Consilium Salwico SW2020 User Manual
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Consilium Salwico SW2020 User Manual

Consilium Salwico SW2020 User Manual

Gas sampling system
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Gas Sampling System
Salwico SW2020
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Summary of Contents for Consilium Salwico SW2020

  • Page 1 Gas Sampling System Salwico SW2020 User Manual çConsilium...
  • Page 2 The contents of this document are subject to revision without notice due to continued progress in methodology, design and manufacturing. Consilium assumes no legal responsibility for any error or damage resulting from the usage of this document. Consilium Marine & Safety AB P.O.

  • Page 3: Table Of Contents

    Contents GENERAL INFORMATION 1.1 DESCRIPTION OF THE SYSTEM 1.2 GENERAL BLOCK DIAGRAM INSTALLATION 2.1 CONTROL UNIT 2.2 ANALYZING UNIT 2.3 REPEATER UNIT - MN400 2.4 PIPE SYSTEM 2.5 FLAME TRAPS 2.6 MANUAL SHUT-OFF VALVES 2.7 SAMPLING PIPE ACCESSORIES 2.8 SAMPLING POINTS 2.9 OPTIONS 2.10 ELECTRICAL CONNECTION 2.11 COMMISSIONING DOCUMENTS...

  • Page 4: General Information

    Salwico SW2020 General Information 1. GENERAL INFORMATION...
  • Page 5 Salwico SW2020 General Information...

  • Page 6: Description Of The System

    Salwico SW2020 General Information 1.1 DESCRIPTION OF THE SYSTEM The SW2020 Gas Sampling System is an automatically A test gas cylinder is connected to or built into the system scanning Gas Sampling System permanent installed for for calibration of the gas detectors.

  • Page 7: General Block Diagram

    Salwico SW2020 General Information GENERAL BLOCK DIAGRAM Conceptual drawing REPEATER UNIT CONTROL UNIT ALTERNATIVE: TWO SEPARATE WALL MOUNTED CABINETS OR ONE SINGLE CABINET ANALYSING UNIT MEASURING POINT INSIDE ANALYSING UNIT (Testgas connection is located inside the cabinet) S-4-005.285/E...

  • Page 8: Installation

    Salwico SW2020 Installation 2. INSTALLATION...

  • Page 9: Control Unit

    Salwico SW2020 Installation 2.1 CONTROL UNIT DETECTOR The control unit is the man-machine interface and controls the electronics in the analysing unit. It consist of a LCD clear text Display, LED Display, LED's, keyboard, microprocessor and memory for the software, definitions, additional texts etc.

  • Page 10: Analyzing Unit

    Salwico SW2020 Installation 2.2 ANALYSING UNIT The analysing unit contains all functions for detection and transport of the test samples. Its components comprise: gas detectors, solenoid valves, sampling and transport pump, flame traps, flow meter, remote I/O - PCB-boards, power...
  • Page 11 Salwico SW2020 Installation 2.2.1 PIPE CONNECTIONS Suction Pipes The sampling pipes from the manual shut-off valves are connected to the pre- mounted and numbered flame trap on the side of the analysing unit by means of the stainless steel connection nipples on the flame traps.

  • Page 12: Repeater Unit - Mn400

    Salwico SW2020 Installation 2.3 REPEATER UNIT - MN400 The function of the LCD repeater units is to indicate alarms and faults to the duty watch personnel. The unit is designed for wall or panel mounting and should first of all be placed on the bridge in a well visible and easily accessible location.

  • Page 13: Pipe System

    Salwico SW2020 Installation 2.4 PIPE SYSTEM The pipe system transports the test samples from the sampling points to the analysing unit. In addition to the piping, the system includes: shut-off valves, flame traps, pipe couplings, sleeves, filters and pipe terminations.
  • Page 14 Salwico SW2020 Installation 2.4.4 BENDING OF SAMPLING PIPES In order to avoid unnecessary air resistance in the sampling pipes and risk of deformation and the formation of fractures, a minimum bending radius of approx. 150 mm is recommended. Refer to separate instructions for installation of other components of the pipe system.
  • Page 15 Salwico SW2020 Installation SHUT-OFF VALVES...
  • Page 16 Salwico SW2020 Installation DECK BULKHEAD PASSAGE...
  • Page 17 Salwico SW2020 Installation SUSPENSION & FIXING CLAMP FOR PIPE on the deck/deckhouse "JIRVA" PIPE FITTING CLAMP FOR PIPE in the pipe tunnel/ cofferdams etc. ALTERNATIVE: PIPE PIPE PIPE...
  • Page 18 Salwico SW2020 Installation PIPE INSTALLATION EXAMPLE...

  • Page 19: Flame Traps

    Salwico SW2020 Installation 2.5 FLAME TRAPS The flame traps are normally supplied fitted to the analysing unit. Refer to the installation instructions for the analysing unit in this chapter for pipe connection instructions. NB! The flame trap must be of an approved type.

  • Page 20: Manual Shut-Off Valves

    Salwico SW2020 Installation 2.6 MANUAL SHUT-OFF VALVES The task of the manual shut-off valves is, where necessary, to shut off the pipe system in an explosion risk zone from the system in a safe zone. This may occur when a certain sampling area has a temporary high gas concentration or is filled with inert gas.

  • Page 21: Sampling Pipe Accessories

    Salwico SW2020 Installation 2.7 SAMPLING PIPE ACCESSORIES 2.7.1 FILTERS Each individual sampling pipe should be protected with filters in order to avoid fouling of both the pipes themselves as well as flame traps, valves, flow meter and detector. Two types of filters have been developed for this purpose: •...
  • Page 22 Salwico SW2020 Installation End-Line Filter The end-line filter should always be fitted at a sampling point where it is practically feasible with regard to accessibility for future replacement. This is in order to ensure that as much of the pipe system as possible is protected.
  • Page 23 Salwico SW2020 Installation 2.7.2 OPTIONS Water Separator In certain sampling points there may be risks that small accumulations of ”splash” water will be sucked into the sampling tubes and thus preventing sampling from a low placed sampling point. The fitting of a special pipe termination section with a small hole, in correct relation to the suction inlet end and at a right distance above the pipe, prevents suction in this case.

  • Page 24: Sampling Points

    Each sampling pipe must be marked with its number at the sampling point as well as the manual shut-off valve. (Each sampling point is numbered at the flame trap on the analysing unit.) Salwico SW2020 has one sampling point for internal monitoring of the analysing cabinet, normally the last sampling point.

  • Page 25: Options

    The counter pressure system, when supplied, is built into the Salwico SW2020 system. The operation of the counter pressure system is based on compressed...
  • Page 26 Salwico SW2020 Installation Installation of cone (option) MANUFACTURED BY CONSILIUM...

  • Page 27: Electrical Connection

    Salwico SW2020 Installation 2.10 Electrical Connections External connections ANALYSING UNIT SYSTEM FAILURE GAS WARNING GAS ALARM (ALARM 1) (ALARM 2) NORM. ACT. NORM. ACT. RESET WHEN RESET WHEN RESET WHEN RESET WHEN RESET WHEN RESET WHEN WARNING WARNING ALARM ALARM FAIL.
  • Page 28 Salwico SW2020 Installation 2.11 COMMISSION DOCUMENTS...
  • Page 29 Salwico SW2020 Installation GAS SAMPLING SYSTEM SW2020, COMMISSIONING SET-UP Ref no: SG- Yard: Hull no: Start up time: Alarm delay time: Date: ALARM LEVELS Det #1: Det#2: High High Det #3: Det#4: High High SAMPLING POINTS SET-UP POINT NO LOCATION DISTANCE SAMPL.
  • Page 30 Salwico SW2020 Installation Salwico SW2020 Gas Sampling System. Commissioning record. To be used and filled in with signature by the personnel in charge of the installation. Shipyard / Installation Company: Hull No: Ref.no: Fill in Description / Task / Check Sign./ Date:...

  • Page 31: Operation

    Salwico SW2020 Operation 3. OPERATION...

  • Page 32: General Principles

    Salwico SW2020 Operation ALARM SAMPLING POINT LEVEL DETECTOR FAULT 3.1 GENERAL PRINCIPLES The Control Unit of the SW2020 Gas Sampling System is divided into two separate parts. The left-hand side consists of only three keys: ALARM MUTE, ALARM RESET and ALARM IN QUEUE.
  • Page 33 Salwico SW2020 Operation HOME Go to the standby menu.  List the next list entry. The LED is lit when the button is active.  List the previous list entry. The LED is lit when the button is active. Pg ...

  • Page 34: Display Modes

    Salwico SW2020 Operation 3.2 DISPLAY MODES 3.2.1 NORMAL MODE The control unit is in standby mode most of the time. The display below shows that the measurement sequence is running. The system always displays the last measurement. ** RUNNING ** <12:01:54>...
  • Page 35 Salwico SW2020 Operation 3.2.3 MEASUREMENT RANGES Each type of gas detector has its own defined measurement range. See List of recommended gas detectors in chapter 4.7. An under-range indication is marked with a (-) sign after the displayed value. An over-range indication is marked with a (+) sign after the displayed value.
  • Page 36 Salwico SW2020 Operation Moisture fault (option). 10. Fault compressed instrument air. Indicates that the pressure from the pressure regulator is below 2.8 Bar.
  • Page 37 Salwico SW2020 Operation 11. Power fault (Option). As indicated if there are two independent power supplies and one fails. 12. Flow fault on SP#. Indicates a flow fault on the SP listed. Before indication of a flow fault the automatic pipe cleaning function first attempt to remove the cause of the flow fault by flushing the sampling pipe during two minutes and then tries to obtain a new sample.
  • Page 38 Salwico SW2020 Operation 3.3 LISTS All operations required by the average user can be performed from the four lists in the system. 3.3.1 ALARM LIST The left-hand side of the control unit always displays the sampling point in alarm (1- 60) and the alarm level (Hi or Low).
  • Page 39 Salwico SW2020 Operation 3.3.2.1 Fault codes The following faults can be detected. See section C, part 3.7, for a more thorough explanation of the fault codes Analyse pump, flow failure Presuction pump, flow failure Analyse Pump or Internal Leakage Calibration...
  • Page 40 Salwico SW2020 Operation 3.3.3 SAMPLING POINT LIST Press LIST SAMPLING POINTS to enter the Sampling Point List. Select a sampling point with the arrow keys (sampling point 5 is selected in the example below) and then use the function keys to perform an action.
  • Page 41 Salwico SW2020 Operation 3.3.3.1 IG Mode (option) IG (Inhibit Gas-Alarm) Mode is a type of disconnection used for areas where high contamination levels are expected. The detectors inhibited from giving alarm in IG Mode are configured on delivery. IG Mode is typically used for measuring gas levels in tanks with inert gas. In this case, for instance O2-detectors are inhibited from generating alarms when the sampling point is in IG Mode.
  • Page 42 Salwico SW2020 Operation Sampling points belonging to a group can still be disconnected or reconnected individually, this makes the situation below valid since the SP’s in a group can have mixed disconnection status. ** GROUP 1(3) ** Grp1: STB Water ballast tanks, SP 1-8 RECONNECT DISCONNECT 3.3.4 DISCONNECTIONS LIST...

  • Page 43: Setup - General Settings

    Salwico SW2020 Operation 3.4 SETUP – GENERAL SETTINGS The system changes the access level and enters CONFIGURATION MODE when the correct access code for level 2, 3 or 4 is entered. The system will not start until the user chooses to start the system again (the access level is automatically changed back to 1) or the user timeout expires after 30 minutes.
  • Page 44 Salwico SW2020 Operation Change the date (4) Enter the date (YYYYMMDD) and push ↵. The result is displayed on row 3. (4) Change the date Current: 19970101 New: Enter a new date ..(YYYYMMDD) Change LED intensity Enter a new intensity and then push ↵ to change the intensity of the LED’s.
  • Page 45 Salwico SW2020 Operation Check the valves for internal leakage (10) Push F1 to check the system (valves and connections) for internal leakage. (10) Start checking the valves Status: ABORTED START STOP 3.4.2 GENERAL SETTINGS - ACCESS LEVEL 2 Restart the system, save current setup (11) Push F1 to restart the sampling sequence.
  • Page 46 Salwico SW2020 Operation 3.4.2.1 Span and zero calibration of gas detectors Calibrate span on a gas detector (13) Gas detectors must be adapted and calibrated to the system on the A/D inputs with two different gas concentrations: Zero and a Span gas value determined by the user (the span gas value must be in the area 25-100% off the highest measurement for the gas detector).
  • Page 47 Salwico SW2020 Operation Select one detector (1-4) to calibrate by entering a numeric input and ↵. Push F1 to continue. (13a) Calibrate span on a gas detector Current: (1)CxHy New: Enter detector no (1 - no of detectors) CONTINUE Enter the concentration of the span-gas. Push F1 to continue. Note that the procedure for calibrating span for Oxygen will differ.
  • Page 48 Salwico SW2020 Operation Adjust zero on a gas detector (14) Calibration of zero in the system on the A7D inputs for a gas detector is done with air from the fresh air inlet (except for O2, described separately below). (14a) Adjust zero on a gas detector...
  • Page 49 Salwico SW2020 Operation Adjust zero on an O detector (14) Calibration of zero on an O detector is done with Nitrogen (N ) from the test gas bottle. (14a) Adjust zero on a gas detector Current: (1)CxHy New: Enter detector no (1 – no of detectors) CONTINUE Select the O2 detector to calibrate by entering a numeric input (1-4) and ↵.
  • Page 50 Salwico SW2020 Operation 3.4.2.2 Calibration procedure for gas detectors with 4-20 mA output signal. Gas detectors of type Optima Plus and GD10: These types of detectors are factory calibrated. They have a continuous self-test function and report dirty optics and fault by setting the output signal:...
  • Page 51 Salwico SW2020 Operation Examples: Oxygen detector, range 0-25 %: Calibration gas: normal air: => 20,9 % O2 => 16/25 x 20,9 + 4 = 17,4 mA Hydrogen sulphide detector, range 0-25 ppm: Calibration gas: 20 ppm H2S: => 16/25 x 20 + 4 = 16,8 mA Hydrogen sulphide detector range 0-30 ppm.
  • Page 52 Salwico SW2020 Operation 3.4.3 GENERAL SETTINGS - ACCESS LEVEL 3 Change the start-up time (17) Change the current start-up time with a numeric input and ↵. The start-up time determines how long the SW2020 will wait after power-on before starting the sampling sequence (to allow warm-up of gas detectors).
  • Page 53 Salwico SW2020 Operation Same alarm level all SPs (20) Change the current alarm level for all sampling points. Observe that alarm levels for individual measurement points will be lost. Choose a gas detector with a numeric input and ↵. Continue with F1.

  • Page 54: Setup - Sampling Points

    Salwico SW2020 Operation 3.5 SETUP - SAMPLING POINTS (ACCESS LEVEL 2) Push SETUP - Sampling Points and then use the Arrow Keys to choose the sampling point (or group) to configure. Access level 2 is required to enter the Sampling Points Setup.
  • Page 55 Salwico SW2020 Operation Change the alarm levels for a detector (ALARM LVL) Push F2 to change the alarm level. Choose a detector with a numeric input and ↵. Push F1 to continue. Sp3: Water ballast tank 2 STB Current: (1)CxHy...
  • Page 56 Salwico SW2020 Operation 3.5.2 CONFIGURING A GROUP If a number of groups are configured in the system (see 3.4.), they will be present in the Sampling Point List. Use the Arrow Keys to select a Group. ** GROUP SETUP 3(3) **...
  • Page 57 Salwico SW2020 Operation 3.6 THE MINI REPEATER UNIT – MN400 Figure 3: The Mini Repeater - MN400 The Man Machine Interface • Gas alarms are shown on the Mini Repeater. - The previous and next alarms (if any) can be listed with the Arrow Keys.

  • Page 58: Guidelines For Daily Handling

    Salwico SW2020 Operation 3.7 GUIDE LINES FOR DAILY HANDLING Important notes: The Pressure Air to the system must never be shut off! The manual shut-off valves shall remain open during normal operation and when there is water in the Water Ballast Tanks. This will keep the Counter-pressure-air flow and avoid water entering the pipes.

  • Page 59: Technical Data

    Salwico SW2020 Technical Data 4.TECHNICAL DATA...

  • Page 60: Internal Connection

    Salwico SW2020 Technical Data 4.1 INTERNAL CONNECTION...
  • Page 61 Salwico SW2020 Technical Data 4.2 INTERNAL CONNECTIONS ON RIOK-40 AND RIOK-41 Analogue inputs on RIOK-40 Input Terminal Description 19-20 Gas Detector 1 21-22 Detector 2 (option) 23-24 Detector 3 (option) 25-26 Detector 4 (option) Digital inputs on RIOK-40 Input Terminal...
  • Page 62 Salwico SW2020 Technical Data Outputs on RIOK-41´s Output Terminal Position Description V101 Solenoid Valve Sampling Point 1 V102 Solenoid Valve Sampling Point 2 V103 Solenoid Valve Sampling Point 3 V104 Solenoid Valve Sampling Point 4 V105 Solenoid Valve Sampling Point 5...

  • Page 63: Pneumatic Block Diagram, Analysing Unit

    Salwico SW2020 Technical Data Pneumatic diagram, Analysing unit 4.3.1 One pump system...
  • Page 64 Salwico SW2020 Technical Data 4.3.2 Two pump system...

  • Page 65: Flow Examples

    Salwico SW2020 Technical Data Flow examples 4.4.1 One pump system Normal operation, sampling and analysing of sampling point no 2 (SP2)
  • Page 66 Salwico SW2020 Technical Data 4.4.2 One pump system Pipe cleaning function on sampling point no 2 (SP2). Pump connected to fresh air inlet.
  • Page 67 Salwico SW2020 Technical Data 4.4.3 One pump system Draining of water drainage filter. Pump connected to fresh air inlet.
  • Page 68 Salwico SW2020 Technical Data 4.4.4 One pump system Calibration with test gas.
  • Page 69 Salwico SW2020 Technical Data 4.4.5 Two pump system Sampling and analysing of sampling point no 1 (SP1) and presuction of SP2.
  • Page 70 Salwico SW2020 Technical Data 4.4.6 Two pump system Pipe cleaning of sampling point no 2 (SP2) and analysing of sampling point no 1 (SP1).
  • Page 71 Salwico SW2020 Technical Data 4.4.7 Two pump system Draining of water drainage filter and presuction of sampling point no 2 (SP2).
  • Page 72 Salwico SW2020 Technical Data 4.4.8 Two pump system Calibration with test gas and presuction of sampling point no 2 (SP2).
  • Page 73 Salwico SW2020 Technical Data 4.4.9 Two pump system Calibration of zero with fresh air and presuction of sampling point no 2 (SP2).
  • Page 74 Salwico SW2020 Technical Data 4.4.10 Two pump system Pump redundance function (when analysing pump has failed). Sampling and analysing of sampling point no 1 (SP1).

  • Page 75: Calculation Of Sampling Time

    Salwico SW2020 Technical Data 4.5 CALCULATION OF SAMPLING TIME 100m 150m 200m 250m 300m Pipe length, meter Sampling pipe length, m 25 50 75 100 125 150 175 200 225 250 275 300 Sampling time, sec 10 15 22 28...
  • Page 76 Salwico SW2020 Technical Data 4.6 Vacuum Pump The vacuum pump 107 CCD20 used in the SW2020 Gas Sampling System is a membrane pump designed for a high degree of efficiency when it is used for vacuum. It is designed for continuous operation with permanently lubricated bearings, a long life Buna “N”...
  • Page 77 Salwico SW2020 Technical Data...

  • Page 78: Gas Detectors

    Salwico SW2020 Technical Data 4.7 Gas Detectors LIST OF RECOMMENDED GAS DETECTORS FOR SW2020 GAS SAMPLING SYSTEMS: Name Range Gas detector Type Art.no. Propane 0-100% LEL Optima Plus Infrared 5200204-00A Methane 0-100% LEL Optima Plus Infrared 5200204-01A Methane 0-100% VOL...

  • Page 79: Spare Parts List

    Salwico SW2020 Spare Parts List 5 SPARE PARTS LIST...
  • Page 80 Fuse 315 mAT 5 x 20 8219 Fuse 3.15 AT 5 x 20 8204 Fuse 4 AT 5 x 20 8225 Consilium Marine AB, P.O.Box 8763, SE-40276 GÖTEBORG, SWEDEN Tel: +46-31 710 77 00, Fax: +46-31 710 78 00 E-mail: spares@consilium.se WEB: www.consilium.se...

  • Page 81: Products List

    Salwico SW2020 Products list 6. PRODUCTS LIST...
  • Page 82 Salwico SW2020 Products list ANALYZING UNIT Description Code Type Data Art.No Pump P1, P2 107 CCD20 15 l/min, 230V 50/60 Hz 007350 Solenoid Valve V1 (one pump syst.) 6014-C-2.0 24V, 8W 5201059-00A Solenoid Valve V1 (two pump syst.) 6014-C-2.0 24V, 8W...
  • Page 83 Salwico SW2020 Products list Description Code Type Data Art.No 22 Filter/Pressure Reg. N1204-D00 0 - 4 Bar 007307 23 Pressure Instrument M043 0 - 4 Bar 007308 24 Filter N204-F00 007309 25 Choke Valve S4, S5-Sx SCO - 604 - 1/8”/ 8290 - 1/8" Adjustable...

  • Page 84: Maintenance

    Salwico SW2020 Maintenance 7. MAINTENANCE...
  • Page 85 The daily handling of the system is described in the document “Guidelines for the daily handling of Salwico SW2020”. It is essential to follow these guidelines in order to have a reliable and functional system.
  • Page 86 Salwico SW2020 Maintenance Additional information There is an online or end-line filter on each sampling line and it might get filled with dust or dirt etc. If such a filter is blocked the remedy is to replace the filter. The central will generate a sampling point flow fault alarm any filter is blocked.

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