Fuel Conditioning Module

1.2 Normal Operation

1.2.1 Before Start

The following procedures assume the system pipework and valve arrangement is set for operation with open valves and pipework secure, and that commissioning action described in he installation instruction book has been successfully performed.

Ensure that the electric trace heating (if installed) thermostat is set to 50ºC so the heating is switched off when the oil is heated.

· Switch on the EPC with the switch inside the cabinet.
· Set automatic filter switch in “auto” position.
In this position the filter is hard wired to start when the respective pump us started (supply pump if filter is after the supply pumps, or circulating pump if filter is after the circulating pumps).
· Set regulating valve switch in “EPC” position.
· Switch on the isolators on each starter.

NOTE:
If the one pump is starter is not available (due to maintenance or other reasons) the unit cannot be started in EPC mode but has to be started manually.

1.2.2 Start

1 Set all four pump switches to the EPC position.

2 Press “start” on the EPC. A question will appear in the display, “Start? + = Yes - = No.” Pressing the “+” button will start the system. Pumps and heating will be started according to the module starting sequence.

Pre-selected supply pump is started.

When pressure above PT1 alarm low limit – system waits 30 seconds.

Then (preselected) circulation pump starts.

When pressure above PT2 law alarm limit – system waits 30 seconds.

Then heating starts.

At start up: low pressure alarms are blocked for 4 minutes, or until the pressure is above the alarm limit. Then the low pressure alarm delay time is as set with parameter Fa9.
NOTE
If the optional automatic fuel change over function has been installed, Automatic change over from DO to HFO will be as set with parameters Fa 15 and Fa 16.


Alternatively
1 Start the supply and the circulation pumps in the manual position (in any order).

2 Start the EPC. (Heating will start if under set point.)

3 Set the stand-by pump switches to the EPC position.

4 Change the running pump switches to the EPC position. (The running pumps will stop, and the pumps selected in the EPC will start.)

1.2.3 Stop – complete shutdown

By stopping the system as follows, no alarm will be activated.

The system is designed so that the pumps cannot be stopped from the EPC controller even if an error occurs in the controller.

The EPC can only start or switch pumps, but never stop them. For safety reasons, this has to be done manually.

1 Press “stop” on the EPC.

2 A question will appear in the display “Stop heater?”

3 Heating will be stopped.

4 An instruction will scroll across the display,
‘Stop pumps manually’
NOTE
Wait until the system has cooled before stopping the pumps (if not already on diesel oil)
5 Pumps can now be stopped in any order.
NOTE
To increase the life-span of the pumps seals, it is recommended to stop (and thus start) the pumps on diesel oil. Cold Heavy Fuel Oil subjects the seals to more wear on start.

1.2.4 Stop – pumps remain on

Each set of pumps (circulating & supply) can be stopped independently of each other. For example, when the engine is not on service, the supply pumps can be stopped, and the circulating pumps (and heating) can remain running.

To stop the supply pumps but leave the circulating pumps on the circulate oil in the engine fuel rail and heater circuit, the EPC should remain on so that the stand-by functions is activated.

Stop the following order to avoid alarm and starting the stand-by pump.

1 Stop the stand-by supply pump (switch from EPC to STOP).

2 Stop the running supply pump (switch from EPC to STOP).

NOTE
The time allowed to stop the stand-by and running pump in 1 & 2 above is Fa9 seconds (factory default 8 seconds).

If you want the circulation pump to remain on leave switches in “EPC” position.

To restart the pumps, set the switches from “STOP” to “EPC”

1.2.5 Pump operation

To change over the running pump(s) during normal operation change Pr1 or Pr2 (see parameter list).

NOTE
To increase the life-span of the pump seals, it is recommended to minimize the number of starts and stops on Heavy Fuel Oil.
Keep the same pump running as long as possible. It is recommended to change pump in connection with the regular service overhaul of the pump.

The control unit can be set to change pumps (running to stand-by, and stand-by to running) at preset intervals during operation.

Alternatively, the control unit can be set to indicate when the time has come to change over pumps.


1.2.6 Pump stand-by function

The pump stand-by function is always active when the four pump switches are in the “EPC” position and the EPC is on (indicated by the green LED next to the START/STOP button).

NOTE
When a stand-by pump has been started due to a fault and you want to change back to the stopped pump or enable the stopped pump as the stand-by, it is necessary to check the setting of parameters Pr1 or Pr2 and change them to suit the required pump selection.

Automatic change over pumps always changes the selected running (running/stand-by) pump parameter Pr1 or Pr2.

If there is a fault on one pump (e.g. one of the supply pumps) the stand-by function continues to be active on the other pumps set (e.g. circulating pumps).

The stand-by function has two different time delays:
· When the running pump contactor opens (perhaps due to over-current protection), there is a 2 second delay before the stand-by pump contactor closes.
· When a low pressure alarm is received the time before the stand-by pump starts is determined by parameter Fa9 (factory default of 8 seconds).

1.3 Oil Operating Mode

The controller works with two different control modes (set with the control mode button on the EPC); DO control mode, and HFO control mode. The EPC controller has thus two sets of set points and alarm limits, one set for each mode. The fuel modes are indicated by respective LED’s. Heating control is carried out depending on the selected mode. See 1.3.1 Heating Function from OFF to DO, and 1.3.2 Heating Function form OFF to HFO, or DO to HFO.

In connection with bunkering, it may be necessary to adjust some of the parameter settings. This is certainly the case when changing to an HFO that is much different grade. Some of the following parameters may have to be changed:

· Density parameter Pr 23. If changing to an oil of a different density, change the density parameter in order to obtain the most accurate viscosity measurement.
· HFO temperature setpoint parameter Pr 30. The new oil must be heated to a different temperature (as this temperature set point is used for the end of the temperature start ramp) to obtain the same viscosity setpoint.
· Temperature Pr 32.

1.3.1 Heating Function from OFF to DO

When the control unit is switched ON to DO mode (for temperature control), the fuel oil temperature and viscosity are monitored and displayed.
The heating start sequence is controlled by Fa 31, temperature start ramp, which allows the oil to be heated to the set temperature within a set time. (If Fa 31 = 0, the ramp function is inhibited, and the control unit regulates directly using normal set points, alarm limits etc.). The TT LED flashes during ramp function.

When the fuel oil temperature is within 3 ºC of the set temperature, the start ramp is stopped and normal temperature control is initiated. The TT LED changes to steady shine.

· Low viscosity and low temperature alarms are disabled during start ramp.
· At the beginning of the start ramp, a maximum time is set for start ramp duration to ensure that it does not run for too long a time. An alarm is activated if the start ramp exceeds maximum time. See the “Alarms and fault Finding” booklet.


1.3.2 Heating Function from OFF to HFO, or DO to HFO

To change from DO to HFO

1 Press the DO / HFO button

2 A question appears in the display.
‘Change oil mode? + = yes, - = no’

3 Press ‘+’ to start the change over.

4 If an electric or pneumatic change over valve is fitted the valve will immediately start changing over to HFO.

NOTE
If the electric valve with the change over ramp function is installed the change over time can be set with factory parameters Fa 12 and Fa 13.

When the control unit is switched ON to HFO, or switched from DO to HFO, the fuel oil temperature and viscosity are monitored and displayed. The start sequence is controlled by Fa 30, temperature start ramp, which allows the oil to be heated to the set temperature within a set time. The VT LED flashes during ramp function; the TT LED shines steadily if change-over from DO to HFO has been made, but does not shine if change-over from OFF to HFO has been made. (If Fa 30 = 0, the ramp function is inhibited, and the control unit regulates directly using normal set points, alarm limits etc.)

On change-over from DO to HFO, heating of the oil begins when the controller detects an increase viscosity, indicating that Heavy Fuel Oil is entering the system.

Heating the temperature has reached 3 ºC below the temperature set value of HFO, the control unit automatically switches to viscosity control. When the TT LED switches off and the VT LED shines steadily, the start sequence is complete and viscosity control attained.

· Low viscosity and low temperature alarms are disabled during start ramp.
· At the beginning of the start ramp, a max. Time is set to start ramp duration to ensure that it does not run for too long. An alarm is activated if the start ramp runs to max. Time.
· When changing over for DO to HFO and vice versa the viscosity at 50 ºC is displayed in the instantaneous values list. This makes it possible to see how much DO to HFO is in the system at the usual reference temperature of 50 ºC.


1.3.3 HFO Control Heating Mode

HFO control type

The HFO control type (temperature or viscosity), is set in parameter Pr 19. The selected type is shown by the sensor LED’s on the display.

If the viscosity sensor (VT) LED is lit, the unit is in viscosity control.

If the temperature sensor (TT) LED is lit, the unit is in temperature control.

1.3.4 Change-over from HFO to DO

When a change is made from HFO to DO, the control unit continues to control the fuel oil viscosity. The viscosity value is maintained by decreasing the temperature of the HFO-DO blend. The TT LED is flashing and the VT LED shines steadily.

When the temperature reaches the DO set value, the control is automatically switched over to DO mode (temperature control). The TT LED then changes to steady shine, and the VT LED switches off.

1.3.5 Automatic change-over-HFO/DO

Engine conditions

The EPC controller can be figured to change between DO and HFO based on engine conditions. There are two alternatives:

Auto change-over-input signal

The controller receives information from the diesel engine control system on whether or not the conditions are right during for HFO operation. If the conditions are right during a two minute period, the controller can be set to either change over automatically, or simply display that the engine conditions are met.

Auto change-over-relative engine consumption

The controller will change to DO when the engine percentage consumption is below a set limit for a two minute period.
During the two minute delay in both cases, the change-over process can be aborted by pressing the DO/HFO button. The function is then cancelled for 20 minutes. If a permanent cancellation of the function is required, the corresponding parameter must be set to zero.

For further information, see the Parameter List.

Heater fault

In the event of a heater fault it is possible to arrange for a controlled change over to DO.

The automatic change over valve has to be installed; then by using parameter Fa 14 the system can be set to automatically change over to DO in the event of a heater fault.

It is recommended to set Fa 14 to a lower value than the low temperature alarm limit. When the set low temperature limit is reached, the change-over countdown timer (2 minutes) starts. The DO LED next to the DO/HFO change-over button starts flashing, and a text appears intermittently showing the time to change-over. The change-over countdown timer can be aborted by pressing the DO/HFO push button.


1.3.6 DO to HFO to DO valve time

When the electric change-over valve is installed the new fuel can be introduced into the system gradually by regulating the time it takes for the change-over valve to change from DO to HFO, or HFO to DO. Although this will be strongly influenced by the level in the respective HFO and DO service tanks.

See parameter Fa 12 and Fa 13.

1.4 Automatic Filter

The filter needs very little attention during operation. See Operation in the filter component description for further information.

1.5 Mixing Tube Deaeration

If the mixing tube needs venting during operation, an alarm will be activated.

If automatic deaeration function is installed, the mixing tube will be automatically deaerated. If the automatic deaeration valve is open for more than 12 seconds, an alarm will be activated.

1.6 Manual Operation

These functions are provided in the unlikely event that the EPC50B is not working. They enable components within the system to be operated independently, direct supervision by the operator will be required.

The module is equipped with visual indicators – thermometers, pressure indicators, position indicators – that can be used when the EPC is not working.

1.6.1 Manual operation of parts of the system

Pumps
Pumps can be operated manually by switching the pump switch to the manual position.

NOTE

If both pump switches (for one pump set) are set to “manual” the pump w/c was switched on first will be the one running. If the contactor of the pump in operation is released, for example, by the motor protection, the other pump will start.

If the EPC is switched off or stops working during operation, the running pumps will continue running ( with the selector switches in the EPC position). After the I/O board has been replaced the EPC will take over control when switched on again.

If the pumps have to be run for a longer time w/out the EPC in control, it is recommended that the pump selectors are switched to manual position.

Heating

Heating can be controlled by the EPC50B (if it is working ) even if the pumps are run manually. Pressing the start button on the EPC will start the heating.

The heating media control valve can also be activated directly by first switching the heating media control valve form EPC to manual, then using the switch to activate the valve to open or close as necessary

There is also a hand lever under the cover of the valve actuator.

For electric heating the fixed loads within the power unit can be switched on step wise, in up to 5 steps (depends how big the heater is as to be number of elements and the number of steps).

Automatic filter

The Alfa Laval Automatic filter can remain in the “Auto” position, even when the EPC50B is not working, because it is hard wired to start when the pump before the filter is started.

The Alfa Laval Automatic filter can alternatively be switched on in the manual position to start the filter when the pumps are not working.

The automatic drain function is not working if the EPC50B is not working.

The filter then needs to be drained manually at regular intervals (every 8 hours) by putting the filter switch in the DRAIN position (for about 10 seconds). The filter can also be manually drained by using the by-pass valve.

HFO/DO change over valve

The HFO/DO change over valve can be manoeuvred with the hand lever. (It will be necessary to change Fa 12 to disable the change over valve form the EPC, if the EPC is still ON)

1.7 Automatic start up after power failure


The module can be set to be automatically restarted after a power failure, and if an alarm should be activated or not, with a software parameter; see the parameter list.

When the electric power returns after the power failure, the supply pump, circulating pump and heater are restarted again (after a set delay time) with one second intervals. The same pumps that were running before the power failure will be started. If, however, the power to the EPC is not interrupted, the stand-by pump will be started and alarm activated when power to the pumps returns.

1.8 Regular checks on the system

Regularly check the process values to note any unusual changes. Also, regularly check the automatic filter pressure drop indicator.

If SRV position (or instantaneous electric heater power in the case of electric heater) changes dramatically, this could be an indication of heater clogging, provided other process criteria remain the same.

When the outside ambient temperature is high, regularly check the internal control panel temperature (see parameter list Pr7). This should be max. 70 ºC.

1.9 Remote control and monitoring

The fuel conditioning module is prepared for 4 levels of remote control. The levels are:

1 Basic Level 1
2 Extended Level 2
3 Advanced Level 3
4 Fully automated Level 4

It is important that you firstly identify which level of automation is installed (also see the Installation System Reference manual).
NOTE
Every module is prepared for Remote Control, and the pump mode selection switches indicate this with their 4 positions; MANUAL/OFF/EPC/REMOTE. This does not mean there is remote control location.

Basic Level 1

This control panel is not supplied by Alfa Laval, but will have been produced by a 3rdd party.

Basic Level 2

Control panel supplied by Alfa Laval.

Advanced Level 3

Features of duplicate Operators panel as on the Fuel conditioning module.

Fully automated Level 4

Fieldbus system integrates with central computerised automation system. (not supplied by Alfa Laval).


1.9.1 Basic Level 1

Operation is dependent on the functions installed by the automation supplier.

Possible remote features

· Fuel mode change over DO / HFO
· Heating start / stop
· Common alarm
· High temperature / low viscosity
· High viscosity / low temperature
· Automatic filter differential pressure high
· Fuel oil pressure low
· Switched to stand-by pump
· 4 -20mA, 2 outputs
· Temperature signal
· Supply pump 1 running
· Supply pump 2 running
· Circulating pump 1 running
· Circulating pump 2 running
NOTE
Alarm accept/reset has to be made at the EPC50B operators panel on the fuel conditioning module.

1.9.2 Extended level 2

Extended level 2 – features
NOTE

Alarm accept/reset has to be made at the EPC50B operators panel on the fuel conditioning module.

The local pump selection switches have to be set to ‘remote’. If you intend to change the running/ stand-by pump selection during operation, the switches have to be in “EPC” position (as all pump selection is made from the EPC). First check that the pump mode selection switches on the remote are in the ‘EPC’ position.

1.9.3 Advance Level 3

Advanced Level 3 – features
NOTE
Alarm accept/reset is possible with the remote operators panel.
The local pump selection switched have to be set to ‘remote’. If you intend to change the running/ stand-by pump selection during operation, the switches have to be in ‘EPC’ position (as all pump selection is made from the EPC). First check that the pump mode selection switches on the remote panel are in the ‘EPC’ position.