TeamTec Golar OG 200
Shipboard incinerator (sludge oil, sewage sludge and solid waste)
The TeamTec Golar OG 200 burns ship's waste oil sludge, sewage sludge and solid refuse at up to 465 kW (400,000 kcal/h). It has a refractory-lined circular combustion chamber with garbage and ash doors interlocked for at least 4 hours after burning, a two-stage Fremo diesel oil burner, a steam/air-atomised sludge burner fed by a Mono dosage valve on a frequency inverter, a 1100 l steam-heated sludge tank with circulating pump, and a flue gas fan with automatic damper keeping the furnace under negative pressure. The manual covers controls and indicators, the function test program, alarms, instrument and controller settings, operating instructions for solid waste, sludge and slagging, daily to yearly maintenance, troubleshooting, and appendices for the burner control, pumps, nozzles and parts lists.
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Apkopes procedūras
Burning solid waste
- Main switch and Power switch on; inspect the chamber and remove foreign objects. 37. lpp.
- Load the waste through the garbage door and close the doors. 37. lpp.Oily rags and separator sludge only in small amounts (about 3 kg) and only with the flue gas fan running
- Start the flue gas fan and set the damper to Auto: chamber pressure settles near −24 mm WC. 37. lpp.
- Set Diesel oil burner to position 1; use position 2 (both stages) if more heat is needed. 37. lpp.
- When burnt out, switch off burner and fan; the fan stops after about 4 h cooling, then reload. 37. lpp.
Burning sludge
- Heat the sludge tank and drain off water. 37. lpp.
- Start the sludge circulating pump and check sludge pressure 0.5–1 bar. 37. lpp.
- Set Sludge burner to Auto: fan and diesel burner start, the sludge burner takes over above the set chamber temperature. 37. lpp.
- For sewage sludge or very wet sludge use position 1 (diesel burners keep burning); positions 2 and 3 give fixed dosage of about 12 and 14 Hz. 38. lpp.
- Switch Sludge burner off to stop; the fan runs about 4 h for cooling. 38. lpp.
Slagging (removing ash)
- Make sure all solids are extinguished and the chamber has cooled. 38. lpp.
- Start the flue gas fan, set the damper to Manual and close it with CL/OP. 38. lpp.
- Open the doors, remove ash and slag with a hoe and clean the bottom air inlets. 38. lpp.Heat and cool slowly to protect the refractory
Emergency stop
- Inside the room turn Power off; outside push the emergency stop. Burner, fan and pump stop. 38. lpp.
- If the chamber is above 200 °C or waste is still burning, restart the flue gas fan as soon as possible. 38. lpp.
Cleaning the diesel oil pump filter
- Do this when pressure falls below 11 bar and cannot be adjusted. 49. lpp.
- Close the pump suction and return valves and remove the 8 bolts of the end cover opposite the drive. 49. lpp.
- Pull out the filter, wash in diesel oil, blow dry, refit with the gasket and reset pressure to 11 bar. 49. lpp.
Tehniskās apkopes intervāli
| Objekts | Kad | Darbība | Rokasgr. |
|---|---|---|---|
| Combustion chamber | Daily | Remove ash and slag when cold; clean the bottom air inlets | 39. lpp. |
| Diesel oil and sludge pressure | Daily | Check diesel oil 11 bar and sludge 0.5 bar; check pump for leaks | 39. lpp. |
| Photo resistor and air inlets | Weekly | Clean the photo resistor with a damp cloth; check combustion and cooling air inlets | 39. lpp. |
| Sludge dosage valve | Weekly | Check for leaks and turn the shaft by hand | 49. lpp. |
| Burners, belts, refractory | Monthly | Clean blast tube, flame scrod and nozzle; check fan belts and refractory; lubricate moving parts; clean spark arrester | 39. lpp. |
| Diesel pump filter, dosage valve, fan bearings | 6 months | Clean the oil pump filter, check dosage valve rotor and stator, regrease fan bearings (heat resistant grease) and door hinges | 39. lpp. |
| Controls and safety devices | Yearly | Run the function/test program and alarm checks, calibrate safety devices, check oil valves and solenoids for leaks | 39. lpp. |
Bojājumi un ko darīt
Flame failure alarm at startNo ignition spark, diesel solenoids not opening, dirty nozzle, too much primary air, dirty photo resistor, poor oilFlame failure when stage 2 startsToo much primary air, damper opening too earlyLow diesel oil pressure alarmNo oil supply, faulty pressure switch b13, pump problemDraught failure alarmLow furnace negative pressure, damper in manual, controller settings, blown fuse, faulty controller or damper motorFlue gas temperature high alarmAbove set value (normal 400 °C), faulty controller u1 or thermocoupleCombustion chamber temperature high alarmAbove 1200 °C, faulty controller u2 or thermocoupleSludge dosage valve does not startCirculating pump off, chamber below 600 °C, relay, inverter or motor faultSludge dosage valve stops after a whileChamber temperature falls (wet sludge) or motor overload (OL2 on inverter)No flame from the sludge burnerSteam/air solenoid, low atomising pressure, too much water or air, damaged sludge nozzleLow sludge / steam pressure alarmSludge below 0.5–1 bar or steam/air below 6–9 bar, closed valves, faulty switchesFlue gas fan does not startTripped breaker e11, contactor, motor or switch
Tehniskie parametri
| Max capacity | 400,000 kcal/h (465 kW) | 28. lpp. |
|---|---|---|
| Sludge oil capacity | max 55 l/h | 28. lpp. |
| Sewage sludge capacity | max 20 l/h | 28. lpp. |
| Solid waste charge | Type II waste up to 400 l per charge every 4–6 h | 28. lpp. |
| Combustion chamber temperature | normal 850–1200 °C, max 1200 °C at top refractory | 38. lpp. |
| Flue gas temperature | normal 200–350 °C, max 400 °C | 38. lpp. |
| Furnace negative pressure | −10 to −30 mm WC (auto set about −24/−25 mm WC) | 28. lpp. |
| Diesel oil burner | Fremo H-520-30 K-HF two-stage, 2 × 2.5 gph nozzles, pump Suntec J3-CAB-1002 set to 11 bar (max 14.5) | 31. lpp. |
| Flue gas fan | 7000 Nm³/h at 200 mm WC, 7.5/8.7 kW, 1450/1740 rpm | 31. lpp. |
| Sludge dosage valve | Mono SB 14 R5, 0.37 kW, 280–800 rpm via ATV-16 inverter; start speed about 10.5 Hz | 32. lpp. |
| Sludge tank | 1100 l net, 1650 l total, steam heated | 33. lpp. |
| Sludge circulating pump | E-JET SRG 102 N, 18 m³/h at 1.5 kp/cm² | 33. lpp. |
| Normal pressures | diesel oil 11 bar, sludge 0.5–1 bar, steam/air 6–9 bar | 21. lpp. |
| Alarm and trip set points | draught failure < 5 mm WC, low diesel oil < 5 bar, low sludge < 0.2 bar, low steam/air < 2 bar | 18. lpp. |
| Temperature controller u2 (combustion chamber) | sludge only at 850 °C, start sludge burner 600 °C, stop burners 1200 °C | 23. lpp. |
| Door lock / fan cooling time | about 4 h after burner stop | 20. lpp. |
| Flue gas fan belt | 10 mm deflection at about 3 kg | 49. lpp. |
Rezerves daļas un kataloga numuri
| Detaļa | Numurs | Daudz. | Rokasgr. |
|---|---|---|---|
| Burner motor ASEA MT 71 | D254 | 1 | 136. lpp. |
| Ignition transformer ZM20/10 | D256 | 1 | 136. lpp. |
| Photo resistor Landis & Gyr QRB1 | D587 | 1 | 136. lpp. |
| Nozzle 2.5 gph 45° | D810 | 2 | 136. lpp. |
| Ignition cable, 400 mm | D847 | 2 | 136. lpp. |
| Solenoid valve coil | 3927 | 3 | 141. lpp. |
| Fan wheel 160 x 75 | 4200 | 1 | 141. lpp. |
| Oil pump Suntec J3-CAB-1002 | 6404 | 1 | 141. lpp. |
| Nozzle set 2.5 and 4.5 gph | 8054 | 1 | 141. lpp. |
| Pressure switch XMJ-A0207 | 8152 | 1 | 141. lpp. |
| Mono pump SB 14 R5 stator | 2718 | 1 | 89. lpp. |
| Mono pump SB 14 R5 rotor | 2720 | 1 | 89. lpp. |
| Mono pump mechanical seal | 9233 | 1 | 89. lpp. |
| Oil heater heating element 1.5 kW | 1972202 | 1 | 172. lpp. |
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