDERGROUND PITS

Ultraspin does not supply in-ground collection pits. However, the following general recommendations

apply. Where there is more than one pit, each pit must be interconnected with an under/overflow pipe

rising and delivering below the water level from each pit, to ensure that the sediment and oil layers which

form in the first pit are not carried over to the second pit.

J.2.1 Collection Pit

The oily water collection pit must be sized to accommodate the maximum flow into the pit from any

sources where oily water is generated, as well as having capacity to capture water from other sources

(hose-downs or the maximum expected rainfall over a given collection area).

This pit must also handle the decanted water returning from the Decant Tank.

Important Note:

The area around the underground pits must be kept clear of falling tree leaves, bark, loose soil and

rubbish. All of these items can easily enter the pits and either foul the water or block the pump suction

piping, and this may have detrimental effects on the operation of the Ultraspin Separator.

For correct operation, Ultraspin recommends that the collection pit for the OS35 Separator be at least

1000 L working capacity. The pit size must be at least 2575 L x 950 W x 1700 H mm to allow the

skimmer to operate correctly.

The pit needs to be sized to accommodate expected peak inlet flows and to take into account the

requirements of authorities.

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The pit needs to be designed to have minimum protruding components on the inside, i.e. cut the inlet

pipe back flush with the pit wall. Install ladder on the side where the drain line from the bund enters

(this means the floating skimmer will be on the opposite side of pit and will not get hung up).

Position the pit lid as close to the entrance into pit of drain from bund. This ensures good access to the

level switch for servicing and allows for the best access to the skimmer hose to retrieve the skimmer

without having to enter pit during maintenance.

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J.3 ULTRASPIN SEPARATOR INSTALLATION

J.3.1 Safe Maintenance Access

Position the Ultraspin Separator and Decant Tank to allow ease of maintenance and operation. Allow

good access to strainer basket for cleaning and pump access for maintenance. Approximately 1000mm

all around the equipment items should be allowed to enable good maintenance access.

Important Note:

1. For stand-alone Ultraspin units, a concrete bund must be installed on site, as per Section K.3.1

2. For Ultraspin units supplied with an integral galvanised bund, refer to Section K.3.2

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J.3.2 Procedure for Installing a Stand-Alone Ultraspin Separator and Decant Tank

J.3.2.1 Concrete Bund Requirements

1. Refer to drawing I-P-0054-01 for details of the concrete bund layout and size.

2. Observe the minimum bund size requirements for where to locate the separator and decant tank.

3. The position of the floor drain and other connections should be noted, to prevent them from

obstructing the oil tank.

4. Arrange the slope on the bund floor so there is a reasonably level base for the oil tank.

5. Ensure that there is piping or floor drain (if fitted) to return the recycled water stream and decant

water from the Decant Tank back to the collection pit for retreatment.

6. Ensure that there is a sewer connection in which to direct the treated water stream from the

Ultraspin Separator to sewer.

J.3.2.2 Bolting Down the Separator to the Concrete Bund

1. The separator skid base should be located according the site layout drawing I-P-0054-01.

2. The foundation must be able to absorb any vibration and to form a permanent rigid support for the

skid. There must be no dirt, oil, water or chips on the foundation prior to lifting the equipment into

its final rest position.

3. The separator skid should be lifted and lowered to a point 50 mm above its final position, then

aligned square with the nearest reference survey point, prior to the final drop occurring. The skid

bolthole positions should be marked and then the skid raised and moved away.

4. Drill 13mm holes in concrete with a masonry drill with hammer action.

5. Return the separator skid into position and secure the base with four (4) stainless steel M12 x 65

Chem-set fasteners (or similar) into the marked positions. Allow the appropriate curing time for the

fasteners, as per the manufacturer’s recommendations.

6. Level the skid with a laser-guided alignment level and make up any height differences beneath the

skid with stainless steel packing plates and shims. Level the skid base to within 3.2 mm over the

length of the baseplate and 1.5mm over the width of the base by adjusting the shims.

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7. If concrete bund is significantly sloped, the skid base should be levelled with packing before bolting

to bund.

8. Secure the Chem-set in fasteners in the ground with stainless steel nuts.

9. Grout around the packing plates, ensuring that there are no unsupported footplates. The thickness

of grout will vary according to the height of the packing under each footplate. Grout should be

placed so that it completely covers the sides of the packing beneath each footplate. Prepare the

grout in accordance with the manufacturer’s specifications.

10. Ensure that the recycle line can be routed to floor drain line.

11. Position the skid to allow ease of maintenance and operation. Allow good access to strainer basket

for cleaning and pump access for maintenance.

J.3.2.3 Oil Tank Positioning

1. Position the oil tank such that it does not cover the floor drain and so that the decant water return

line can be readily piped to floor drain.

2. Ensure that base under tank is flat and clear of any debris that could puncture the tank.

Important Note:

The Ultraspin Separator and Decant Tank must be located level to ensure correct operation.

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J.3.3 Procedure for Installing an Ultraspin Separator with Integral Skid Base

J.3.3.1 Concrete Bund Requirements

• Refer to drawing I-P-0054-01 for details of the concrete bund layout and size.

• Observe the minimum bund size requirements for where to locate the separator skid base.

• Ensure that there is piping or floor drain (if fitted) to return the recycled water stream and decant


• Ensure that there is a sewer connection in which to direct the treated water stream from the

Ultraspin Separator to sewer.

Important Note:

The Ultraspin Separator with integral skid base must be located within a concrete bund.

J.3.3.2 Positioning of the Ultraspin Separator with Integral Skid Base Within the Concrete Bund

1. Position the separator skid base within the bunded area.

2. Arrange the slope on the skid base on the bund floor so there is level base for the entire skid.

3. There is no requirement to bolt down the separator skid base, as the weight of the skid and filled

decant tank will stabilise the skid base.

4. If the separator skid is located within a cyclone prone area, then additional bolting must be

considered.

Important Note:

The Ultraspin Separator and Decant Tank must be located level to ensure correct operation.

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J.3.4 Procedure for Installing an Ultraspin Separator Units with Integral Galvanised Bund

J.3.4.1 Concrete Pad Requirements

1. Ensure that a level concrete pad, large enough to suit the galvanised bund with Ultraspin Separator,

is available.

2. Ensure that there is piping or floor drain (if fitted) to return the recycled water stream and decant


3. Ensure that there is a sewer connection for directing the treated water stream from the Ultraspin

Separator to sewer.

Important Note:

The galvanised bund for the Ultraspin Separator must be located level to ensure correct operation.

J.3.4.2 Positioning of the Ultraspin Separator with Integral Galvanised Bund

5. Position the galvanised bund on a concrete pad.

6. Arrange the slope on the galvanised bund on the concrete pad so there is a level base for the entire

bund.

7. There is no requirement to bolt down the galvanised bund, as the weight of the skid and filled

decant tank will stabilise the skid base.

8. Footings can be provided for the galvanised bund to enable it to be bolted to the concrete pad.

9. If the galvanised bund is located within a cyclone prone area, then additional bolting must be

considered.

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J.4 LEVEL SWITCH INSTALLATION

J.4.1.1 General

The Ultraspin Level Switch shall be bolted to the inside wall of the collection pit with four (4) M12

masonry fasteners (SS316 Dynabolt or Chemset).

Install the level switch on the same side of the pit as the skimmer hose connection to ensure that the

skimmer floats away from level switch and minimises interference.

The high and low float levels are installed 300 mm apart. This allows the Ultraspin Separator to operate

more frequently. This configuration has the following advantages:

• Less compressor stress: System does not run for an extended period

• More recycle times ensure more treatment and furthermore better water quality

Important Note:

The level switch box should be above any overflow drain from pit.

J.4.2 Level Switch Connections

Three 6 mm O.D. nylon air line tubes (not supplied by Ultraspin in standard scope) are required to

connect the level switch to the Ultraspin Separator skid. Use black nylon tube, as this is UV resistant.

These three lines are run through the 100 mm drain line from the separator bund to the pit.

Each tube needs to be firmly pushed into one of the fittings marked ‘S’, ‘P’ & ‘T’ on the level switch. The

other ends of the nylon tubes are pushed into the corresponding fittings marked ‘S’, ‘P’ & ‘T’ on the skid

(at the filter/regulator). Therefore ‘S’ on the level switch connects to ‘S’ on skid, etc.

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J.4.2.1 Mechanical Installation

Mount the level switch so that it is at an acceptable level to access without having to enter the pit.

Install floats at heights as shown on typical schematic OS drawing.

Figure K.4.1

Left image: Do not use the whole length of the rods to avoid bending

Middle image: Correct installation

Right image: Distance between high and low level float is too long (must be reduced)

Figure K.4.2

Left image: Level switch too high, both level floats are down position (system will never run)

Right image: Level switch is too low, the water will never reach the high level float (system

will never run)

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J.5 EXTERNAL PROCESS CONNECTIONS TO/FROM ULTRASPIN SEPARATOR SKID

Important Note:

• The installer is to supply all interconnecting hoses and fittings (scope defined in drawing).

• Ultraspin can provide hoses and fittings once required lengths are specified (if requested).

J.5.1 Pneumatic Connection to Separator Pump – ½” BSP (f) Screwed Connection

The pneumatic pressure to the Ultraspin Separator is provided via a ½” NB screwed line. The flow of

pneumatic air to the Ultraspin separator is controlled via an on/off solenoid valve, which actuates in

response to level within the oil collection pit. At high level, the solenoid will actuate and allow

compressed air to the air-operated diaphragm pump on the Ultraspin Separator, which will start the

operation of the unit. When the pit level is low the solenoid valve will close and shut off air supply to the

pump, thereby stopping the Ultraspin Separator.

J.5.2 Effluent inlet – 1½” BSP (f) Screwed Connection

Dirty water flows from the Oil Skimmer in the oily water collection pit and connects to the strainer on the

Ultraspin Separator skid, before entering the pump suction.

The effluent inlet line size must be at least 1½” ID diameter, which is the size of the skimmer suction

hose. The skimmer suction hose may be connected to the strainer basket using the camlock fitting

provided and connecting the mating camlock to the skimmer suction hose to this fitting.

Typical material for this line is suction-rated hose (oil resistant)V.as provided by Ultraspin.

To minimise the pressure drop, the line length between the Oil Skimmer and the Oil Separation skid,

shall be not greater than ten (10) metres, the vertical rise shall be not greater than three (3) metres, and

the number of elbows shall be kept to a minimum.

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Important Note:

The suction piping must be of good quality and airtight. Any air leaks will cause the pump to behave

erratically.

J.5.3 Treated Water Outlet – 1” BSP (m) Screwed Connection

The treated water outlet from the Ultraspin Separator typically connects to sewer or trade waste.

The treated water outlet line size must be at least ¾” NB diameter with the inclusion of connections at

appropriate locations to facilitate future maintenance on the system. The piping materials should be

either stainless steel or PVC, and supported at the appropriate locations for each type of pipe material

used.

Important Note:

An orifice is located prior to the valve termination point on the Ultraspin skid on the treated water

outlet manifold. This must always remain installed (between the BSM fittings) to maintain the correct

backpressure for correct operation of the Ultraspin Separator.

Important Note:

There are to be no pressure restrictions installed on the downstream side of the treated water stream

(such as filters, water meters. Etc.), as these will adversely effect the performance of the separator.

J.5.3.1 Recycle Water Outlet to Sediment Trap – 1” BSP (m) Screwed Connection

The recycled water outlet from the Ultraspin Separator returns water to the collection source for a pre-

determined period of time, so that treated water may be recycled back for retreatment (particularly

during initial process start up when the oil load may be high).

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The recycle water outlet line size must be at least ¾” NB diameter with the inclusion of connections at


either stainless steel or PVC, and supported at the appropriate locations for each type of pipe material

used.

J.5.4 Oily Reject Line from Separator to Decant Tank – ½” ID Flexible Hose

This reject oil from the Ultraspin Separator flows to the Decant Tank for storage and decanting of

separated water.

This line is supplied a ½” ID oil resistant and UV stabilised flexible hose. The length of this line has

been carefully selected to provide the optimum backpressure on the deoiler reject and typically will

provide an ideal backpressure of 50 kPa. (Extending or cutting back the line beyond the recommended

length will reduce the efficiency of the deoiler separator.)

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J.5.5 Decant Tank Outlet Return to Collection Pit – 2” NB PVC (Class 12)

The Decant Tank outlet returns decanted water back to the collection pit for retreatment.

The decant water outlet line size must be at least 2” NB diameter with the inclusion of connections at


PVC, and supported at the appropriate locations for each type of pipe material used. This pipe is

gravity fed and must be free draining back to the collection pit

Important Note:

There are should be no rise in elevation in the decant water line returning to the pit, as this will

adversely effect the operation of the tank.

J.5.6 Sample Points – ½” Hosetail

Sample points are to allow observations of separation performance and these do not normally require

connection to client piping. The sample points are provided on the effluent inlet manifold and treated

water manifold.

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J.6 INSTALLATION CHECKLIST

The following installation checklist confirms all of the major requirements to complete the installation of

the Oil Separation system.

Item Equipment Name Installation Requirements

1 Oil Skimmer

• Install suction hose

• Lift skimmer and hose into oily water collection pit

• Check that skimmer is free floating

2

Ultraspin Separator • Lift skid base into position and bolt down

• Process connections from oil skimmer and to recycle and

treated water discharge points

• Drop the main float level switch into the oil collection pit.

Air Diaphragm Pump

Back-Up Strainer

3 Decant Tank

• Lift decant tank into position and bolt down

• Process connections from Ultraspin separator to the decant

tank

• Process connection from the decanted water overflow and

return back to the collection pit for retreatment

J.7 CLEANING AND FLUSHING OF EQUIPMENT AFTER INSTALLATION

Remove all sand, grease and foreign material after installation and seal ends to prevent ingress of

contaminants.

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J.8 COMMISSIONING

J.8.1 Introduction

All work should be carried out in accordance with Company, Government or National Standards and the

requirements of any other relevant authority and permits must be obtained where required. Prior to

commissioning this equipment, please ensure that all aspects of installation have been dealt with.

J.8.2 Equipment Check

Check all piping and connections installed as per Piping and Instrumentation Diagram and general

arrangement drawing.

J.8.3 Pneumatic Air Supply

Ensure that the pneumatic air is switched on (air compressor operating) and that the supply lines to the

Ultraspin skid are pressurised and leak-free.

Open the valve prior to the filter-regulator on both the separator pump and waste oil transfer pump, to

allow air to flow to the filter-regulator. Set the pressure on the filter-regulator to be 500 kPa.

J.8.4 Effluent Feed Supply

Clean out all the debris in the pit and drain lines, including silt traps. If the oily water collection pit is

empty, introduce water (or effluent fluid to be treated) and cease filling when full.

Ensure appropriate approvals have been obtained for effluent discharge and inspect clean water outlet

connection to sewer or other.

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J.8.5 Piping and Valving

Open all the isolation valves on the inlet and the discharge lines. Close all the drain and sample point

valves.

J.8.6 Separator Pump Priming

The separator pump can be primed by removing suction line and filling pump inlet and suction strainer

housing with water. Make sure there is fluid in the feed source which the separator will draw from.

Priming is necessary if the pump:

• Is being run for first time

• The pump has been drained (i.e. for maintenance)

• Or for any other reason the pump does not contain fluid.

J.8.7 Decant Tank

Fill the Decant Tank with mains water (or clean water from another source) up until the point

where water begins to overflow the water decant pipe. This will ensure that the Decant Tank is

ready for decanting as soon as the system is started.

Important Note:

Filling the Decant Tank will ensure proper operation of the system and prevent oil overflow back to the

collection pit.

J.8.8 Recycle/Discharge Function

Ensure that the recycle and discharge valve actuate after the preset ‘recycle’ period. This is typically

set to 30 minutes, but may be adjusted down to a few minutes for commissioning purposes, so that the

valve may be observed to actuate.

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The recycle valve, which is normally open, should actuate to the closed position, and the discharge

valve, which is normally closed, should actuate open.

Wait for the recycle set time and observe diversion of outlet flow from recycle (to pit) over to discharge

(to sewer).

J.8.9 Adjustment of Pneumatic Timer

• Remove lid on weatherproof box on the separator skid that contains pneumatic timer.

• Ensure that the timer is set to required time; typically this is 30 min.

Timer is factory set

to 30 min

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J.8.10 Pre Start-up Checks

The following pre-start up check must be completed before starting the system for continuous operation.

• Sample points are closed

• All valves in suction and discharge (both reject oil and treated water) lines are open

• The skimmer is primed with water and floating freely

J.8.11 Checking the Pump Operation

The pump should operate smoothly and rhythmically at the rate of one beat per second. During

priming, the pump may pump quicker, but this will settle down after the pump is fully primed.

J.8.12 Starting the System

Fill the main collection pit with water (or wait until the pit is full). Once the level in the pit rises, the low

level and then high level ball floats will be activated. Once water reaches the high level float, the pump

will begin to operate.

The inlet pressure can be observed via the pressure gauge mounted on the end of the inlet manifold.

The pump discharge pressure will rise to 400 kPa after steady state operation is achieved (after

approximately 1-2 minutes).

J.8.13 Stopping the System

Switching the pneumatic valves OFF on both the separator pump and waste oil transfer pump filter-

regulators will shut down the air supply to the air diaphragm pumps and stop operation.

J.8.14 System Checks

Other system checks at first start-up:

• Reject oil flow check (the reject flow should be approximately 5% of the total flow)

• Decant water flow from Decant Tank water decant nozzle

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J.8.15 Fine Tuning

For the separator to perform properly a minimum oil/oil flow rate must be maintained. Typically the

reject oil flow rate is between 5 and 10% of the total system flow rate. One way of determining that this

minimum flow rate is maintained is to calculate the Pressure Differential Ratio (PDR). The formula is:

)overflowreject underflow,(outPoutPin

PrejPinPDR ==

−

−=

The pressures are obtained from the 4” dial analogue pressure gauges located on each manifold.

• ‘Pin’ is the inlet pressure which can be read off gauge PI1

• ‘Prej’ is the oil-rich stream pressure, and is typically 0 kPa

• ‘Pout’ is the cleaned water stream and this can be read off gauge PI2

+0.05

The PDR is preset to 1.65 0

The PDR can be altered by changing the size of the backpressure orifice located at outlet nozzle N2.

Depending on the site-specific set-up of the system it may be necessary to adjust the backpressure

orifice to maintain the correct PDR.

Making the PDR too large, that is above 1.7, will not improve separation performance but can lead to

overloading of the oil processing portion of the system. Two additional orifice plates have been included

with the separator if backpressure adjustment is required. If these sizes do not provide the correct

system backpressure custom sizes can be produce on request.

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K OPERATING INSTRUCTIONS AND INFORMATION

K.1 GENERAL

When installed correctly, the Ultraspin Separator is extremely reliable and requires little maintenance. In

between the recommended scheduled services simple routine checks are all that is normally required to

ensure good operation.

K.2 OPERATION OF ULTRASPIN SEPARATOR

K.2.1 Adjusting the Separator Filter-Regulator

1. Ensure that the plant air compressor is operational.

2. Open the main compressed air inlet valve on the Ultraspin Separator filter-regulator.

3. Ensure that the there is sufficient water level in the collection pit to ensure that both the low and high

level floats are actuated (in the UP position), in order to operate the pneumatic circuit on the Ultraspin

Separator

4. Wind out the regulator to the lowest possible pressure (normally zero pressure).

5. Adjust the pneumatic regulator on skid until the pressure gauge on the filter-regulator reaches 500

kPa.

6. Air will now flow to the pump via the filter-regulator.

7. The pump should commence pumping (quickly at first while priming, and then beating smoothly and

rhythmically when pumping liquid).

8. Check for any air or water leakage and tighten fittings as required.

9. Adjust the filter/regulator to give the correct pump discharge pressure of about 400 kPa (average

between pulses).

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K.2.2 Automatic Recycle Start

• As the pit fills up and the water level rises above the low level float, the buoyancy of the float causes

it to rise.

• As the water level rises to the high level float, it will trigger a switch and allow air to flow to the

separator pump.

• The pump will start and the timer will commence counting up to the set count time. The actuated

valve stays in the recycle position. The pump will draw water from the pit and to the separator unit,

and treated water will flow back to the pit.

• Once the timer has reached the set count time, air will produce an output to the ‘valve actuate’

outlet on the timer box and trigger the 3-way valve. It moves from the ‘recycle’ to the ‘discharge’

position. Treated water will now be discharged to sewer.

• The system will continue pumping and discharging to sewer until the low level float drops to the

down position.

• The system will reset the timer and 3-way valve back to the recycle position when the water drops

below the low level float.

Important Note:

In recycle mode the system will return treated water back to the collection pit and will not discharge

water.

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K.2.3 Manual Start

• Push the manual start valve (green button) located on the pneumatic control circuit of the filter-

regulator (labelled ‘manual start’).

• If the water level in the collection pit is above the low level float, then the system will continue

pumping until the water level drops below the low level float.

• If the water level in the collection pit is below the low level float, then the system will only operate

when the manual start button is depressed.

Important Note:

The manual start function must be used for commissioning purposes only by an Ultraspin technician or

a customer-appointed technician.

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K.3 DAILY OPERATIONAL CHECK SHEET

Typically, no daily operator checks are required. Some operators may wish to inspect daily, and in this

case a simple daily check of the following will ensure that the unit is operating correctly:

• The oil skimmer should be drawing surface fluid in a consistent and evenly distributed flow across

its donut shaped weir.

• Pump discharge pressure is 400±100kPa (or as shown in data sheet)

• Reject stream is flowing at required rate (see data sheet) into oil tank.

• Pump is running smoothly and without unusual noises

• Monitor the amount of oil in the oil tank.

• Ensure that the waste oil pump discharges to an appropriate oil disposal point.

• Empty the strainer basket as required.

• Monitor the amount of oil (swirl surface or use water-finding paste) in the oil tank and order pump-

outs as necessary.

• If there appears to be any problem with these routine operating checks, proceed to the

troubleshooting section of this manual.

K.4 WEEKLY OPERATIONAL CHECKS

• Start the Ultraspin Separator manually, by pushing the green “manual start” button.

• Check the separator pump operation to ensure that it beats smoothly and rhythmically (once per

second)

• Check treated water flow from the Ultraspin Separator

• Check reject/decant water flow

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K.5 CHECKING FOR CORRECT SEPARATOR FLOWS

• Water being discharged to sewer (or other) will form the bulk of the flow from the Ultraspin

Separator Vabout 95%.

• An oil water mixture will continuously be discharged to decant tank when the separator is operating.

The lid of the decant tank may need to be lifted to observe this flow, which is typically 6% of total

flow.

• Flow measuring should be conducted with a graduated bucket and stopwatch.

Check Correct Operating Condition

Separator Inlet Pressure, Pin Operating range 250 kPa (greater than) >= Pin <= (less than) 500 kPa

Oil Reject Flow, Qrej Measured flow (l/min) to beV

• OS35 Separator 8.5% of total flow

Treated Water Outlet Flow, Qout Measured flow (l/min)

1. If Separator Inlet Pressure, Pin is within acceptable range, then proceed to next step.

2. If Oil Reject Flow, Qrej is within acceptable range, then proceed to next step.

3. If Treated Water Outlet Flow, Qout + Oil Reject Flow, Qrej = total rated flow of separator then separator is operating correctly and efficiently.

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K.6 DEALING WITH EMERGENCY SITUATIONS

K.6.1 Stopping the Ultraspin Separator Pump

The system operation can be stopped at any time by closing the air inlet valve to the individual filter-

regulator on either the separator pump or treated water transfer pump.

K.6.2 Oil Spills

Oil spills or leaks from the equipment items must be stopped immediately. The source of the leak (either

from a connection or equipment rupture) should be determined and then action taken to stop the problem

and prevent further incidents. The concrete bund will isolate the spill or leak to the immediate area

around the Ultraspin Separator

The spilt oil/water in the bunded area can be pumped back to the oil water collection pit for re-treatment

and oil separation.

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K.7 RECOMMENDED OIL AND GREASE TEST METHOD

The recommended test method for determining Total Oil and Grease (TOG) in the treated water outlet

stream is the APHA 5520 B Partition-Gravimetric Technique (attached).

Important Note:

Only laboratories fully familiar with this test technique should be used to determine oil and grease

readings. Ultraspin can provide the sampling and testing analysis service where required.

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K.8 SAMPLING PROCEDURE

This section describes the procedures that MUST be followed in order to obtain a representative and meaningful

oily water sample.

Collecting reliable accurate oily water samples is very difficult and requires great care and expertise. It is a lot

more difficult than most people imagine. A very common mistake is Environmental or Water experts assume

that techniques appropriate for general water sampling are appropriate for oily water sampling – they are not!

Most often the only effective way to obtain a reliable oily water sample is to have a trained Ultraspin

representatives collect the samples. End use Customers do not have staff that are qualified and trained in the

science and art of oily water collection.

K.8.1 Caution – look after yourself!

You must be careful when collecting any samples from a process. You

must always assume the water is nasty till proven otherwise!

Ask questions, get proof or test any water before sampling. Don’t take the

word of someone you do not trust, always validate before proceeding.

Watch for:

• High or low pH

• Very hot or very cold

• Contains carcinogenic or hazardous chemicals or additives

• Is biologically active

Always wear gloves, eye protection and other PPE equipment appropriate to the hazard.

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K.8.2 The Process Sample Point

An often overlooked basic of sampling is to ensure that the sample is being collected from a suitable location in

the process.

Do not blindly use an existing sample point just because you have been told “that it is where we collect our

samples from”; the existing location may not be representative or suitable!

The ideal location for collecting an oily water sample:

• Gives a reliable representation of the process.

• Is insensitive to process variables such as consistency, flow velocity and pressure.

• Easy to get to and allow easy, quick and safe sampling.

• Allows the volume of sample to be controllable.

• Makes the sample independent of the user.

• Allows flushing of the system.

• Does not become fouled or plugged.

Keeping all these factors in mind some general guidelines:

• Best:

o Isokinetic sample point

o Location in an area of turbulence or high mixing – i.e. more than 1 m/sec velocity.

• Next best:

o Side of pipe

o In an area of turbulence or high mixing – ie more than 1 m/sec.

• Don’t ever use any of the following:

� Top of pipe – usually too much oil and gas.

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� Bottom of pipe – too many solids and may contain oil wet solids

� Dead legs in piping

� Areas of low flow

� Areas within 3 pipe diameters downstream of elbows, ‘tees’ or bends in piping.

� Areas downstream or 1 diameter upstream of chemical injection points

Diagram above shows a typical Isokinetic sample point.

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K.8.3 The Sample Piping and Valves

Assuming we have identified a good location and paid attention to all the matters above the next important point

is to make sure that the design of the sample piping and valves is appropriate.

Some process piping sample points and apparatus are incredibly expensive and complicated. I find that these

are almost always not good designs. SIMPLE is best!

Some factors to consider:

• The sample line size: ½” and ¼” are typical. Do not use lines larger than ½” or smaller than ¼”.

• Line length: Less than 300 mm or as short as possible.

• Valve size and type: Use full bore ball valves that can be fully open at sample collection time. Avoid

needle, plug, gate, or globe valves as they tend to allow debris to accumulate behind the valve

controller.

K.8.4 The Sampling Jar

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The actual container used to collect the sample is very important. ‘Jars’ or wide mouthed containers are the

preferred choice.

Guidelines:

• Use a 1000 ml glass bottle.

o If this is not possible (and there is a good reason why it is not possible) use 500 ml glass jars as

a second preference.

o If you use 500 ml jars some regulating authorities, such as the EPA, will not accept the result as

valid.

• Use a wide mouthed jar.

o A wide mouth on the jar helps to prevent splashing, foaming and overflow of the sample.

o A wide mouth jar is easier to clean fully and carefully.

o PTFE lined lid.

• Secure Screw top lid

• The sample bottles must be washed and cleaned with an appropriate solvent.

o The approved standard APHA 5520 says: “Collect a representative sample in a wide-mouth

glass bottle that has been rinsed with solvent to remove any detergent film, and acidity in the

sample bottle.”

• Attach label to the jar. Make sure it is solvent and water proof.

o Nothing is worse than a weeks’ worth of samples being ‘lost’ because labels are removed, or

become unreadable due to smudging or water contamination.

o Only write with ‘permanent markers’ that will not wash off or degrade.

Plastic jars: Plastic jars, or any plastic container must never be used for sample collection.

There are many reasons not to use plastic:

• Oils and greases can dissolve into the walls of the jar and be lost from the analysis.

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• Most plastics are not compatible with the solvents required for rinsing and laboratory work. Because of

this sometimes the Laboratory may not rinse the plastic jar with solvent, thus leaving residual oil/grease,

or if rinsed with an incompatible solvent then the dissolved plastic gives enormous results.

• Oil and grease is not easy to remove from plastic jars even using solvent.

• It is unsafe. Some plastics are not compatible with process water and the contaminants in the water.

The containers may rupture and the contents hard operators or nearby equipment.

Using plastic jars usually leads to a HIGH oil and grease reading error. Don’t use!

K.8.5 Sample Collection Technique

Assuming we are using a good location to collect the sample, and we also have appropriate hardware to collect

the sample the next important aspect is to use goo technique to collect the sample.

It is very important to understand that collecting a reliable representative oily water sample is very difficult and

takes training! The actual mechanics of the sampling affect the results.

Oil and grease are not stable in water as a homogeneous mixture. Presented with a surface the oil in the oily

water will stick to that surface rather than remain suspended in the water. This means that all pipes, valves and

similar quickly become coated in oil. This is why effective sample line flushing is required.

The walls of the sample collection jar will most commonly be coated with the majority of the oil and grease

originally in the sample. For this reason jars used for collection and shipment of oil & grease samples must

never be pre-rinsed with the sample. The first rinse coats the walls of the jar with oil and grease, then the water

is dumped out and another coat of oil and grease applied to the walls with the next rinse, resulting in a

concentration effect.

Composite samplers must never be used for collecting oil and grease samples, because the majority of the

analyses end up coating the tubing inside the sampler rather than being delivered to the collection bottles.

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The proper technique is to collect a sample from a well-mixed area as a single grab using a wide-mouth glass

jar.

Follow these steps to ensure a reliable sample:

• Flush sample line:

o If the sample apparatus has been designed correctly it should be possible to almost fully open

the sample valve to get a very high jet of water.

o We are looking for a velocity in the sample piping of over 3 m/sec during flushing.

o This normally means a ½” sample line will flow at least 25 l/min for 60 seconds.

o If you cannot get a very high jet of water during the flush the sample point is not suitable.

o Leave the sample valve open to a flow sufficient to clean the sample lines of any accumulated

rubbish.

• Adjust Flow - If required

o Adjust the sample flow rate to that appropriate to collect the sample without splashing or risking

overfilling.

o We are looking for a velocity in the sample pipe of between 1 and 3 m/sec.

o The flow should be as high as possible.

o If required practice on a sample jar – one that you will not be using for an actual sample! Once

set - Do not adjust valve:

o Remove your hand from the sample valve.

o Never adjust the sample flow with the valve whilst actually collecting a sample.

• Sampling:

o Place the sample jar under the sample point and remove when full (leaving the sample valve

open and running without adjustment).

o Watch the sample as it flow. If any unusual material or ‘slug’ of material is observed – start

again.

o Cap the sample jar tightly- there must be no leakage.

o Then close the sample valve.

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• Any Problems?

o If there is any problems (e.g. overflow, spill, slug of material) whatsoever start entire process

again from the beginning.

o Discard the jar and start with a fresh jar

o If the sample is accidentally overfilled the bottle must be cleaned and rinsed with solvent.

o Never resample with a used jar. Do not rinse with water and resample as the oil from the

previous attempt will have adhered to the glass. Re-sampling without a full careful solvent wash

will result in a HIGH oil and grease reading error.

o Do not test the pH of a sample once collected. Why? Oil will stick to the pH paper or pH probe.

• Preserve and store the sample as described below.

K.8.6 Number of Samples and dividing the sample in the Laboratory

Each jar of sample is a single sample. This means that multiple jars of the sample must be taken to perform

duplicates and other quality controls. Oils and greases attach to walls of the jar, and no amount of shaking will

ever evenly disperse them back into the water. This means that dividing the sample into identical sub-samples

is not possible. This concern also applies to using a bucket or other secondary jar to collect a sample from a

conduit or manhole, then pouring sub-samples from the bucket into glass sample jars. Low oil and grease

values will be obtained as most of the analyses are attached to the sides of the bucket and do not get

transferred to the jar.

• Do not divide any oil and grease samples. In other words one sample cannot be used for oil and

grease and say suspended solids or BOD.

• Instruct the Laboratory that they are not allowed to divide the samples.

• If separate parameters are to be measured then separate samples will be required. This adds to cost

but is the only correct way to proceed.

• APHA 5520 says... “Collect a separate sample for an oil and grease determination and do not subdivide

in the laboratory”.

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It is unlikely that the oil/grease will be divided in proportion to the water as it will mostly be adhering to the initial

sampling jar. Dividing a sample can result in a HIGH oil and grease reading error.

Oil and grease samples MUST be preserved by use of acid. This will lead to errors with other measurements

such as BOD and suspended solids.

K.8.7 Sampling with Ultraspin systems

It must be at the FINAL discharge from the ULTRASPIN equipment and NOT in any other location.

This may sound very obvious but Ultraspin has observed clients collecting “treated” water samples from:

o Untreated inlet.

o Partially treated water in the recycle loop

The Ultraspin recycling can take 60 to 100 min. and sample collectors may be very reluctant to wait for the

recycling phase to conclude.

K.8.8 Composite Samples

A composite sample is a sample that is collected over a period of time. For example the one jar might be used

in an attempt to get a profile over 24 hrs.

• Do not use composite samples.

• The collection of composite samples is not approved by the EPA.

• Approved standard APHA 5520 says... “When information is required about average grease

concentration over an extended period, examine industrial portions collected at prescribed time intervals

to eliminate losses of grease on sample equipment during collection of composite sample”.

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• Composite samples cannot be preserved until the entire sample is collected. Oil and grease cannot be

collected effectively with composite samplers.

K.8.9 Sample Preservation

Once a sample is collected it needs to be ‘preserved’ to prevent bacterial and biological activity. Bacterial and

biological growth will lead to the oil being eaten or consumed. There is always enough naturally occurring

bacteria and microbes in oily water for the population to grow exponentially after the sample is collected.

Preserving is needed with 30 min. of the sample being collected to limit the error caused by this activity.

This is achieved by a combination of lowering the pH and cooling to below 4 oC.

• Acid:

o Best Option:

� Preferably acid is added on site at the collection time.

� In that manner the collector can be certain the acid is added, and the correct amount

and type is added. See note further on regarding sample preservation.

� The Standards require than the final sample has a pH of less than 2.

o Next Best option:

� If there are not facilities on site to add acid as above the next best option is to add acid

to the sample jars prior to dispatching them.

� The laboratory arranging sample analysis can arrange. Make sure that you instruct the

Laboratory carefully to ensure they understand exactly how much acid to add, and what

type of acid is acceptable, and at what strength.

� Usually 5 ml of concentrated Hydrochloric acid with adjust a 1000 ml sample at start pH

of 7 to a pH of less than 2 as required.

o With either technique make sure you run a pH test with a dummy sample.

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• Cooling

o Cooling the sample to 4°C (don’t freeze).

o Analyze within 48 hrs.

The acidification serves to halt biological activity in the sample. Most microorganisms can degrade oil and

grease components, and their activity can reduce the amounts present, even when the sample is cooled to 4°C.

The addition of acid can also convert fatty acids from water soluble salts to non-water-soluble free acids,

increasing the oil and grease content.

The pH of the sample after acid preservation should never be checked by dipping a pH probe or pH paper into

the sample itself, or by pouring off an aliquot for checking. These actions serve to reduce the sample oil and

grease content. Surface oils and greases will adhere to the paper or probe, or preferentially decant with the

aliquot. A separate jar of sample should be obtained so that the amount of acid necessary to lower the pH below

2 is determined on it, then the contents of this preservation test jar are discarded. The same amount of acid is

then added to the other oil & grease sample jars.

• Add acid to all collected samples

• Refrigerate all oil and grease samples until they arrive at the laboratory. The laboratory must analyze

the samples within 48 hrs. APHA 5520 says... “Acidify to pH 2 or lower; generally 5mL HCl or sulphuric

is sufficient”.

Without acidifying and cooling then bacteria can consume contaminants and the oil/grease. This can lead to

generation of by-products that will lead to errors.

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L FACTORS AFFECTING OIL WATER SEPARATION PERFORMANCE

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M MAINTENANCE INSTRUCTIONS AND PROCEDURES

M.1 OPERATIONAL MAINTENANCE

Approved client staff can carry out operational maintenance; however, it is recommended that advice

from Ultraspin qualified staff be sought before carrying out scheduled maintenance and servicing.

M.1.1 Back-Up Strainer Cleaning

The frequency of the cleaning depends on water quality and should be closely monitored. To clean the

strainer, follow this procedure:

• Switch off system by closing the manual isolation ball valve prior to the pneumatic filter-regulator.

• Bleed down pressure via the separator sample points.

• Loosen, but do not completely unscrew, the clamp on top of the strainer. The clamp will swing away

from the lid and the lid can be lifted off. Note that a slight vacuum pressure may initially hold the lid

tight to the strainer body, but this can be overcome with slight force.

• Remove the filter basket from the housing and remove debris from within the basket.

• Debris from the strainer should be disposed of in an appropriate location (not back in the pit).

• Re-installing the basket is the reverse of the removal procedure above.

Important Note:

DO NOT open the strainer with the separated pump operating or in any mode where auto start-up

could occur. Isolate the feed pump at the local isolator prior to clearing the strainer.

M.1.2 Leak Checking

Inspect for leaking pipes, hoses, fittings, and valves or pump seals.

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M.1.3 Air Diaphragm Pump Maintenance

For maintenance on the oil separator pump, please refer to the OEM manual for this pump (at the back

of this manual). Whenever maintaining the oil separator pump, the following procedure should be

followed:

• Switch off system via isolation switch on the front panel of the control box.


• The Ultraspin Separator Pump is self-lubricating and does not require lubrication.

• Follow the instructions in the OEM pump manual, or contact Ultraspin on 1800 467 266 if unsure.

M.1.4 Ultraspin Separator Reject Holes Cleaning

If the water treatment quality appears to be below standard, the separator reject port may be blocked.

• Shut down the pump by closing the isolator “STOP’ switch on the control box.


• Undo the piping flanges and the piping connected to the flanges end of the separator vessel.

• Undo the 4” BSM nut on the larger-diameter end of each separation shell.

• Remove the 4” cap assembly.

• Remove the small o-ring and UHMWPE (plastic) separation liner.

• Gently clear the reject ports with a suitably sized stiff wire or rod.

• Return head and all seals to separation tube and re-install all seals.

• Replace the cap.

• Close sample valves.

• The system is now ready to operate.

M.1.5 Separator Seals

The Ultraspin Separator contains several static elastomer seals, which should be periodically checked

for wear and damage.

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M.1.6 Recycle/Discharge Valve

Ensure that the recycle and discharge valve actuates as expected by manually changing the timer

setting to a lower timescale so that actuation can be observed.

Important Note:

DO NOT check for reject blockages with the pump operating or in any mode where auto start-up could

occur. Isolate the feed pump at local isolator prior to checking reject blockages.

Important Note:

DO NOT damage the reject ports as it is important that the holes remain perfectly round with a sharp

edge.

Important Note:

All seals removed with the inlet head must be re-installed on re-assembly to ensure correct operation

of the separation tube.

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M.1.7 Liner Removal

Important Note

Prior to removal of the liner the system must be isolated (by closing the ½” ball valve on the

compressed air inlet to the unit) and then de-pressurised (by opening the sample valves).

The OS Separator must be allowed to cool prior to removing the liner, as operating the system at

elevated temperatures will cause the liner material to undergo thermal expansion and expand against

the stainless steel shell, making the liner removal more difficult.

The OS Separator may be cooled by waiting for the separator shell to cool back to ambient

temperature or by running cold water over the shell until it is cool.

Important Note

Disassembly of individual liner components is discouraged, as cleaning of the liner assembly can be

completed by flushing water through each end of the liner, without disassembly.

If liner disassembly is required, then care must be taken to ensure that the threads are clear of debris

and obstructions before re-assembly. (Failure to do so may cause the system to lose efficiency and

stop working).

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Unscrew the cap. Place the removal tool in the first chamfer of the liner.

Place a piece of wood behind the liner removal tool to keep it in place/ prevent the fork from sliding off.

Place a screwdriver between the deoiler shell and the cap and use it as a lever arm to lift the deoiler.

Pull out the liner.

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M.1.8 Decant Tank

Intermittently drain the decant tank to remove built up solids and scum within the tankV.every six (6)

months.

When draining the decant tank, ensure that the built up oil layer is first removed by a registered waste

disposal vacuum truck.

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M.2 SCHEDULED MAINTENANCE

Ultraspin recommends that the Ultraspin Separator be serviced once every six (6) months. For some

sites this time interval may need to be altered. Please note that some regulating authorities require

maintenance to be carried out at defined intervals (consult local authorities for details). The requirements

of AS/NZS 4494: 1998 should also be considered. Checks are done for unusual noise, vibration or high

bearing temperatures as well as checking for any leaks.

M.2.1 Training for Maintenance Personnel

Ultraspin has qualified service personnel familiar with all aspects of this equipment design. Ultraspin can

provide information about all aspects of service work for this product including routine service programs

and breakdown service.

M.2.2 Specialised Labour Required

There are no specialised labour requirements for the installation or commissioning the Oil Separation

equipment.

M.2.3 Access Procedures

Ultraspin recommends that only qualified technicians, in accordance with this guide, should service the

Ultraspin Separator and ancillary equipment.

M.2.4 Special Tools for Maintenance

There following special tools are required for the maintenance of this equipment:

• 4” BSM Spanner

M.2.5 List of Consumables Required

There are no consumables required for the installation or commissioning the Oil Separation equipment.

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M.3 TROUBLESHOOTING MATRIX

M.3.1 Ultraspin Separator

No Problem Possible Cause/Problem Suggested Action

1 Low or no Ultraspin reject

(oil/water) flow

Ultraspin reject orifice blocked

Treated water outlet orifice is

missing

Low Pump Flow

Shut system and use de-blocking tool to clear

blockage.

Important: Shut unit off before removing the

reject cap. Replace before restarting.

Replace treated water outlet orifice

See 4.

2 High Ultraspin Reject Flow Ultraspin underflow blocked

Reject O-Ring Seal is missing

Clean water outlet piping is

blocked

Ultraspin inlet head not installed

correctly

Shut system down, unscrew outlet union and

clear blockage, ensuring plastic back-pressure

orifice is replaced.

Shut down system, de-pressurise and replace

liner O-rings.

Clear the Ultraspin clean water outlet pipes

(recycle and discharge lines).

Remove Ultraspin inlet head and re-install

correctly. Check for missing O-rings.

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3 Poor Oil Separation

Performance

Needs a further recycle

Low or no reject flow

Low pump flow

Chemicals, e.g. Detergent or

Glycol, in the pit

Skimmer needs cleaning

Oil collection pit/vessel full

Blockage in the underflow piping

or Ultraspin

Complete another recycle sequence of the

system (i.e. restart Ultraspin).

See 1.

See 4

Pump out, clean and flush pit. Investigate how

these chemicals entered the pit and take

action to prevent further ingress.

Adjust or clean skimmer.

Empty or pump out oil collection vessel.

See 2

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4 Low pump flow

a. Pump operating too

slowly (< 55 beats/min)

b. Pump operation erratic

High pump flow

a. Pump operating too fast

(> 60 beats/min)

Low air supply pressure/volume

Pump regulator pressure

adjusted too low

Blocked pump suction strainer

Blockage in the underflow piping

or Ultraspin

Poor air quality (i.e. wet air)

Other pump problems

Pump not priming

Blocked suction line

Skimmer running dry

Check compressor setting. Check for

blockages or restrictions in air supply lines.

Readjust with pump operating to about 55

beats per min.

Clean Strainer.

See 2.

Check compressor operation and water drains

in air lines.

See Pump manual.

Check for leaks in the strainer lid, skimmer, or

pump suction piping.

Backflush line, check for blockage in skimmer

or hose.

Pit empty (manual control not turned off), Low

level switch failed to shut unit off (see 5.0).

Remove skimmer from obstruction in pit and

rectify to prevent reoccurrence.

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5 Separator not auto starting

Air not turned on

Level switch not functioning

Open air valve or start compressor

Check that nothing (including skimmer) is

obstructing high level float

Check valves (x 2) inside switch box are not

jammed.

6 Separator not auto

stopping

Level switch not functioning Check nothing (including skimmer or built up

silt) is preventing low level ball dropping.

Check valves (x 2) inside switch box are not

jammed.

7 Reset system If the water level is still between

the high and low level floats

when the air supply is isolated

Turn air supply back on (system will start).

Manually push both high and low level floats

down.

This will stop the pump and reset the valve and

timer.

8 No Decant Water Flow

from Oil Tank

No Reject

Oil Tank Water Decant blocked

Oil Tank filling

See1

Clean.

Wait for tank to fill up.

9 Other Consult Ultraspin Contact Ultraspin.

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N HAZARD ANALYSIS

N.1 GENERAL HAZARDS

N.1.1.1 Slipping

Due to nature of product being processed, i.e. oily water effluent, any spillage may cause a slip hazard.

• Any spills should be immediately cleaned using appropriate equipment and footwear.

N.1.1.2 Sudden Expansion

The oil separation process includes pressurised water and effluent lines.

• Before opening any valve/connection for operational needs, be aware of operating conditions and

potential outcomes of such actions.

• Before opening any valve/connection for maintenance purposes, ensure line is depressurised by

isolating upstream/downstream and/or removing source of pressure, i.e. shut down pumps/

compressors and isolate electrically, including tagging. Some residual pressure may be present.

Vent or drain this off or crack valve/connection slowly to relieve pressure in a controlled manner.

• Wear safety glasses when taking samples.

• Open sample point valves slowly.

N.1.1.3 Toxicity

• Care should be taken not to breathe or ingest vapours on liquids.

• Gloves should be worn and spills washed from skin if they occur.

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N.2 PROPRIETARY EQUIPMENT HAZARD

N.2.1 General

The oil separation process includes standard proprietary equipment such as motors, pumps, valves,

instruments, etc., with these being selected to be fit for purpose and being of user industry type.

Operation and maintenance of these items should be carried out per the manufacturer’s

recommendations.

N.2.2 Unauthorized Use

• Unauthorized use of the system by untrained persons may lead to hazardous circumstances.

• Site to be maintained securely so that only authorised personnel gain access.

• Operators to be trained and have access to operation and maintenance manuals.

• Maintenance personnel to carry out work with assistance of operator and with access to operation

and maintenance manuals.

N.2.3 General Safety Procedures

When carrying out electrical and mechanical maintenance, company standard procedures to be

conformed to. This to include but be not limited to:

• wearing correct safety equipment

• locking/tagging of isolated items

• using correct lifting gear

• maintaining item tagging for correct identification

• using an appropriate and relevant permit system

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N.3 PERSONAL PROTECTIVE EQUIPMENT REQUIRED

The steps necessary to protect the health of employees involve the prevention and control of risks

associated with conducting a task. The use of personal protective equipment (PPE) becomes necessary

to protect employees’ health through the use of clothing, face/eye protection, gloves and footwear.

PPE will prevent hazardous substances coming in contact with skin, prevent damage to hearing, prevent

the ingestion or inhalation of substances, and protect personal clothing.

Employees must wear PPE whenever completing a task that involves an identified hazard. Employees

are responsible for maintaining their PPE in good working order and must advise management if damage

has occurred and a replacement is required.

In addition, where specialised equipment is located, additional PPE should be located next to this

equipment.

Task PPE

• Angle grinder Safety glasses and hearing protection (ear plugs)

• Portable or battery drill Safety glasses and hearing protection (ear plugs)

• Testing standard equipment Safety glasses and hearing protection (ear plugs)

• Air compressor operation Hearing protection (ear plugs)

• Equipment assembly Knee pads (where applicable)

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N.1 OPERATING NOISE LEVEL OF ULTRASPIN OS SEPARATOR

The Ultraspin OS Separator is a relatively simple piece of equipment. As such the only moving parts are

the pneumatic pump and pneumatically actuated valve.

Pneumatic air is supplied to drive the air operated diaphragm pump, which exhausts the spent air used to

drive the pump air end. As a result of the pneumatic air being exhausted and reducing in pressure from

around 6 Bar(g) to atmospheric pressure, the expansion of the air over the pump outlet orifice creates

noise. The exhausted air exhausts through a muffler, thereby dampening the noise created.

In addition, the air operated pump itself clicks when the air shuttle changes from side to side. A very

small amount of pneumatic air is also exhausted from the pneumatically actuated valve, and again as this

exits through a silencer, the noise impact is minimal.

Tests within the Ultraspin factory have measured the noise level of an operating OS Separator to

be 75 dB(a) at a distance of 0.5 metres from the pumpJ.which is below the Victorian noise

exposure standard is a level of 85 decibels 'averaged' over an eight-hour period. Therefore,

hearing protection is not required to operate the Ultraspin equipment.

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O AVAILABLE OPTIONS

O.1 AERATION TANK

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O.2 OIL STORAGE AND WATER DECANT TANK FACT SHEET

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O.3 DESANDER MODULE

The Ultraspin M45 de-sander separator is typically used to remove solids from effluent oil waters that collect in a

pit or tank. The separated solids are collected in a tank, while the treated water is discharged to a sewer or

other approved discharge source.

A typical schematic showing the Ultraspin System is shown in the drawing below. The separated solids are

discharged from the bottom of the Ultraspin separator and are sent the collection tank.

Ultraspin Solids Separator

This separator uses the same high strength vortex separation principle except that the

treated water is removed via the hole in the separator end face, while the lesser flow

containing heavier-than-water solids is discharged out the tapered end.

It does not require back flushing and has no moving parts.

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M45 SOLIDS SEPARATOR

S

P

E

C

I

F

I

C

A

T

I

O

N

S

Application Treatment of Water Containing Small Amounts of

Solids

Nom. Feed Flow (l/h) 3,100

Max. Allowable Water Temperature °C 60

Fluid pH 5 – 9

Solids Separator Inlet Pressure (kPa) 350

Typical Discharge Water Pressure (kPa) 100

Typical Max. Discharge Solids Pressure (kPa) 0

Typical Solids Underflow Reject Ratio (solids/feed) 15.7%

Solids Separator Inlet Opening Size 8.0 mm

Solids Separator Water Overflow Size 14.0 mm

Solids Separator Underflow Orifice Size 5.5 mm

Other Inlet and Outlet sample points provided

Solids Slurry Outlet Returned to Primary Pit for Settling and

Retreatment

Treated Water Outlet Treated Water to Process for Reuse

D

I

M

E

N

S

I

O

N

S

Feed Inlet Connection 1½” BSM Nut and Liner

Solids Slurry Outlet Connection 1½” BSP (f) Screwed Connection

Treated Water Outlet Connection 1½” BSP (f) Screwed Connection

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O.4 MANUAL CONTROL

O.4.1 Summary

This function is manually operated by the site operator in response to the level in the collection pit, and does not

require a level switch.

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O.5 SEMI-AUTO OPERATION (SYDNEY WATER KIT)

O.5.1 Summary

Used in Sydney Water controlled areas, and requiring the operator to inspect the pit contents before starting the

Ultraspin Separator and allowing it to then run in auto-recycle mode.

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O.6 OS45 SEPARATOR (HIGHER FLOW SEPARATOR)

S

P

E

C

I

F

I

C

A

T

I

O

N

S

Model No. OS45 Separator

Application Treatment of Water Containing Oil and Suspended Solids

Nom. Flow (L/h) 3,500

(with de-sander option) (L/h) (3,050)

Max. Allowable Water Temperature (°C) 60 o

C

Fluid pH 5 – 9

Max. Discharge Water Pressure (kPa) 150

Max. Discharge Oil Pressure (kPa) 50

Air Usage at 450 kPa (scfm) 32

Typ. Compressor Capacity (scfm)* 42

Required Compressed Air Inlet Pressure 800 kPa

Compressed Air Supply Pipe Size (min) 1” OD Tube

Typical Oily Water Reject Ratio (Ratio of Overflow to Feed)

6.5%

Typical Oil Reject Orifice Size (mm) 4.5

De-sander Inlet Size (mm) 8.0

De-sander Overflow Size (mm) 14.0

De-sander Underflow Size (mm) 5.5

Recycle Timer 90 min

Pump Type Low shear air operated double acting diaphragm pump

1½”

Other Inlet and Outlet sample points provided

D

I

M

E

N

S

I

O

N

S

Height (H mm) 1600

Width (W mm) 400

Length (L mm) 750

Feed Inlet Connection 1½” BSP (f)

Oil Outlet Connection 1½” BSP (m) on the end of a 1” ID hose

Water Outlet Connection 1½” BSP (f)

Solids Outlet Connection 1½” BSP (f)

Shipping Weight (kg) 80

NOTE: Figures quoted are for an 80% efficient piston compressor with a 100% duty cycle (running all the time). When selecting a new compressor, or

appraising the suitability of an existing one, the efficiency, type, duty cycle and general operating demands of the compressor need to be considered. The best

source of information in this regard is a compressor vendor or manufacturer.

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P PROPRIETARY EQUIPMENT DETAIL

P.1 PUMP MANUAL

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�2007 CCN 81660219� (800) 276-4658 � FAX (800) 266-7016

INGERSOLL RAND COMPANY LTDP.O. BOX 151 � ONE ARO CENTER � BRYAN, OHIO 435060151

OPERATOR’S MANUAL 66615X-X-CRELEASED: 5-31-88REVISED: 1-2-07(REV. X)

INCLUDING: OPERATION, INSTALLATION & MAINTENANCE

1-1/2” DIAPHRAGM PUMP1:1 RATIO (METALLIC)

READ THIS MANUAL CAREFULLY BEFORE INSTALLING,OPERATING OR SERVICING THIS EQUIPMENT.

It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.

SERVICE KITS

Refer to the Model Description Chart to match the pump material options.

637118C for air section repair (see page 6).637124XX for fluid section repair (see page 4).637155 Abrasion Resistant Conversion Kit is available for use in heavy

and abrasive material applications (see page 4).

PUMP DATA

Models see �Model Description Chart" for �XXX". . . . . . . . . . . . Pump Type Metallic Air Operated Double Diaphragm. . . . . . . . . Material see �Model Description Chart". . . . . . . . . . . . Weight Aluminum 51.54 lbs (23.4 kgs). . . . . . . . . . . . . . .

Cast Iron 79.54 lbs (36.1 kgs). . . . . . . . . . . . Stainless Steel 84.54 lbs (38.3 kgs). . . . . . . . [add 23 lbs (10.4 kgs) for cast iron air motor section]

Maximum Air Inlet Pressure 120 p.s.i. (8.3 bar). . . . . . . . Maximum Material Inlet Pressure 10 p.s.i. (0.69 bar). . . . Maximum Outlet Pressure 120 p.s.i. (8.3 bar). . . . . . . . . Maximum Flow Rate (flooded inlet) 90 g.p.m. (340.7 l.p.m.). . . . Displacement / Cycle @ 100 p.s.i.g. 0.64 gal. (2.42 lit.). . Maximum Particle Size 1/4" dia. (6.4 mm). . . . . . . . . . . Maximum Temperature Limits (diaphragm / ball / seat material)

Acetal 10� to 180� F (12� to 82� C). . . . . . . . . . . . . . . . . E.P.R. 60� to 280� F (51� to 138� C). . . . . . . . . . . . . . . . . Hytrel� 20� to 150� F (29� to 66� C). . . . . . . . . . . . . . . . Kynar� PVDF 10� to 200� F (12� to 93� C). . . . . . . . . . . Neoprene 0� to 200� F (18� to 93� C). . . . . . . . . . . . . . Nitrile 10� to 180� F (12� to 82� C). . . . . . . . . . . . . . . . . Polypropylene 35� to 150� F (2� to 66� C). . . . . . . . . . . Polyurethane 10� to 150� F (12� to 66� C). . . . . . . . . . . . Teflon� PTFE 40� to 225� F (4� to 107� C). . . . . . . . . . . Santoprene� 40� to 225� F (40� to 107� C). . . . . . . . . . . Viton� 40� to 350� F (40� to 177� C). . . . . . . . . . . . . . . .

Dimensional Data see page 8. . . . . . . . . . . . . . . Noise Level @ 70 p.s.i. 60 c.p.m.� 77.7 dba(A)�. .

� Tested with 93139 muffler assembly installed.� The pump sound pressure levels published here have been updated to an Equivalent

Continuous Sound Level (LAeq) to meet the intent of ANSI S1.131971, CAGIPNEUROP S5.1 using four microphone locations.

NOTICE: All possible options are shown in the chart. However, certaincombinations may not be recommended, consult a representative or thefactory if you have questions concerning availability.

66615XXXXC11/2" DIAPHRAGM PUMP

Figure 1

MODEL DESCRIPTION CHART

6661 X X X X X C

6661XX X X X C

637124 X XDiaphragmBall

FLUID SECTION SERVICE KIT SELECTION

EXAMPLE: MODEL # 666150361CFLUID SECTION SERVICE KIT # 63712461

Seat Material1 Aluminum 4 Kynar PVDF2 316 Stainless Steel 5 Carbon Steel3 Polypropylene 8 440 Stainless Steel

Diaphragm Material1 Neoprene 5 E.P.R.2 Nitrile 9 Hytrel3 Viton B Santoprene4 Teflon PTFE / Santoprene

Center Body Material, Threads5 Aluminum, N.P.T.F. 7 Aluminum, BSP6 Cast Iron, N.P.T.F. 8 Cast Iron, BSP

Fluid Cap / Manifold Material, Hardware(Steel Hardware) (Stainless Steel Hardware)

0 Aluminum A Aluminum1 Stainless Steel B Stainless Steel2 Cast Iron C Cast Iron

Ball Material1 Neoprene 6 Acetal2 Nitrile 8 Polyurethane3 Viton A Stainless Steel4 Teflon PTFE C Hytrel5 E.P.R. E Santoprene

66615XXC (en)Page 2 of 8

OPERATING AND SAFETY PRECAUTIONS

READ, UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.

EXCESSIVE AIR PRESSURESTATIC SPARK

HAZARDOUS MATERIALSHAZARDOUS PRESSURE

WARNING EXCESSIVE AIR PRESSURE. Can cause person

al injury, pump damage or property damage. Do not exceed the maximum inlet air pressure as stated on the

pump model plate. Be sure material hoses and other components are able to with

stand fluid pressures developed by this pump. Check all hosesfor damage or wear. Be certain dispensing device is clean andin proper working condition.

WARNING STATIC SPARK. Can cause explosion resulting in

severe injury or death. Ground pump and pumping system. Sparks can ignite flammable material and vapors. The pumping system and object being sprayed must be

grounded when it is pumping, flushing, recirculating or spraying flammable materials such as paints, solvents, lacquers,etc. or used in a location where surrounding atmosphere isconducive to spontaneous combustion. Ground the dispensing valve or device, containers, hoses and any object to whichmaterial is being pumped.

Use the pump grounding screw terminal provided. Use ARO�part no. 668851 ground kit or connect a suitable ground wire(12 ga. minimum) to a good earth ground source.

Secure pump, connections and all contact points to avoidvibration and generation of contact or static spark.

Consult local building codes and electrical codes for specificgrounding requirements.

After grounding, periodically verify continuity of electrical pathto ground. Test with an ohmmeter from each component (e.g.,hoses, pump, clamps, container, spray gun, etc.) to ground toinsure continuity. Ohmmeter should show 0.1 ohms or less.

Submerse the outlet hose end, dispensing valve or device inthe material being dispensed if possible. (Avoid free streamingof material being dispensed.)

Use hoses incorporating a static wire. Use proper ventilation. Keep inflammables away from heat, open flames and sparks. Keep containers closed when not in use.

WARNING Pump exhaust may contain contaminants. Cancause severe injury. Pipe exhaust away from work area and personnel.

In the event of a diaphragm rupture, material can be forced outof the air exhaust muffler.

Pipe the exhaust to a safe remote location when pumping hazardous or inflammable materials.

Use a grounded 3/4" minimum i.d. hose between the pump andthe muffler.

WARNING HAZARDOUS PRESSURE. Can result in seriousinjury or property damage. Do not service or clean pump,hoses or dispensing valve while the system is pressurized.

Disconnect air supply line and relieve pressure from the system by opening dispensing valve or device and / or carefullyand slowly loosening and removing outlet hose or piping frompump.

WARNING HAZARDOUS MATERIALS. Can cause serious in

jury or property damage. Do not attempt to return a pump to thefactory or service center that contains hazardous material.Safe handling practices must comply with local and nationallaws and safety code requirements.

Obtain Material Safety Data Sheets on all materials from thesupplier for proper handling instructions.

WARNING EXPLOSION HAZARD. Models containing alumi

num wetted parts cannot be used with 1,1,1trichloroethane,methylene chloride or other halogenated hydrocarbon solvents which may react and explode.

Check pump motor section, fluid caps, manifolds and allwetted parts to assure compatibility before using with solventsof this type.

CAUTION Verify the chemical compatibility of the pump

wetted parts and the substance being pumped, flushed or recirculated. Chemical compatibility may change with temperature and concentration of the chemical(s) within thesubstances being pumped, flushed or circulated. For specificfluid compatibility, consult the chemical manufacturer.

CAUTION Maximum temperatures are based on mechani

cal stress only. Certain chemicals will significantly reducemaximum safe operating temperature. Consult the chemicalmanufacturer for chemical compatibility and temperature limits. Refer to PUMP DATA on page 1 of this manual.

CAUTION Be certain all operators of this equipment have

been trained for safe working practices, understand it’s limitations and wear safety goggles / equipment when required.

CAUTION Do not use the pump for the structural support of

the piping system. Be certain the system components areproperly supported to prevent stress on the pump parts.

Suction and discharge connections should be flexible connections (such as hose), not rigid piped, and should be compatiblewith the substance being pumped.

CAUTION Prevent unnecessary damage to the pump. Do

not allow pump to operate when out of material for long periodsof time.

Disconnect air line from pump when system sits idle for longperiods of time.

CAUTION Use only genuine ARO replacement parts to as

sure compatible pressure rating and longest service life.

NOTICE Replacement warning labels are available upon

request: �Static Spark" (936161) & �Diaphragm Rupture"(93122).

WARNING

CAUTION

NOTICE

= Hazards or unsafe practices which couldresult in severe personal injury, death orsubstantial property damage.

= Hazards or unsafe practices which couldresult in minor personal injury, product orproperty damage.

= Important installation, operation or maintenance information.

Page 3 of 866615XXC (en)

GENERAL DESCRIPTION

The ARO diaphragm pump offers high volume delivery even at low airpressure and a broad range of material compatibility options available.Refer to the model and option chart. ARO pumps feature stall resistantdesign, modular air motor / fluid sections.Air operated double diaphragm pumps utilize a pressure differential inthe air chambers to alternately create suction and positive fluid pressurein the fluid chambers, valve checks insure a positive flow of fluid.Pump cycling will begin as air pressure is applied and it will continue topump and keep up with the demand. It will build and maintain line pressure and will stop cycling once maximum line pressure is reached (dispensing device closed) and will resume pumping as needed.

AIR AND LUBE REQUIREMENTS

WARNING EXCESSIVE AIR PRESSURE. Can cause pump

damage, personal injury or property damage. A filter capable of filtering out particles larger than 50 microns should

be used on the air supply. There is no lubrication required other thanthe �O" ring lubricant which is applied during assembly or repair.

If lubricated air is present, make sure that it is compatible with the �O"rings and seals in the air motor section of the pump.

OPERATING INSTRUCTIONS

Always flush the pump with a solvent compatible with the materialbeing pumped if the material being pumped is subject to �setting up"when not in use for a period of time.

Disconnect the air supply from the pump if it is to be inactive for a fewhours.

The outlet material volume is governed not only by the air supply, butalso by the material supply available at the inlet. The material supplytubing should not be too small or restrictive. Be sure not to use hosewhich might collapse.

When the diaphragm pump is used in a forcedfeed (flooded inlet)situation, it is recommended that a �Check Valve" be installed at theair inlet.

Secure the diaphragm pump legs to a suitable surface to insureagainst damage by vibration.

MAINTENANCE

Refer to the part views and descriptions as provided on pages 4 through7 for parts identification and service kit information. Certain ARO �Smart Parts" are indicated which should be available

for fast repair and reduction of down time. Service kits are divided to service two separate diaphragm pump

functions: 1. AIR SECTION, 2. FLUID SECTION. The FLUID SECTION is divided further to match typical part MATERIAL OPTIONS.

Provide a clean work surface to protect sensitive internal movingparts from contamination from dirt and foreign matter during servicedisassembly and reassembly.

Keep good records of service activity and include pump in preventive maintenance program.

Before disassembling, empty captured material in the outlet manifold by turning the pump upside down to drain material from thepump.

FLUID SECTION DISASSEMBLY

1. Remove top manifold(s).2. Remove (22) balls, (19) �O" rings and (21) seats.3. Remove (15) fluid caps.NOTE: Only Teflon diaphragm models use a primary diaphragm (7) anda backup diaphragm (8). Refer to the auxiliary view in the Fluid Sectionillustration.4. Remove the (14) screws, (6) washers, (7) or (7 / 8) diaphragms and

(5) washers.5. Remove (3) �O" rings.NOTE: Do not scratch or mar the surface of (1) diaphragm rod.

FLUID SECTION REASSEMBLY

Reassemble in reverse order. Clean and inspect all parts. Replace worn or damaged parts with

new parts as required. Lubricate (1) diaphragm rod and (2) �O" ring with KeyLube �O" ring

lube. Use ARO pn / 98931T bullet (installation tool) to aid in installation of

(2) �O" ring on (1) diaphragm rod. Be certain (7) or (7 / 8) diaphragm(s) align properly with (15) fluid

caps before making final torque adjustments on bolt and nuts toavoid twisting the diaphragm.

For models with Teflon diaphragms: Item (8) Santoprene diaphragmis installed with the side marked �AIR SIDE" towards the pump center body. Install the Teflon diaphragm with the side marked �FLUIDSIDE" towards the fluid cap.

Recheck torque settings after pump has been restarted and run awhile.

Viton�, Teflon� and Hytrel� are trademarks of the DuPont Company Kynar� is a trademark of Arkema Inc. Loctite� is a registered trademark of Henkel Loctite Corporation Santoprene� is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. ARO� is a registered trademark of IngersollRand Company

MATERIAL CODE

[A] = Aluminum[B] = Nitrile[C] = Carbon Steel[CI] = Cast Iron[Co] = Copper[D] = Acetal[E] = E.P.R.[H] = Hytrel[K] = Kynar PVDF[N] = Neoprene[P] = Polypropylene[SH] = Hard Stainless Steel[Sp] = Santoprene[SS] = Stainless Steel[T] = Teflon PTFE[U] = Polyurethane[V] = Viton

637155ABRASION RESISTANT

CONVERSION KIT

Includes:93266 (4) [SH] Seat927578 (4) [U] Ball

Service Note: Part no. 98931T installation tool is available separately for use with items 1 and 2.� �Smart Parts", keep these items on hand in addition to the service kits for fast repair and reduction of down time.


PARTS LIST / 66615X-X-C FLUID SECTION

� 637124XX Fluid Section Service Kits include: BALLS (see Ball Option, refer to XX in chart below), DIAPHRAGMS (see Diaphragm Option, refer to XXin chart below), 937061 KeyLube grease packet, plus items: 2, 3, 9 and 19.

SEAT OPTIONS BALL OPTIONS

�21" � �22" (13/4" dia.)

XXX Seat Qty [Mtl] XXX Ball Qty [Mtl] XXX Ball Qty [Mtl]

1XX 92760 (4) [A] X1X 927571 (4) [N] X8X 927578 (4) [U]

2XX 92776 (4) [SS] X2X 927572 (4) [B] XAX 94804 (4) [SS]

3XX 92924 (4) [P] X3X 927573 (4) [V] XCX 92757C (4) [H]

4XX 94514 (4) [K] X4X 927574 (4) [T] XEX 92757A (4) [Sp]

5XX 95676 (4) [C] X5X 927575 (4) [E]

8XX 93266 (4) [SH] X6X 927576 (4) [D]

DIAPHRAGM OPTIONS

� Service Kit � �7" � �8" � �3" (1/16" x 3/4" o.d.) � �19" (1/8" x 23/4" o.d.)

XXXXX = (Ball)XX = (Diaphragm) Diaphragm Qty [Mtl] Diaphragm Qty [Mtl] �O" Ring Qty [Mtl] �O" Ring Qty [Mtl]

XX1 637124X1 927551 (2) [N] −−−−− −−− −−− Y32516 (4) [B] Y325230 (4) [B]

XX2 637124X2 94615G (2) [B] −−−−− −−− −−− Y32516 (4) [B] Y325230 (4) [B]

XX3 637124X3 927553 (2) [V] −−−−− −−− −−− Y32816 (4) [T] Y327230 (4) [V]

XX4 637124X4 94617 (2) [T] 94616 (2) [Sp] Y32816 (4) [T] Y220230 (4) [T]

XX5 637124X5 927555 (2) [E] −−−−− −−− −−− Y32816 (4) [T] 92761 (4) [E]

XX9 637124X9 946159 (2) [H] −−−−− −−− −−− Y32816 (4) [T] Y327230 (4) [V]

XXB 637124XB 94615A (2) [Sp] −−−−− −−− −−− Y32816 (4) [T] 92761 (4) [E]

WETTED PARTS OPTIONSAluminum Stainless Steel Cast Iron

6661X0X, 6661XAX 6661X1X, 6661XBX 6661X2X, 6661XCX

N.P.T.F. BSP N.P.T.F. BSP N.P.T.F. BSP

Item Description (size) Qty Part No. Part No. [Mtl] Part No. Part No. [Mtl] Part No. Part No. [Mtl]

15 Fluid Cap (2) 92750 92750 [A] 92773 92773 [SS] 92778 92778 [CI]

16 Manifold (2) 92749 927491 [A] 92774 927741 [SS] 92777 927771 [CI]

HARDWARE OPTIONSCarbon Steel Stainless Steel

6661X0, 1, 2 6661XA, B, C

Item Description (size) Qty Part No. [Mtl] Part No. [Mtl]

5 Plate (air side) (2) 92752 [C] 92775 [SS]

26 Bolt (3/8" 16 x 11/4") (8) Y666C [C] Y666T [SS]

27 Bolt (5/16" 18 x 21/4") (4) Y6510C [C] Y6510T [SS]

29 Nut (5/16" 18) (20) Y125C [C] Y125S [SS]

32 Leg (2) 92759 [C] 927591 [SS]

59 Bolt (5/16" 18 x 2") (16) 93608 [C] Y659T [SS]

COMMON PARTSItem Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]

� 1 Rod (1) 987201 [C]

� 2 �O" Ring (3/32" x 1" o.d.) (1) Y330117 [B]

� 6 Plate (fluid side) (2) 92775 [SS]

(models 6661X0 only) (2) 92752 [C]

� 9 Washer (0.630" i.d.) (2) 93065 [SS]

14 Screw (5/8" 18 x 11/2") (2) Y5107T [SS]

43 Ground Lug (see page 7) (1) 93004 [Co]


PARTS LIST / 66615X-X-C FLUID SECTION

1

29 �

FOR THEAIR MOTOR SECTION

SEE PAGES 6 & 7

� TORQUE REQUIREMENTS �NOTE: DO NOT OVERTIGHTEN FASTENERS.

(14) Diaphragm screw, 65 70 ft lbs (88.1 94.9 Nm.).(26) Bolts, 120 140 in. lbs (13.6 15.8 Nm).(29) nuts, 120 140 in. lbs (13.6 15.8 Nm).

LUBRICATION / SEALANTS� Apply KeyLube to all �O" rings, �U" Cups & mating parts.� Apply Loctite� 271 to threads. Apply antiseize compound to threads and bolt and nut

flange heads which contact pump case when using stainless steel fasteners.

View for 6661XXXX4C (Teflon diaphragm) configuration only.

Tab

7 � 3

COLOR CODEDiaphragm Ball

Material Color Color

Acetal N / A OrangeE.P.R. Blue (−) Blue ()Hytrel Cream CreamNeoprene Green (−) Green ()Nitrile Black Red ()Santoprene Tan* TanTeflon PTFE White WhitePolyurethane N / A RedViton Yellow (−) Yellow ()

(−) Stripe () Dot

* See item 8 in inset below.

21

19 �

22

26 �

16

59

15

22

21

19 �

16

27

32

14 � �96

5

2 �

Tab

7 Teflon

(white)

Santoprene 8(Green when used as backer)

AirSide

FluidSide

FluidSide

AirSide

Cross Section View of Diaphragms

5

7

2

3

4

1

8

6

Torque Sequence

10 9

3 �

26 �

Figure 2


PARTS LIST / 66615X-X-C AIR SECTION

� Indicates parts included in 637118C Air Section Service Kit.SERVICE KIT NOTE: Service Kit 637118C is a general repair kit for all 1" and larger ARO diaphragm pump air motors. It contains extra �O" rings and

extra parts that may not be needed to service this model.

Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]

101 Motor Body (66615XX, 66617XX) (1) 94744 [A]

(66616XX, 66618XX) (1) 94742 [CI]

� 102 �O" Ring (1/16" x 11/4" o.d.) (2) Y32524 [B]

� 103 Sleeve (1) 94528 [D]

� 104 Retaining Ring, TruArc (15/32" i.d.) (2) Y14526 [C]

105 Screw / Lockwasher (1/4" 20 x 5/8")

(models 6661X0X, 6661X1X, 6661X2X)

(8) 93860 [C]

Cap Screw (1/4" 20 x 5/8") (models

6661XAX, 6661XBX, 6661X5CX)

(8) Y642T [SS]

106 Lockwasher (1/4") (models 6661XAX,

6661XBX, 6661XCX only)

(8) Y14416T [SS]

107 Plate (2) 937071 [SS]

� 108 Gasket (with notch) (1) 92878 [B/Ny]

� 109 Piston (1) 92011 [D]

� 110 �U" Cup (3/16" x 13/8" o.d.) (1) Y18651 [B]

� 111 Spool (models 66615XX, 66617XX) (1) 92005 [A]

(models 66616XX, 66618XX) (1) 93047 [C]

� 112 Washer (1.557" o.d.) (5) 92877 [Z]

� 113 �O" Ring (small) (1/8" x 11/4" o.d.) (5) Y325214 [B]

� 114 �O" Ring (large) (3/32" x 19/16" o.d.) (6) Y325126 [B]

� 115 Spacer (4) 92876 [Z]

� 116 Spacer (1) 92006 [Z]

� 117 Gasket (1) 92004 [B/Ny]

118 Pilot Rod (1) 933092 [C]

� 119 �O" Ring (1/8" x 3/4" o.d.) (4) 93075 [U]

120 Spacer (3) 115959 [Z]

121 Sleeve Bushing (2) 987232 [Bz]

� 122 �O" Ring (3/32" x 9/16" o.d.) (2) 94820 [U]

� 123 Screw (#8 32 x 3/8") (4) Y15441 [C]

126 Pipe Plug (1/2 14 P.T.F. x 17/32") (1) Y2275L [C]

127 90� Street Elbow (3/4 14 N.P.T.) (1) Y435C [C]

128 Pipe Plug (1/8 27 P.T.F. x 1/4") (1) Y2272L [C]

197 Button Head Screw (1/4" 20 x 1/4") (2) 94987 [SS]

198 Button Head Screw (1/4" 20 x 3/8") (1) 949871 [SS]

201 Muffler (1) 350568

231 Pipe Plug (1/4 18 N.P.T. x 0.41") (models

66616XX and 66618XX only)

(2) Y1751S [SS]

� KeyLube �O" Ring Lubricant (1) 937061

10 Pak of KeyLube (10) 637175

� Service Kits include: Y212101 (2) Screws (#10 32 x 1/4") used on units mf’d be

tween 8/90 and 4/92 to retain the pilot bushing.

AIR MOTOR SECTION SERVICE

Service is divided into two parts − 1. Pilot Valve, 2. Major Valve.GENERAL REASSEMBLY NOTES: Air Motor Section Service is continued from Fluid Section repair. Inspect and replace old parts with new parts as necessary. Look for

deep scratches on metallic surfaces, and nicks or cuts in �O" rings. Take precautions to prevent cutting �O" rings upon installation. Lubricate �O" rings with KeyLube. Do not overtighten fasteners, refer to torque specification block on

view. Retorque fasteners following restart.

PILOT VALVE DISASSEMBLY

1. Remove (104) retaining ring.2. Remove (123) screws and (122) �O" rings.3. Remove (118) piston rod, (121) sleeve bushing, (119) �O" rings and

(120) spacers from the (101) motor body.4. Remove (103) sleeve and (102) �O" rings.

PILOT VALVE REASSEMBLY

1. Replace two (102) �O" rings if worn or damaged and reinstall (103)sleeve.

2. Install one of the (121) sleeve bushings, (119) �O" rings, (120)spacers and the remaining (121) bushing.

3. Carefully push (118) pilot rod into bushings etc. and retain on eachend with the two (122) �O" rings, retain with (123) screws.

4. Replace (104) retaining rings.

MATERIAL CODE[A] = Aluminum [CI] = Cast Iron [SS] = Stainless Steel[B] = Nitrile [D] = Acetal [U] = Polyurethane[Bz] = Bronze [Ny] = Nylon [Z] = Zinc[C] = Carbon Steel

MAJOR VALVE DISASSEMBLY

1. Remove (107) plate (or leg depending on model), (108 and 117)gaskets.

2. On the side opposite the air inlet, push on the inner diameter of (111)spool. This will force the (109) piston out. Continue pushing the (111)spool and remove. Check for scratches and gouges.

3. Reach into the air section (exhaust side) and remove (116) spacer,(115) spacers, (113) �O" rings, (114) �O" rings, (112) washers, etc.Check for damaged �O" rings.

MAJOR VALVE REASSEMBLY

1. Replace (112) washer, (114) �O" ring and (113) �O" ring onto (115)spacer and insert etc.NOTE: Be careful to orient spacer legs away from blocking internal ports.

2. Lubricate and carefully insert (111) spool.3. Install (117) gasket and (107).4. Lubricate and install (110) packing cup and insert (109) piston into

(air inlet side) cavity, the (110) packing cup lips should point outward.5. Install (108) gasket and replace (107).

� �Smart Parts", keep these items on hand in addition to the service kits for fast repair and reduction of down time.


PARTS LIST / 66615X-X-C AIR SECTION

MAJOR VALVE

PILOT VALVE

118 �

111

112

� 113

� 114

115 116

117

119 �

102 �

104

123 �

121

122 �

120

108

109

� 110

106

� 105

� TORQUE REQUIREMENTS �NOTE: DO NOT OVERTIGHTEN FASTENERS.

(105) 40 50 in. lbs (4.5 5.6 Nm).

LUBRICATION / SEALANTS� Apply KeyLube to all �O" rings, �U" Cups & mating parts.� Apply Loctite 262 to threads.� Apply Loctite 271 to threads. Apply Loctite 572 to threads.

See cross section detail, figure 4.

128

MAJOR VALVE CROSS SECTION DETAIL

109 110 � 112 114 � 113 � 115 111 116

Figure 4

107126

IMPORTANTBE CERTAIN TO ORIENT (115) SPACER LEGSAWAY FROM BLOCKING INTERNAL PORTS

WHEN REASSEMBLING AIR SECTION.

197 �

� 198

101

231

104

103 �

107

106

105 �

� 123

121

� 197

43

201

127

Figure 3


TROUBLE SHOOTING

Product discharged from exhaust outlet. Check for diaphragm rupture. Check tightness of (14) diaphragm screw.

Air bubbles in product discharge. Check connections of suction plumbing. Check �O" rings between intake manifold and fluid caps. Check tightness of (14) diaphragm screw.

Low output volume, erratic flow or no flow. Check air supply. Check for plugged outlet hose. Check for kinked (restrictive) outlet material hose. Check for kinked (restrictive) or collapsed inlet material hose. Check for pump cavitation suction pipe should be sized at least as

large as the inlet thread diameter of the pump for proper flow if highviscosity fluids are being pumped. Suction hose must be a noncollapsing type, capable of pulling a high vacuum.

Check all joints on the inlet manifolds and suction connections.These must be air tight.

Inspect the pump for solid objects lodged in the diaphragm chamberor the seat area.

DIMENSIONAL DATA

(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).

111/2" (292 mm)

195/8"(498 mm)

183/8"(467 mm)

131/8" (333 mm)

113/4" (298 mm)

23/4"(70 mm)

9" (229 mm)

1/2" Slot (14 mm)

Material Outlet11/2 111/2 N.P.T.F. 1 (66615XXC, 66616XXC)

Rp 11/2 (11/2 11 BSP parallel) (66617XXC, 66618XXC)

Figure 5

75/8"(194 mm)

123/4" (324 mm)

Material Inlet11/2 111/2 N.P.T.F. 1 (66615XXC, 66616XXC)

Rp 11/2 (11/2 11 BSP parallel) (66617XXC, 66618XXC)

Air Inlet1/2 14 N.P.T.F. 1

Air Exhaust Thread3/4 14 N.P.T.F. 1

1413/16" (376 mm)

PN 9799996

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