CNOOC Semi Project

CleanCut Cuttings Blower

Model 8/12

Operating and

Maintenance Manual

Shaw Lane Industrial Estate, Doncaster South Yorkshire, DN2 4SE ENGLAND
Telephone: 0044 (0) 1302 554480 Facsimile: 0044 (0) 1302 554481

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OPERATING & MAINTENANCE

INSTRUCTIONS

SYSTEM: Drill Cuttings Handling System

MANUAL NUMBER: 1

REVISON 01

Signature Position Date

Prepared by: Mantovani & Vicentini (MI-SWACO Italy) Project Engineer 03/03/2009

Reviewed by:

Authorised for use

by:

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REVISION HISTORY

REVISION DATE COMMENT

01 03 Mar 2009 First release.

NOTE: The General Arrangement (GA) drawing in this manual is typical, and may not
reflect the equipment delivered in this project. This manual should be read in
conjunction with the specific GA drawing delivered in this project:

General Arrangement drawing - Cuttings blower (CCB)

MH doc.no.: 170073-R-BZ421-XD-0004017 sheets 1 and 2
STEP doc.no.: P0708-R-XD-3002 sheets 1 and 2
Power supply voltage is 480V in project, but is noted as 440V in manual

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CONTENTS

Section

Introduction .................................................................. 1
• Importance of the Manual
• General Safety
• Description of Equipment
• Application & Design Parameters

Functional Design Specification .................................. 2

• Introduction
• Overview
• System at Rest
• Operating Sequence
• Timer Definitions and Values
• Operator Controls and Indications
• Timing Diagram
• Summary of Alarm Conditions

Installation and Operation ........................................... 3

• Installation
• System Start-up Procedure
• System Shut-down Procedure
• Level Probe Calibration Procedure
• Procedure for Removal of 300mm Inlet Cuttings Valve
• Cuttings Valve Maintenance Instructions
• Removal/Replacement of 300mm Cuttings Valve Bearings
• Procedure for Removal of 125mm Outlet Cuttings Valve
• Removal/Replacement of 125mm Cuttings Valve Bearings

Fault Diagnosis ............................................................. 4

Routine Maintenance ................................................... 5

• Daily Maintenance
• Weekly Maintenance
• Monthly Maintenance
• Annual Maintenance

Controller........................................................................ 6

Recommended Spares ................................................ 7

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Section

Proprietary Parts .......................................................... 8

• Actuator
• Blow Valve
• Butterfly Valve
• Cylinder
• Filter/Lubricator
• Level Switch
• Limit Switch
• Motor (Vibrator)
• Pressure Gauge
• Pressure Relief Valve
• Pressure Regulator
• Pressure Switch
• Strainer

Drawings ........................................................................ 9
• General Assemblies
• Circuits

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Section 1

SECTION 1

INTRODUCTION

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Section 1

IMPORTANCE OF THE MANUAL

The manual shall be regarded as an essential part of the product.

The manual shall be kept for the life of the product.

Ensure that any revision received is incorporated in this manual in the correct place
and that the accompanying form is signed and returned.

GENERAL SAFETY

1. PERSONNEL MUST READ THIS MANUAL BEFORE OPERATING THE

EQUIPMENT OR CARRYING OUT MAINTENANCE WORK.

2. ONLY QUALIFIED AND COMPETENT PERSONNEL MUST CARRY OUT ANY

MAINTENANCE OPERATION.

3. BEFORE CARRYING OUT ANY OPERATION OR MAINTENANCE WORK

PERSONNEL ARE TO FAMILIARISE THEMSELVES WITH ON SITE
REGULATIONS AND PRECAUTIONARY INFORMATION REGARDING
HEALTH AND SAFETY AND HAZARDS ASSOCIATED WITH CONVEY
MATERIAL.

4. PRIOR TO CARRYING OUT MAINTENANCE WORK INVOLVING PARTIALLY

DISMANTLING EITHER THE PRESSURE VESSEL OR PIPEWORK, ENSURE
THAT THE CONTROL AND CONVEYING AIR ISOLATION VALVES ARE
FULLY CLOSED AND THAT THE PRESSURE WITHIN THE VESSEL HAS
BEEN FULLY VENTED.

5. ENSURE THAT THE SYSTEM IS FULLY ELECTRICALLY ISOLATED BEFORE

DISMANTLING.

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Section 1

DESCRIPTION OF EQUIPMENT

1 Off Model 8/12 CleanCut Cuttings Blower manufactured to PD5500

Category II and in accordance with the Pressure Equipment Directive
97/23/EC. Standard mild steel pressure vessel, designed for a working
pressure of 7 barg. Complete with 300mm Inlet Cuttings Valve, 1-1/2”
Poppet Valve (Blow Valve) and 50mm Butterfly type vent valve and
125mm Outlet valve. Pneumatic controls housed in an attached,
weatherproof, lockable cabinet with air lubricator and filter set, and
attached lockable Electric & PLC control panel

Suitable for the transfer of material with temperatures up to 100ºC

maximum.

1 Off Type 1000/300/600 HDP lined Vibratory Feed Chute, c/w Vibrator
Motor and flexible adapter to offshore specification.

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Section 1

APPLICATION & DESIGN PARAMETERS

Drill Cuttings Handling System

Number & Type of Conveying Vessel: Model 8/12 CleanCut Cuttings Blower
Material: Drill Cuttings
Bulk Density: typical range 1500 – 2000 Kg/m³
Liquid Content: Various
Maximum material temperature: 100 °C
Conveying Distance: 0 – 100 metres
Conveying Rate: Typically 25 tonnes/hr

Control Air

Pressure: 6 to 10 barg
Average Airflow: 0.1 Sm3/min

Conveying Air

Pressure: 7 barg (minimum)

Peak Airflow: 21 Sm3/min (maximum instantaneous)

Power Supply

Voltage supply: 3 phase, 480 VAC, 60 Hz

Current drain: 10 Amps maximum

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Section 2

SECTION 2

FUNCTIONAL DESIGN SPECIFICATION

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Section 2

INTRODUCTION

This description should be read in conjunction with the following drawings (see Section 9):

P&ID MODEL 8/12 CLEANCUT CUTTINGS BLOWER P32688D-00

The timers and other values given in this description are typical. They may be changed during
commissioning or operations

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Section 2

OVERVIEW

During normal operation of the system, drill cuttings will accumulate in a feed hopper
above the CCB. The drill cuttings will be discharged by gravity to the CCB. The drill
cuttings will then be pneumatically conveyed through pipework to the reception point,
typically the ISO-Pump or Skip Station.

A facility to connect a remote pushbutton station is included within the control panel.
The operation of the lamp and pushbuttons are identical to those fitted to the primary
control panel. If a secondary remote pushbutton station is not required then the
emergency stop and stop signals are to be linked out.

Operator facilities on the control panel include:

Emergency stop pushbutton (HS1-1)

Start pushbutton (HS2-1)
Stop pushbutton (HS2-3)
Status lamp (XI3-0)
Timer selection switch (ZS2-10)
Timer increment pushbutton (HS2-8)
Timer decrement pushbutton (HS2-9)
Sequence controller text display – indication of timer values and I/O

Operator facilities on the remote pushbutton station include:

Emergency stop pushbutton (HS1-2)

Start pushbutton (HS2-2)
Stop pushbutton (HS2-4)
Running lamp (XI3-1)
Probe Override (XS2-2 – Fitted at operating position remote station 1 only)

For operation with the remote pushbutton station NOT connected:

The start pushbutton on the front of the control panel (or the remote cycle start signal,
after the initial cycle) will initiate a conveying cycle. Subsequent cycles will be initiated
by either a cycle timer or a high level probe located above the CCB feed hopper. The
inlet Cuttings Valve will be opened and drill cuttings will fall under gravity into the CCB
vessel. The bin activator motor assists discharge from the feed hopper.

For problematic materials discharge may be further aided with the addition of aeration
nozzles into the bottom of this cone hopper. During filling and whilst at rest the vent
valve will be opened to allow the displaced air to be released from the CCB vessel and
the outlet Cuttings Valve will be closed.

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Section 2

After a timed delay the bin activator will be stopped. Simultaneously or after a further
short delay, the inlet Cuttings Valve will close. When the inlet Cuttings Valve has
closed and sealed, there will be a short timed delay to allow the outlet Cuttings Valve
to fully open. The vent valve will close and simultaneously the conveying air will be
introduced into the CCB vessel. The drill cuttings will be discharged from the CCB
vessel into the pipeline and will be conveyed to the reception point. Short pulses of air
will also be introduced to the CCB vessel at timed intervals via the air sweep nozzles
to help discharge the drill cuttings smoothly during the conveying cycle.

When the drill cuttings have been discharged and the CCB vessel has emptied, a drop
in the conveying pressure indicates most of the useful work of the cycle has been
completed. The conveying air valves will be closed and the vent valve opened. When
the conveying pressure has completely decayed, a ‘Low pressure’ switch will indicate
the cycle is complete.

The bin activator motor will be plug-stopped to prevent ‘running-on’ and possible
compaction of the drill cuttings in the feed hopper. This is achieved by applying reverse
phasing of the supply current thus rotating the motor in the reverse direction to normal
running for a brief time.

The vent from the CCB vessel will be routed into the cuttings ditch or a similar safe
area.

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Section 2

SYSTEM AT REST

When the CCB is stopped and at rest the status of the valves will be as follows:

Control air off Control air on Control air on

Electrical off Electrical off Electrical on
power power power
Controller off Controller off Controller run
mode mode mode
Inlet Cuttings Valve Last position* Closed Closed

Vent valve Last position Open Open

Conveying air valve Closed Closed Closed

(PV02)
Air sweep valve Closed Closed Closed
(PV03)
Outlet Cuttings Last position Open Open
Valve

The CCB vessel should be empty and at zero pressure. The bin activator will be
stopped.

• Note: The inlet Cuttings Valve incorporates an inflating seal. In the event of the
loss of control air pressure, the valve will not be sealed.

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Section 2

Prior to operating the CCB for the first time, or after a period of no use it is
recommended that the adjustable time values be verified as correct for the cycle.
OPERATING SEQUENCE

At the start of each conveying cycle, the sequence controller will check that the
following cycle start interlock conditions are fulfilled:

The start pushbutton is pressed (HS2-1).

OR

The conveying cycle is running i.e. the conveying cycle has been started and the
stop pushbutton has not been pressed.

AND

The emergency stop pushbutton (HS1-1) on the control panel is not operated.
CCB vessel pressure is < 0.3 barg (PSL02).
CCB inlet Cuttings Valve is closed and sealed (PSH01).
Cycle frequency timer is not running (see note a below)

AND

The remote cycle start signal is active:

Feed hopper high level probe covered (LSH01)

OR

Probe override pushbutton pressed (XS2-2)

AND

Not high level at the reception point (XS2-1)

Providing the above conditions are true a conveying cycle will be initiated and will
proceed as follows:

Notes:

a. If running on probe the cycle timer must be set to less than 20 seconds. If
the timer setting is greater than this minimum value then the timer will hold
cycle start off until elapsed irrespective of the probe status.

b. The remote signals are ‘linked out’ if not required.

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Section 2

Step 1
The ‘Inlet Cuttings Valve’ is opened and the ‘Outlet Cuttings Valve’ is closed by
energising solenoid number (EV01). The inlet Cuttings Valve open timer (8 seconds),
cycle watchdog timer (40 seconds) and cycle frequency timer (60 seconds) will be
started. Drill cuttings will fall under gravity into the CCB vessel.

Simultaneously, the bin activator run timer (6 seconds) will be started and air to the
feed hopper air sweeps initiated.

Feed Hopper Air Sweep System

On systems that have air sweep aeration devices fitted to the feed hopper then an air
signal is taken from the Inlet cuttings valve opening supply line to operate a Blow Valve
to provide air to three air sweeps in the ‘Vibro’ Hopper to assist the material flow into
the CCB for the duration the CCB inlet Valve is open.

Please refer to CleanCut Drawing Numbers:

• P33175D-00 Pneumatic Circuit

• P35461D-00 Air Spray Nozzle Assembly
• P35469D-00 Feed Hopper Supply Assembly
• CC0052D-00 1000/300/60 Vibrating Feedchute
• P35532D-00 Feed Hopper Air Sweep Supply Assembly

Step 2
When the bin activator run timer has expired and after a short delay (0.5 seconds) the
bin activator will be plug-stopped by reversing the motor current phases for the
duration of the reverse phase plug-stop run timer (0.4 seconds). The bin activator is
interlocked with the inlet Cuttings Valve to prevent the bin activator running with the
inlet Cuttings Valve in the closed position (if the timers are incorrectly set).

The reverse phase plug-stop will not operate if the bin activator run timer value is set to
zero seconds.

Note: The duration of the bin activator run timer is to be less than the duration of the
inlet Cuttings Valve open timer.
Step 3
When the inlet Cuttings Valve open timer has expired, the inlet Cuttings Valve will be
closed and the outlet Cuttings Valve will be opened by de-energising solenoid (EV01).
Step 4
When the inlet Cuttings Valve (PSH01) has closed and sealed, the blow delay timer (3
seconds) will be started.
Step 5
When the blow delay timer has expired, the conveying air valve will be opened and the
vent valve will be closed by energising the solenoid (EV02). The convey secure timer
(20 seconds) will be started. The pulse interval timer (6 seconds) and delay pulse on

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Section 2

timer (5 seconds) will be started simultaneously with this step. When the delay pulse
interval timer expires the air sweep valve will be pulsed open by energising the air
sweep valve solenoid (EV03) for a period of time equal to (pulse interval timer) –
(delay pulse on timer) i.e. 6-5 = 1 second. This introduces pulses of air to the CCB
vessel through the air sweep nozzles at regular intervals throughout the conveying
cycle and helps discharge the drill cuttings smoothly. Air will enter the CCB vessel and
the drill cuttings will be discharged into the conveying pipe.

The drill cuttings will be conveyed through the pipeline to the reception point.
Step 6
When the convey secure timer has expired and the pressure in the CCB vessel has
fallen to less than 1.0 barg (PSL09), most of the useful work of the cycle is complete.
The conveying air valve (PV02) will be closed and the vent valve (PV05) will be
opened by de-energising solenoid (EV02). Simultaneously the air sweep valve (PV03)
will stop being pulsed open by de-energising solenoid (EV03).

Step 7
When the pressure in the CCB vessel has dropped to less than 0.3 barg (PSL02) and
the cycle frequency timer has expired, the ‘cycle-reset’ timer (3 seconds) will be
started.
Step 8
When the ‘cycle-reset’ timer has expired, the conveying cycle is complete.

Note:

If during the cycle any start interlocks become untrue, then that cycle will be permitted
to continue and end. The system will then stop until all of the start interlocks conditions
again become true.

Similarly, where an event has to occur to permit the cycle to proceed to the next step,
then the progress of the cycle will be halted until that interlock condition has become
true. The cycle will then proceed to the next step. The progress of the cycle to the next
step will be latched for the remainder of the cycle, so that in the event of the interlock
condition subsequently becoming untrue, the cycle will not stop or regress. The latches
are released at the end of the cycle during the cycle-reset timer.

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Section 2

TIMER DEFINITIONS AND VALUES

Timer name Purpose of timer Default Timer Adjustable

Timer ‘Typical timer
setting Range’
Bin activator During the filling of the CCB vessel, 6 sec 0 – 60 sec
run timer the bin activator will ‘run’ for the 1 second A
duration of the bin activator run timer. increments
Note a value for this timer greater
than the Inlet Valve open timer will not
be accepted by the controller
Inlet Cuttings This sets the period of time that the 8 sec 0 – 60 sec
Valve open inlet Cuttings Valve is open and 1 second A
timer duration of Feed Hopper Air Sweep increments
Blow (if Fitted)
Cycle The cycle watchdog timer provides a 40 sec 0 – 600 sec N
watchdog fault alarm if the conveying cycle is 1 second
timer not completed within the pre-set time increments
period.
Cycle This regulates the maximum 60 sec 0 – 600 sec
frequency conveying cycle frequency. 1 second A
timer increments
Pulse Air This sets the total cycle frequency of 30 x 0.2 0 – 999 sec
Cycle timer the pulse air arrangement. = 6 sec 0.2 second A
increments
Delay Pulse This sets the delay duration from the 25 x 0.2 0 – 999 sec A
On timer beginning of the “Pulse Air Cycle = 5 sec 0.2 second
Timer” before the pulse air is turned increments
on.

Therefore

On time = (Pulse Air Cycle timer) -

(Delay Pulse On timer)

= (6) – (5)
= 1 second
Convey secure The convey secure timer is to allow 20 sec 0 – 120 sec
timer time for the pressure in the CCB N
vessel to rise before both vessel low
pressure switches (PSL02) & (PSL09)
are interrogated.

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Section 2

Cycle reset The cycle reset timer provides time 3 sec 0 – 20 sec
timer for the pressure in the CCB vessel N
and conveying pipework to be
completely released before the start
of the next conveying cycle.
Bin activator This allows a delay for the bin 0.3 sec 0 – 20 sec
fault timer activator-running signal to be received N
when requested to ‘run’.
Blow delay This timer provides a delay for the 3 sec 0 – 20 sec
timer outlet Cuttings Valve to be opened N
before the conveying air valve is
opened.
Reverse This sets the duration of the reverse 0.4 sec 0 – 20 sec
phase plug- phase plug-stop on the bin activator N
stop timer motor.

A – Adjustable Timer from control panel

N – Non-adjustable Timer from control panel (timer settings adjustable via PLC)

It shall be noted that the actual wording for each of the above Adjustable Timers on the
controller display, due to a limit on the number of characters, is abbreviated as shown below:

Timer Number Timer Description Control Display wording

1 Bin Activator Run Bin A

2 Cuttings Inlet Valve Open Dome
3 Pulse Air Cycle Pulse Air Cycle >Pulses .2x
4 Cycle Frequency Freq
5 Delay Pulse On Delay Pulse On .2x

Note:

It is only possible to view or adjust the timer values when the CCB is not in a
conveying cycle. The preferred procedure for this action is:

1 View the selected timer value.

2 Adjust the selected timer value, up or down as required.
3 View the selected timer value.

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Section 2

To view the timer values:

1 Timer select switch (ZS2-10) in the ‘off’ position.

2 Turn the timer select switch (ZS2-10) to select the timer value to be viewed.

Note:
The timer values are displayed on the text display of the sequence controller
(viewed through the window in the door).

3 Return the timer select switch (ZS2-10) to the ‘off’ position.

To adjust the timer values:

1 Timer select switch (ZS2-10) in the ‘off’ position.

2 Turn the timer select switch (ZS2-10) to select the timer value to be adjusted.
3 To increase the selected timer value, press the ‘increment timer value’
pushbutton.
To decrease the selected timer value, press the ‘decrement timer value’
pushbutton.

Note:
Each press of the pushbutton will increment / decrement the selected timer value
by one second.

4 Return the timer select switch (ZS2-10) to the ‘off’ position.

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Section 2

OPERATOR CONTROLS AND INDICATIONS

PNEUMATIC CONTROL PANEL

The pneumatic control panel at the CCB vessel houses the solenoid valves and the
inlet Cuttings Valve closed (PSH01) pressure switch.

ELECTRICAL CONTROL PANEL

The sequence controller located in the electrical control panel will control the CCB. The
operator interface is by means of pushbuttons, a selector switch, a lamp and the text
display of the sequence controller.

Pushbuttons

Emergency stop (HS1-1)

When the emergency stop pushbutton is pressed, the sequence controller will stop and
reset the sequence, all outputs will be ‘off’ (the position of the valves will be as for loss
of electrical supply). Pull to reset the emergency stop pushbutton.

Start (HS2-1)

When the start pushbutton is pressed, the conveying cycle will be started
(when the start interlock conditions are fulfilled). This will also reset the bin
activator fault alarm and will cancel the operation of the stop pushbutton.

Stop (HS2-3)

When pressed this will enable the conveying cycle to continue, and then stop
at the end of the cycle.

Increment timer value (HS2-8)

Providing the timer adjust selector switch (ZS2-10) is not in the ‘off’ position and a
conveying cycle is not in progress, this pushbutton will increment the selected
adjustable timer by one second with every ‘press’ of the pushbutton.

Decrement timer value (HS2-9)

Providing the timer adjust selector switch (ZS2-10) is not in the ‘off’ position and a
conveying cycle is not in progress, this pushbutton will decrement the selected
adjustable timer by one second with every ‘press’ of the pushbutton.

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Section 2

Selector Switch

Timer adjust (ZS2-10)

Providing a conveying cycle is not in progress, this allows one of the
adjustable timers to be selected, in order to view or adjust the timer value.

Lamps

Running (XI3-0)
Lamp status is as follows:

Condition Priority Indication

Off none lamp off
Cycle running low lamp on
Bin activator fault alarm high lamp pulse on
Cycle watchdog fault alarm high lamp pulse on
Stop pushbutton pressed low lamp pulse off
Cycle start fault high lamp pulse on

Lamp pulse on = 0.3 seconds lit and 1.2 seconds unlit

Lamp pulse off = 1.2 seconds lit and 0.3 seconds unlit

Note:

If the ‘lamp pulse on’ and ‘lamp pulse off’ conditions are required at the
same time, then the higher priority condition will be displayed.

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Section 2

TIMING DIAGRAM

CONVEYING COMPLETE PRESSURE <

CUTTINGS VALVE CLOSED AND

VESSEL PRESSURE LOW <

START INTERLOCKS HEALTHY

EARLIEST START OF NEXT

OUTLET CUTTINGS VALVE
INLET SEALED (PSH01)

0.3 BARG (PSL02)

1.0 BARG (PSL09)

END OF CYCLE
FULLY OPEN
VALVE AND MOTOR

CYCLE
STATUS

VENT VALVE
OPEN (EV02)
INLET CUTTINGS VALVE
OPEN (EV01)
BIN ACTIVATOR MOTOR
RUNNING (M001)
CONVEYING AIR
VALVE OPEN (EV02)
OUTLET CUTTINGS VALVE
OPEN (EV01)
AIR SWEEP VALVE
OPEN (EV03)

TIMERS

BIN ACTIVATOR RUN 6 SEC

TIMER
REVERSE PHASE 0.4 SEC
PLUG-STOP TIMER
INLET CUTTINGS VALVE 8 SEC
OPEN TIMER
BLOW DELAY 3 SEC
TIMER
CONVEY SECURE 20 SEC
TIMER
CYCLE RESET 3 SEC
TIMER
CYCLE FREQUENCY 60 SEC
TIMER
CYCLE WATCHDOG 40 SEC
TIMER
PULSE AIR CYCLE 6 SEC 6 SEC
TIMER
DELAY PULSE ON
TIMER6 SEC

PRESSURES
VESSEL
PRESSURE 1 BARG

0.3 BARG

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Section 2

SUMMARY OF ALARM CONDITIONS

BIN ACTIVATOR FAULT ALARM

Definition:

Thermal overload tripped (automatic reset with the start pushbutton).

Thermistor tripped (automatic reset with the start pushbutton).
Circuit breaker tripped (manual reset).

Control Action:

Visual alarm (only when the bin activator is requested to run).

CYCLE WATCHDOG FAULT ALARM

Definition:

The cycle watchdog timer has expired and a conveying cycle is still in progress.

Control Action:

Visual alarm only

CYCLE START FAULT

Definition:

Failed to start a conveying cycle.

Control Action:

Visual alarm and inhibit the start of cycle until the conveying cycle start conditions are
fulfilled.

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Section 3

SECTION 3

INSTALLING AND

OPERATING THE CCB

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Section 3

IMPORTANT

The CleanCut Cuttings Blower conveying vessel is, for insurance purposes, classed
as a pressure vessel.

CleanCut Cuttings Blower™ Vessel Design: PD5500 Category II

Design Pressure: 7 barg

Hydraulic Test Pressure: 10.9 barg

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Section 3

INSTALLATION

25mm Jacking Allowance

The CleanCut Cuttings Blower is installed beneath a feed chute with an allowance of
25mm made on overall height to allow the CleanCut Cuttings Blower to be slid into
position and raised on the jacking screws provided.

The CleanCut Cuttings Blower does not normally require bolting down since there is
no reaction or vibration during conveying. However in offshore applications after
installation. The vessel may be welded as necessary to the deck using the four
sacrificial mounting pads provided

Lifting

Care must be taken during any lifting of the CleanCut Cuttings Blower during
installation. Damage may be caused to the Cuttings Valve sealing head if any bar or
lifting device is placed inside the Cuttings Valve in order to obtain a lifting point. It is
recommended that the lifting lugs provided or eyebolts be used to lift the CleanCut
Cuttings Blower. Refer also to the erection and installation procedure

Pipework & Connections

A gasket is fitted between the CleanCut Cuttings Blower and the vibratory feed
chute. An air tight seal is required on all equipment above the CleanCut Cuttings
Blower since the air displaced from the material chamber during the Cuttings Valve
open period will tend to 'blow out' material from any loose fitting flange or simple
slide type isolating valve.

Air Supply

The air supply line size may appear larger than that required for the stated air
consumption, this is due to the fluctuating usage of air by the CleanCut Cuttings
Blower. Airflow is approximately twice the average air consumption stated for a brief
period during each conveying cycle.

Normally no special water removal or dirt removal equipment is required associated

with the air supply unless the material being conveyed is hygroscopic or adversely
effected by moisture.

Each CleanCut Cuttings Blower™ is equipped with its own air strainer to prevent
pipe scale and dirt from causing pressure regulator malfunction. An automatic drain
filter and oil fog lubricator set is fitted into the airline that is used for the pneumatic
controls.

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Section 3

Any air line stop valves which are fitted into the air supply to the CleanCut Cuttings
Blower must be of the 'gate' or 'ball' type which do not cause a restriction to air flow
when open.

Airline filters with fine mesh porous elements should not be fitted as these cause an
airflow restriction during peak air demand periods.

SYSTEM START UP PROCEDURE

The CCB once installed should be operated in fully automatic mode in conjunction
with the high level probe located within the feed hopper.

For a detailed description of the working cycle of the CCB section 2 of this manual
should be observed.

The basic start up checks are however detailed below:

1. Ensure compressor is operational and on load and the 2” CCB pilot operated
regulator is set to 6.0 barg.

2. Ensure the electrical supply is healthy and the main isolator ion the CCB is
switched to the ON position.

3. With the CCB set at rest check the timer settings are as in accordance with
section 2 of this manual.

4. Check calibration of the level probe as detailed in following sub section.

5. Start the system by pressing the green start push button. CCB cycle will
commence as soon as the high level probe is covered or to check depress the
level probe override button.

6. The CCB will now cycle at a frequency relative to the cuttings rate of
production.

7. To bring the unit to a controlled stop press the red stop button or alternatively
if an upset or fault condition occurs the CCB can be brought to an immediate
stop by depressing the Emergency Stop button.

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Section 3

SYSTEM SHUT DOWN PROCEDURE

1. Close isolating valve above CleanCut Cuttings Blower (if installed) , run the
vessel until empty by pressing the probe override button located on front of
operator control panel (where fitted). Turn relevant selector switch to 'OFF'
position.

2. Shut off mains air supply valve to the vessel (lock off if it is mounted remotely)

3. Shut off control air supply to the pneumatic panel and drain through the filter
on filter/ lubricator set, if venting has not been achieved in the normal through
the venting isolating valve.

4. Isolate electrical control panel(s). Use warning legends to inform other

personnel of the work being carried out

5. CAUTION before working on vessel, ensure vessel pressure gauge is

reading zero, which is located on vessel or on pneumatic panel.

Level Probe Calibration Procedure

1. Remove the lid from the large remote control pot (blue aluminium housing). As
the unit is IS Rated this operation can be conducted with the system running.

2. On the side of the electronics unit there is a Fail-Safe High/Fail-Safe Low selector
switch. Ensure this is set to Fail Safe High (upper most switch position).

Notes

• The LED on indicates the normal condition (i.e. LED will be extinguished when
material is covering the probe)

• Turning the adjustment pot clockwise will raise the level at which the LED
operates and turning counter clockwise will lower the level at which the LED
will operate.

Two methods can be employed

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 Revision No: 06
Section 3

Method 1

Requires the material level to be physically above the probe or for the hopper to be
empty of cuttings (Swaco/CleanCut Engineers will need to verify this work as a team)

Method 2

Relies on initially an empty condition and then a full level condition.

Method 1a – Hopper full above probe

1. Ensure probe is completely covered with cuttings.

2. Rotate the pot to find the operating point of the material i.e. until the LED is just
extinguished.
3. Now rotate the pot counter clockwise 1 turn

Calibration completed

Method 1b – Hopper empty below the probe

1. Ensure probe is completely empty/clear of cuttings.

2. Rotate the pot to find the operating point of the material i.e. until the LED is just
extinguished.
3. Now rotate the pot clockwise 1 turn

Calibration completed

Method 2

1. Ensure material level is below probe.

2. Rotate set point pot full counter clockwise (CCW)
3. Turn pot slowly clockwise (CW) until the LED just changes state. Although it is
uncovered, this adjustment causes the probe to give a ‘just covered’ output and
gives one extreme of the operating range.
4. Mentally note the position of the adjustment tool pointer.
5. Ensure probe is now covered with cuttings.
6. Counting the number of turns, rotate CW until LED changes state once more.
This gives the sensing point where a covered probe gives a ‘just uncovered’
output. This gives us the other extreme of the operating range.
7. Turn the pot back CCW half the total number or turns that were counted leave the
probe at mid-range sensitivity.
8. Record half the number of turns value as the “Preload” on the inside of the lid.

Calibration completed

PROCEDURE FOR REMOVAL OF 300mm INLET CUTTINGS VALVE

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 Revision No: 06
Section 3

Note:

Numbers in brackets refer to catalogue drawing P33074D-00.

Inlet Cuttings Valve

1. Fully close isolating valve and run the CleanCut Cuttings Blower until
empty.

2. Shut down and isolate system as shown in Section 3.

3. Disconnect and mark nylon pneumatic pipework to the cylinder (12) and
limit switch (26).

4. Remove setscrews securing isolating valve to adaptor if fitted to Cuttings

Valve top plate.

5. Remove setscrews from Cuttings Valve bottom flange to vessel.

6. Lower vessel by means of the jacking bolts on the feet of the vessel
(25mm). Where vessels are welded locally to the deck remove the flexible
adaptor

7. Remove Cuttings Valve by sliding sideways using lifting equipment if

possible

CUTTINGS VALVE MAINTENANCE INSTRUCTIONS

Replacement/Inspection of Cuttings Valve Insert Seal

Note:

Numbers in brackets refer to catalogue drawing P33074D-00.

1. Remove setscrews from top plate/adaptor (16), lift out the sealing head
assembly consisting of top plate/adaptor (16), insert seal (19), insert ring (18)
and spigot ring (17).

2. Note the number and thickness of gaskets (13, 14 & 15) under the spigot ring
(17). Combinations of 0.4mm, 0.8mm and 1.5mm thickness gaskets are fitted
to achieve the required seal gap (between the seal and the dome).

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 Revision No: 06
Section 3

3. Separate the seal (19) from the insert ring (18) and inspect for wear or
damage. Replace immediately if necessary.

4. Rotate the dome (2) by hand to check the condition of the bearings (4). If the
bearings (4) are seized or due for replacement proceed to
'Removal/Replacement of Cuttings Valve Bearings'.

5. When re-assembling the valve ensure that the underside of the top
plate/adaptor is free from corrosion. All surfaces should be clean in order to
form an airtight seal.

6. Lower the gaskets (13. 14 & 15) onto the valve body (1) followed by the spigot
ring (18) and insert seal/ring (18/19).

7. Lower the top plate/adaptor into position taking care not to trap the seal, and
tighten down.

8. Check the gap between the dome (2) (when in the closed position) and the
seal is correct using feeler gauges. The gap required is shown on the
relevant catalogue drawings in this section.

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 Revision No: 06
Section 3

REMOVAL/REPLACEMENT OF 300mm CUTTINGS VALVE

BEARINGS

Note:

Numbers in brackets refer to catalogue drawing P33074D-00.

1. Remove the sealing head assembly.

2. Remove cylinder guard front cover.

3. Remove the nearside circlip on the front clevis assembly (42) and lightly tap
the pin out.

4. The cylinder (12) can now be removed.

5. Turn the valve through 180°; remove grease nipples (41 & 23).

6. Punch out the two inner spring pins (9) securing the dome (2) to the shafts (3)
and remove torque arm (10) if necessary.

7. Remove rear guard.

8. Withdraw the shafts (3) and lift out the dome (2). Note if there are any shims
present on the shafts. The shims are occasionally fitted at the factory for
centralising the dome and should therefore be refitted on subsequent
overhauls.

9. Bearings and seals can now be removed by driving them towards the centre
of the valve.

10. All machined surfaces should be thoroughly cleaned/degreased and

inspected.

11. Check for surface irregularities in the dome (2) and shafts (3) and replace if
necessary. Also de-burr the edges to prevent damage to the replacement
seals and bearings on re-assembly.

12. Press the replacement shaft seal (7) (never put old seals/bearings back) into
the bore, followed by the spacer (8) and the remaining seal (7). Offer the
bearing (4) to the bore; align the grease hole in the bearing with 1/8" NPT hole
in the body. Press squarely until the bearing sits 5mm below the face of the
flange. Repeat for other side.

13. Liberally pack the space between the seals and coat the bearings with Shell
Malleus JB grease or equivalent.

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 Revision No: 06
Section 3

14. Re-fit the shim(s) (if applicable) and slide a new 'O' ring (11) over the shafts
(3) up to the boss.
15. Slide the shaft (3) through the bearing (4) until it touches the first seal.
Repeat for the other side.

16. Hold the dome (2) adjacent to the bores and drive the shaft through the seals
and the dome using a plastic/hide mallet. Re-fit the grease nipples (23 & 41).

17. Rotate the shafts (3) until the holes in the shaft and dome (2) align. Grease
the spring pins (9) and drive in.

18. Turn the valve through 180°.

19. Re-fit the cylinder assembly steps 2 to 7 in reverse order. Secure the guard in
position.

20. Re-fit the sealing head assembly.

21. Setting of Limit Switch

Loosen the lock nut on the striker arm (25) and wind up the setscrew. With the
dome (2) fully closed wind out the screw until the hex-head touches the
plunger on the limit switch (26). Turn the screw a further 4mm (3.25 turns) to
depress the plunger.

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 Revision No: 06
Section 3

PROCEDURE FOR REMOVAL OF 125mm OUTLET CUTTINGS

VALVE

Outlet Cuttings Valve

1. If fitted, fully close isolating valve and run the CleanCut Cuttings Blower until
empty.

2. Shut down and isolate system as shown in Section 3.

3. Disconnect and mark nylon pneumatic pipework to the actuator.

4. Disconnect air supply above the non-return valve on the stub pipe - at the
union.

5. Isolate air supply to air injection point and remove hose at crows foot
coupling. Remove whipcheck from hose side only.

6. Support outlet Cuttings Valve assembly to avoid damage to casting.

Disconnect 125mm Victualic coupling

7. Remove set screws securing Cuttings Valve to cast outlet bend.

8. Using suitable lifting tackle, the Cuttings Valve can now be removed.

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 Revision No: 06
Section 3

REMOVAL/REPLACEMENT OF 125mm CUTTINGS VALVE

BEARINGS

Vane Type Actuator Version

Note! The 125mm outlet valve does not have an insert seal assembly

Note:

Numbers in brackets refer to catalogue drawing P32541D-00.

1. Disconnect the bottom adaptor (33) from the Dome Valve body (1).

2. Remove the sealing head assembly (17).

3. Rotate the dome (2) until it resets in a position halfway between open and
closed.

4. Remove the setscrews that attach the actuator mounting (21) to the valve
body (1) and withdraw.

5. Remove the grease nipples (19 & 20).

6. Turn the valve upside down (through 180°).

7. Punch out the two inner spring pins (11) securing the dome (2) to the shafts
(3).

8. Withdraw the shafts (3) and lift out the dome (2).

9. The bearings and seals can now be removed by driving them towards the
centre of the valve, using a hide mallet

10. All machined surfaces should now be thoroughly cleaned/degreased and

inspected.

11. Check for surface irregularities in the dome (2) and shafts and replace if
necessary. Also de-burr the edges of the two holes and the leading edge of
each drive shaft to prevent damage to the replacement seals/bearings on re-
assembly.

12. Press the replacement shaft seal (9) (never put old seals or bearings back)
into the bore, followed by the spacer (8) and the remaining seal (7). Offer the
bearing (4) to the bore. Align the grease hole in the bearing with 1/8" NPT
hole until the bearing sits 5mm below the face of the flange. Repeat for other
side.

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 Revision No: 06
Section 3

13. Liberally pack the space between the seals and coat the bearings with Shell
Malleus JB or equivalent.

14. Re-fit a new 'O' ring (12) over the shafts (3) up to the boss.

15. Slide the shaft (3) through the bearing (4) until it reaches the first seal in the
bore.

16. Hold the dome (2) adjacent to the bores and drive the shafts (3) through the
seals and the dome (2) using a plastic/hide mallet.

17. Rotate the shafts (3) until the holes in the shaft and the dome (2) align.
Grease the spring pins (11) and drive in.

18. Turn the valve right way up again (through 180°).

19. Fit the grease nipples (19 & 20) and the actuator (13).

20. Re-fit the sealing head assembly.

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 Revision No: 06
Section 4

SECTION 4

FAULT DIAGNOSIS

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 Revision No: 06
Section 4

FAULT DIAGNOSIS - CLEANCUT CUTTINGS BLOWER

WARNING: Prior to Fault Finding on System, Check Air & Electrical Supplies

SYMPTOM PROBABLE CAUSE REMEDIAL ACTION

CCB does not start, 1. Electrical. 1. Check start signal on terminal

Cuttings Valve remains
static.
Open on N/Open, closed on
N/Closed
2. Solenoid valve faulty.
3. Vessel Pressure Low
Pressure switch faulty
to CCB panel, if no signal
trace through on electrical
circuit.
2. Check power to appropriate
coil. If power satisfactory
strip valve, clean and check
3. pneumatic line.
Check pressure switch and
set point

CCB starts, vessel fills, Inlet
Valve closes but does not
convey
1. Pneumatic limit switch
not making.
2. Cuttings Valve not
closing completely,
foreign object trapped
in Cuttings Valve or
shafts seized.
1. Adjust as per maintenance
manual. Replace if faulty.
2. Isolate electrics and
pneumatics. Remove pipe
from bottom bend to clear.
Clear vessel. Disconnect
actuator and operate
manually, checking limit
switch operation.

3. Blow valve not working. 3. Check air supply to valve. If

satisfactory repair or replace
valve. If no air supply, check
blow solenoid operation
(N/Closed system) or limit
switch (N/Open system).

4. No conveying air 4. Check compressor and pilot

regulator

5. Supply air, Pressure 5. Replace regulator and check

regulator failed pressure setting

CCB starts to convey then 1. Conveying pipe 1. Check air and power supply.
stops with high vessel blocked (see conveying
pressure pipe blocked section). Check piping from valve to
control panel.

2. Outlet valve failed to 2. Check solenoid valve

open. connection. Check quick
valve on the outlet valve is
operational

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 Revision No: 06
Section 4

SYMPTOM PROBABLE CAUSE REMEDIAL ACTION

3. Vessel blocked. 3. Air passing into conveying

pipe but vessel is blocked
and pressurised. Isolate air
and electrics. Release
pressure from vessel using
manual drain valve. Remove
pipe to outlet bend and
investigate possible wet or
oversize material and foreign
object.

Air leaks through Cuttings 1. Seal air pressure 1. Check air supply lines.
Valve or Vent Valve during dropping to near
conveying conveying pressure.

2. Inlet Valve inflatable 2. Renew seal, checking gap

seal ruptured. between dome and seal as
per maintenance manual.

3. Vent valve seal split. 3. Fit new valve or seal.

4. Control air Filter 4. Strip and clean.

Lubricator blocked.

Air exhausts continuously 1. Solenoid not working 1. Strip and clean.

through open/closed full travel.
solenoid
2. Inlet Valve actuator 2. Fit new seals.
seals leaking.

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 Revision No: 06
Section 4

Conveying pipe blocked 1. Incorrect regulator 1. Adjust or replace regulator.

setting or faulty
regulator.

2. Oversized material 2. Investigate

3. Blow valve malfunction. 3. Strip and check.

4. Pipe misalignment. 4. Check at block point.

5. Insufficient air 5. Check air supply

6. Electrics cut off mid 6. Investigate cause e.g.,

cycle. operators fingers!

7. Pulse Air settings in 7. Check and/or adjust settings

appropriate.

Pressure relief valve 1. Incorrect regulator 1. Adjust or replace regulator.

operates setting or faulty For the PRV to operate there
regulator. is probably also a blocked
line. Check vessel pressure
and use manual vent if
necessary.

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 Revision No: 06
Section 5

SECTION 5

ROUTINE MAINTENANCE

42
 Revision No: 06
Section 5

ROUTINE MAINTENANCE

NOTE! Before starting any routine maintenance ensure the system is isolated
both electrically and pneumatically, and vented of any residual pressure.

General Notes on all Routine Maintenance

It shall be noted that before starting any routine maintenance ensure the
system is isolated both electrically and pneumatically. Conveying pipes and
CCB/ISO Pump vessels must also be vented of any residual pressure.

DAILY MAINTENANCE

The daily system check is an attempt to identify the possible onset of component
failure before the event effects system performance and ultimately impacts the
overall system reliability.

Unlike the weekly and monthly maintenance routines there are no planned activities
for this regime. The check, assuming a live operational system, is intended to verify
the operational health of the equipment with corrective actions only taking place
should problems or the onset of possible component failure be identified.

In order for the following checklist to be purposefully administered the system should
ideally be operational. If so a combination of pressure readings, pressure settings
and valve functionality tests will be read or determined.

Daily Inspection Check List

Item Check Description Comments
No

1 Pressure Regulator setting should See P&ID Drawing for any

be approximately 6.0 barg with amendment to this set value.
system at rest.

No flow pressure (system at rest) Note two pressure should be near

Pnf barg. identical. If the differential
Air flowing condition (system between Pf and Pnf is > than 0.75
conveying Cuttings) Pf barg barg check supply air source and
system flow plates/nozzles.

2 CCB vessel pressure at rest < 0.15
barg
If pressure >0.15 barg check:
Condition of vent line and vent
valve.
Ensure accuracy of vessel gauge.

43

3 Air manifold and pneumatic signal
tubes have no air leaks
4 Ensure all Poppet Style air manifold
valves are functioning. Each valve
indicator button to be checked:
• Vent line purge air valve
• Conveying pipe ABR valve
• Cycling Air sweep valve
5 Vessel pressure during convey
cycle
6 Vessel pressure when system
vented
7 Cuttings inlet valve opens and
closes with a single smooth action
8 Cuttings outlet valve opens and
closes with a single smooth action
9 Blow phase of the cycle is
terminated when the end of blow
pressure switch is made with a <1.0
barg falling pressure level.
10 Ensure cuttings inlet valve only
opens with a vessel pressure of
<0.2 barg.
Revision No: 06
Section 5
If any leaks are found take
necessary corrective action.
Burkert valve heads enclose a
yellow open/closed indicator
button. The status of each valve
should be individually observed
through a complete cycle
Pressure should rise, typically >
2.5 barg, and momentarily
increase and decay as the
airsweep valves cycle.
Lack of significant vessel pressure
could be symptomatic of:
• Shortage of cuttings delivery
• CCB choked with cuttings
• Vent valve failed
• Lack of conveying air
Decay in pressure down to <0.15
barg should take no longer than
two to three seconds. If vent time
exceeds this check:
• Vent valve operation
• Vent pipe for restrictions
Check apparent switch point of
pressure switch.
Check vessel pressure and hence
pressure switch setting at valve
open instant.
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 Revision No: 06
Section 5

11 Feed hopper vibro motor should Take necessary corrective action if

rotate for a brief period before found to operate out side of these
coming, instantly to rest via the specifications
reverse plug stopping contactor.
Whilst rotating the motor should
generate only minimal noise
typically associated with a running
electrical motor.

WEEKLY MAINTENANCE
Cuttings Inlet and Outlet Valves

Grease Valve shafts and bearings (hydraulic grease nipples located on Valve body)
using Shell Malleus JB Grease.

Filter Lubricator and main manifold strainer

Check lubricator units mounted on outside of pneumatic panels and on control air
supply and top up lubricators as required. Monitor condition of filters and clean as
required (normally annually).

Caution!

When it is necessary to remove a filter for cleaning purposes/renewal, the air

supply to the control panel must be isolated.

MONTHLY MAINTENANCE
Cuttings Inlet Valve
Check settings on cuttings Inlet Valve limit switches where applicable. Refer to
drawings in Section 9.

Pneumatic Control Panel

Inspect condition of exhaust silencers (located on underside of panel) renew as

required. Clean out filter where applicable.

Air manifold strainer

Remove strainer insert from convey airline strainers, clean and replace. General
functional checks of ball valves on system.

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 Revision No: 06
Section 5

ANNUAL MAINTENANCE
The following maintenance is required for long term rental machines else this
maintenance shall only be conducted at the relevant time when the units are
returned to shore between rentals.

Cuttings Inlet and Outlet Valves:

Remove Cuttings Inlet Valve as described in section 3 of the O&M Manual and
check head of dome and seal for signs of wear.

Check Cuttings Inlet Valve shafts for wear and replace bearings and seals as
described in section 3 of the O&M Manual if required.

Remove Cuttings Outlet Valve as described in section 3 of the O&M Manual and
check head of dome and seal for signs of wear.

Check Cuttings Outlet Valve shafts for wear and replace bearings and seals as
described in section 3 of the O&M Manual if required.

Inspect cylinder shaft for score marks scratches, pitting, rust etc. as this can lead to
premature failure of cylinder seals.

Control Panels:

Visual inspection of electrical and pneumatic connections and condition of equipment

within the enclosures.

Pressure Safety Relief Valves:

These shall be tested in accordance with manufacturers and/or Insurance test

schedule. Each valve, as a minimum, shall be visually inspected for signs of
damage.

Manifold Pipe, Flexible Hoses and Valves:

All manifold pipes will be inspected for damage and any corrosion.

Flexible hoses will be inspected for any signs of degradation of the hose wall, which
is manufactured from a nitrile rubber. Degradation will include wall softening, an
increase in outside hose diameter or delamination of the hose fabric.

Valves will be inspected for operational performance and the head will be removed to
assess the condition of the valve seat and seal.

Pressure Control Valve (Pilot Operated Regulator):

The regulator shall be opened and the diaphragm checked for signs of degradation
and wear. The unit shall then be connected with a compressed air source >7.0 barg
and the unit assessed for ease of setting the desired pressure set point.

46
 Revision No: 06
Section 6

SECTION 6

CONTROLLER

47
 Revision No: 06
Section 6

CROUZET MILLENIUM CONTROLLER Part No 6795001

System Voltage: 24VDC

Control Voltage: 24VDC

Software Version Used: Factory Programmed

Interface Required: None

EEPROM Required: Clyde Materials Handling Part No 6795001

This is a non- repairable throwaway unit on failure

The following displays mimic the physical display generated on the LCD Millennium
unit.

In viewing these screens it is possible to identify which PLC Inputs and/or Outputs
are required for healthy CCB operation and the conveying cycle advances.

1.0 System at Rest - Waiting for start signal

Status:
With the status as shown the system is healthy
Vessel Press < 0.3 barg

Vessel Press < 1.0 barg

Remote Cycle Enable

Vibro Motor Running

and is waiting on three conditions becoming true.

Inlet valve Closed

Timer Decrement
Timer Increment

Timer Selection

Level Probe Operation:

If the system is running with probe then Input 12
is required to be true. (Note frequency timer
Start

Stop

should be set to zero seconds to esure probe only

control)
Inputs
1 2 3 4 5 6 7 8 9 10 11 12 Timer Operation:
PLC
If the CCB is operating in timer mode then either
Outputs the level probe should be linked out (across
1 2 3 4 5 6 7 8 terminal numbers 26 & 28) or the probe should be
Inlet Valve open

Pulse Air
Reverse Plug Stop
Conveying Air

System Running
Vibro Motor

set Fail safe low providing a permenant signal to

input 12.
= Output/Input low

= Output/Input high Start Request:

Start push button pressed providing input 1

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 Revision No: 06
Section 6

2.0 Start Conditions Satisfied - cycle commenced

Status:

Vessel Press < 0.3 barg

Vessel Press < 1.0 barg

Remote Cycle Enable

With the status as shown the system is healthy

Vibro Motor Running

Inlet valve Closed
and has initiated the next cycle.

Timer Decrement
Timer Increment

Timer Selection
Level Probe Operation:
Start

Stop

If the system is running with probe then Input 12

will now be true.
Inputs
1 2 3 4 5 6 7 8 9 10 11 12 Timer Operation
PLC
If the CCB is operating in timer mode then either
Outputs
1 2 3 4 5 6 7 8 the level probe should be linked out (across
terminal numbers 26 & 28) or the probe should be
Inlet Valve open

Pulse Air
Reverse Plug Stop
Conveying Air

System Running
Vibro Motor

set Fail safe low providing a permenant signal to

input 12.

3.0 CCB Filling Status:

CCB filling will commence with the system status

Vessel Press < 0.3 barg

Vessel Press < 1.0 barg

Remote Cycle Enable

as shown.
Vibro Motor Running
Inlet valve Closed

Timer Decrement
Timer Increment

Timer Selection

Vent Valve Status:

The vent valve is is directly reverse logic

Start

controled from the blow valve signal output 2.

Stop

Inputs Blow Valve closed - Vent Valve open

1 2 3 4 5 6 7 8 9 10 11 12 Blow Valve open - Vent Valve closed
PLC
CCB Outlet Valve:
Outputs
1 2 3 4 5 6 7 8
The Outlet Valve is is directly reverse logic
Inlet Valve open

Pulse Air
Reverse Plug Stop
Conveying Air

System Running
Vibro Motor

controled from the Inlet Valve signal output 1.

Inlet Valve closed - Outlet Valve open

Inlet Valve open - Outlet Valve closed

4.0 CCB Conveying Material

Status:
With the status as shown the system is healthy
Vessel Press < 0.3 barg

Vessel Press < 1.0 barg

Remote Cycle Enable

Vibro Motor Running

and conveying is in process.

Inlet valve Closed

Timer Decrement
Timer Increment

Timer Selection

Pulse Air:
The pulse air output No 6 will oscillate at the
frequency selected with the combination of pulse
Start

Stop

frequency and delay off timers set by the

Operator.
Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC

Outputs
1 2 3 4 5 6 7 8
Inlet Valve open

Pulse Air
Reverse Plug Stop
Conveying Air

System Running
Vibro Motor

49
 Revision No: 06
Section 6

5.0 Conveying Cycle Completed

Status:

Vessel Press < 0.3 barg

Vessel Press < 1.0 barg

Remote Cycle Enable

With the status as shown the system has

Vibro Motor Running

Inlet valve Closed
successfully completed a conveying cycle. The

Timer Decrement
Timer Increment

Timer Selection
vessel pressure has reduced to less than 1.0 barg
as indicated by the input signal 5. The Blow
Valves will close and the vent line open.
Start

Stop

Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC

Outputs
1 2 3 4 5 6 7 8
Inlet Valve open

Pulse Air
Reverse Plug Stop
Conveying Air

System Running
Vibro Motor

6.0 CCB Cycle Completed and Reset Status:

The CCB has now completed the entire cycle,

Vessel Press < 0.3 barg

Vessel Press < 1.0 barg

Remote Cycle Enable

with the vessel pressure now below 0.3 barg.

Vibro Motor Running

The unit is rest and awaits the next remote cycel

Inlet valve Closed

Timer Decrement
Timer Increment

Timer Selection

enable or cycle frequency timer to initiate the next

cycle.
Start

Stop

Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC

Outputs
1 2 3 4 5 6 7 8
Inlet Valve open

Pulse Air
Reverse Plug Stop
Conveying Air

System Running
Vibro Motor

50
 Revision No: 06
Section 7

SECTION 7

RECOMMENDED SPARES

51
 Revision No: 06
Section 7

The spares required for a CCB can be dependant on a number of issues:

1. Total number of CCB on the Installation

2. The requirement of each CCB (redundancy or dual simultaneous running)
3. The level of safety stock held on shore

To automate the required spares relative to the variables identified above an

interactive spreadsheet has been developed.

For a detailed and tailored spares listing this spreadsheet should be utilised,
however as a general guideline the following spares listing is provided.

This listing represents the full spares list for a single CCB.

52
 Revision No: 06
Section 7

Description Part Number Quantity

Feed Hopper
Feed Chute Skirt P32267E-00 1
Tensioning wire P32262E-00 1
Bottom Gasket ( 300 Isol V/V) P32259E-00 3
Flex adapter Sleeve P32249D-03 1
Band Clamp-300mm P20306E-03 1
Bottom Gasket P2122A-12 2
Inlet Valve
Inlet Dome Valve Spares Kit P33074D-03 M3232 1
Cylinder P34675E-00 1
Cylinder Seal kit A2214 1
300mm Dome V/V Gasket Set P2120A-03 2
Dome Insert Seal P1826C-05 1
Adapter Plate Gasket ( P32201D-00) (V to D) P32206E-00 2
Air Limit Switch (inlet) A1011 1
Quick Exhaust Valve A1067 1
Exhaust Silencer P17951E-00 4
Outlet Valve
Outlet Dome Valve Spare Kit P32541D-00 M3226 1
Actuator A4374 1
Actuator Seal Kit A2201 1
100/125mm Dome Gasket Set P2120A-01 1
Outlet Bend to V/V Gasket P2120A-83 1
Manifold Assembly
Pressure Regulator 2" A2973 1
Seal Kit Pressure Regulator 2" A4445 1
Pilot Regulator for 2" Reg A4359 1
Seal Kit Pilot Regulator for A4359 A4467 1
Pressure Gauge A1058 1
1 1/2" Blow Valve A4373 1
Silencers A1590 4
Pressure Switch A4287 1
Pressure Gauge A4285 1
1/2" Non Return Valve A3527 1
2" Non Return Valve P33043E-00 1
2" NRV Discs P33045E-02 4
Clamps M6870 2
Vent Valve (Butterfly v/v) A4151 1
Fluidising P33442D-00 1
8mm Nylon (1 m ) A1570 25
12mm Nylon (1 m ) A1571 25
"O" Ring (from M2817) M2817 1
Enots Pneumatic fittings 5855006 1
Dunlop gacord hose 3/4"NB M3542 5
Dunlop gacord hose 1 1/2"NB M2780 5
Dunlop gacord hose 1"NB M2781 10
Dunlop gacord hose 2"NB M3079 10
Pneumatic Control Panel
Solenoid Valve CC0067 1
Coils CC0068 2
Silenc A1968 5
Pressure Switch A4097 1

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Electrical Control Panel

PLC Crouzet MilleniumIII 8006330 1
Power Supply Unit E4987 1
EEPROM-Crouzet MilleniunIII 88970108 6795001 1
Bulb 24V DC E5553 2
Contactor E5600 1
Overload E5601 1
Circuit Breaker E5602 1
Fuse Link - 5A E5603 3
Fuse 2A E4121 3
Relay E5604 1
Actuator E5605 1
Switch E5606 1
Pushbuttons (normally open) M-0429/V 1
Pushbutton (normally closed) M-0429/R 1
E-Stop M-0045 1
Mounting Feet-Vessel 8/12 "ES" P32698D-00 1
Vibro Motor 6910006 1
Level probe CC0016 1
Probe remote electronic unit CC0013 1
Probe cable and glands CC0012 1
Level Monitor and Transformer Isolator CC0007 1

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SECTION 8

PROPRIETARY PARTS

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Section 8

ACTUATOR

CLEANCUT PART NO A4374

DESCRIPTION Double Acting Actuator

MANUFACTURER Kinetrol

MANUFACTURER’S PART No 090-100 Low Temp

FURTHER INFORMATION
Operating Temperature: Min –40°C (-40°F) Max 80°C (176°F)
Operating Pressure: Max 7 bar (100psi)

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BLOW VALVE

CLEANCUT PART NO A4373

DESCRIPTION 1 ½” NPT Blow Valve

MANUFACTURER Burkert

MANUFACTURER’S PART No 155682

FURTHER INFORMATION
Operating Temperature - Ambient: -40° to + 100°C
- Fluid: -40° to + 180°C
Operating Pressure: Max 10 bar
Design: 2/2 way piston operated valve, normally closed, spring return, 50mm actuator

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BUTTERFLY VALVE

CLEANCUT PART NO A4151

50mm Butterfly Valve - ANSI 150lb – Nitrile
DESCRIPTION
Seal c/w Double Acting Actuator
MANUFACTURER Bray

MANUFACTURER’S PART No Series 20

FURTHER INFORMATION (VALVE)

Operating Temperature: -18° to + 100°C
Max Shut-off Pressure: 10 bar
Velocity Limit (Gases): 54m/s
Unseating Torque: 15Nm (at 7 bar)
Weight: 2.95kg
FURTHER INFORMATION (ACTUATOR)
Description: Bray GT Series Double Acting Actuator
Rack and Pinion, Opposed Piston
Operating Temperature: -25° to 95°C
Maximum Pressure: 10 Bar
Torque (constant): 15.9 Nm (at 7 bar)
Weight: 0.6kg

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CYLINDER

CLEANCUT PART NO P34675E-00

DESCRIPTION Cylinder 160 x 250 Stk C/Trun (suit. for -40°C)

MANUFACTURER Norgren

MANUFACTURER’S PART No SPC/010318/250 -40°C

FURTHER INFORMATION
Operating Temperature: -40° to + 80°C
Operating Pressure: Min 1 bar, Nominal 10 bar
Design: Single Acting cylinder with spring return

NB: This is a typical cylinder for information only

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FILTER

CLEANCUT PART NO A2426

DESCRIPTION Filter/Lubricator ½” NPT

MANUFACTURER Norgren

MANUFACTURER’S PART No FL 64-408 EX

FURTHER INFORMATION
Operating Temperature: -20° to + 80°C
Operating Pressure: Maximum inlet pressure 17 bar

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LEVEL SWITCH

CLEANCUT PART NO CC0016

DESCRIPTION Level Switch 400mm

MANUFACTURER Drexelbrook

MANUFACTURER’S PART No

FURTHER INFORMATION
Operating Temperature: -40° to + 60°C
Output: 4-10mA covered; 14-20 mA uncovered
Sensitivity: 0.1pF
Design: Level Control Transmitter; Point level; Radio Frequency (RF); Analogue output

Level Probe Assembly

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LIMIT SWITCH

CLEANCUT PART NO A1011

DESCRIPTION Limit Switch ¼” BSP

MANUFACTURER IMI Norgren

MANUFACTURER’S PART No S-1340/14

FURTHER INFORMATION
Operating Temperature: -20° to + 75°C
Operating Pressure: 0.7 – 10 bar

Design: 3/2 way mechanically operated poppet valve, normally closed.

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MOTOR (VIBRATORY CHUTE)

CLEANCUT PART NO 6910006

DESCRIPTION Vibratory Motor EBK20-5/4

MANUFACTURER Invicta Vibrators

MANUFACTURER’S PART No EBK/20-5/4/PW/61

FURTHER INFORMATION
Operating Temperature: -20° to 40°C
Design: 480 Volts, 3 Phase, 60 Hz

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PRESSURE GAUGE
Three gauges are used on the CCB:

GAUGE 1
CLEANCUT PART NO A1008

DESCRIPTION Pressure Gauge 0-14 bar

MANUFACTURER Schrader

MANUFACTURER’S PART No 802M-20D

FURTHER INFORMATION
Port: G ¼”
Diameter: 50mm
Mounting: Centre back

GAUGE 2
CLEANCUT PART NO A1058

DESCRIPTION Pressure Gauge 0-10 bar

MANUFACTURER Norgren

MANUFACTURER’S PART No 18-013-013

FURTHER INFORMATION
Port: R 1/8”
Diameter: 50mm
Mounting: Centre back

GAUGE 2
CLEANCUT PART NO A4285

DESCRIPTION Pressure Gauge 0-11 bar

MANUFACTURER Budenburg

MANUFACTURER’S PART No Grout 100mm

FURTHER INFORMATION
Port: ½” BSP
Diameter: 100mm
Mounting: Bottom entry

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PRESSURE RELIEF VALVE

CLEANCUT PART NO A3837-CERT

DESCRIPTION Pressure Relief Valve

MANUFACTURER IMI Bailey Burkett

MANUFACTURER’S PART No 716 ESL

FURTHER INFORMATION
Operating Conditions: Max pressure 12.5 bar at 150°C
Minimum temperature -40°C
Design: Full Lift Safety Relief Valve

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PRESSURE REGULATOR

The Pressure Regulator is an assembly of two parts:

CLEANCUT PART NO A2973 A1178

DESCRIPTION Pilot (Slave) Regulator 2” NPT Pilot Regulator ¼” NPT

MANUFACTURER IMI Norgren IMI Norgren

MANUFACTURER’S PART No R18 – C00 NNXA R40 – 200 - BNLA

FURTHER INFORMATION
Operating Conditions R18: Max pressure 31 barg
Minimum temperature -20°C
Maximum temperature +80°C

Operating Conditions R40: Max pressure 20 barg

Minimum temperature -20°C
Maximum temperature +80°C

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PRESSURE SWITCH

Two pressure switches are used on the CCB:

CLEANCUT PART NO A4097

DESCRIPTION Pressure Switch 0.7 – 7 bar

MANUFACTURER Sirco

MANUFACTURER’S PART No E (X) 4000RC-LO

CLEANCUT PART NO A4287

DESCRIPTION Pressure Switch 0.14 – 14 bar

MANUFACTURER Sirco

MANUFACTURER’S PART No E (X) 4000RB-AO

FURTHER INFORMATION
Operating Temperature: -20° to + 60°C
Operating Pressure: 0.7 – 10 bar

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STRAINER

CLEANCUT PART NO A4372

DESCRIPTION Strainer 2 ½” NPT (Suitable for –40°C)

MANUFACTURER Spirax Sarco

MANUFACTURER’S PART No Fig 12GM

FURTHER INFORMATION
Operating Range: 0 – 20 barg at 210°C
0 – 25 barg at 60°C
Minimum operating temperature -198°C
Screen: Stainless Steel, 0.8mm perforations

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SECTION 9

DRAWINGS

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Section 9

GENERAL ARRANGEMENT DRAWINGS

DRAWING NO REV TITLE

CC0052D-00 02 1000/300/60 Vibrating Feed Chute, GA Offshore Spec.

P32541D-00 10 Dome Valve-Drill Cuttings-EnpCoated Armourcoted Internarls

P32675D-00 07 Cuttings Blower - Vent Valve assembly

P33005D-00 09 Model 8/12 Cuttings pump - Manifold assembly with 6 nozzles

P330056D-00 08 CCB Assembly fittings

P33074D-00 07 Dome valve - pho - bulkhead - sectional ga 10% strechted

seal - low temp applications - armourcoted internarls

P33109D-00 01 CCB Outline GA

P33175D-00 06 Pneumatic circuit model 8/12 Cuttings blower - with nozzles

P35461D-00 02 Air spray Nozzle Assembly

P35469D-00 05 Feed Hopper Airsweep Supply Assembly

P35532D-00 02 Feed Hopper Airsweep Supply Assembly

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76
77
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81
82
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Section 9

CIRCUIT DRAWINGS

DRAWING NO REV TITLE

P32688D-00 02 P&ID Model 8/12 CleanCut Cuttings Blower

CleanCut Cuttings Blower - motor and supply wiring

P33088D-00 02
diagram.

P33089D-00 02 CleanCut Cuttings Blower - input wiring diagram

P33090D-00 01 CleanCut Cuttings Blower - Output wiring diagram

P33091D-00 02 CleanCut Cuttings Blower - Block diagram

P33092D-00 01 CleanCut Cuttings Blower - Pneumatic Panel

P33175D-00 0 CleanCut Cuttings Blower - Pneumatic Circuit

CleanCut Cuttings Blower level switch LSH01-wiring

P34838D-01 03
details.
CleanCut Cuttings Blower remote pushbutton stations 1 &
P35395D-01 01
4 wiring diagram.
CleanCut Cuttings Blower remote pushbutton stations 1 &
P35396D-01 01
4 wiring diagram.
CleanCut Cuttings Blower remote pushbuttons stations
P35397D-01 01
1,2,and 4 wiring diagram.
CleanCut Cuttings Blower remote pushbutton stations 1-4
P35398D-01 01
wiring diagram
CleanCut Cuttings Blower remote pushbutton station 1
P35399D-01 01
wiring diagram.
CleanCut Cuttings Blower remote pushbutton stations 1 &
P35444D-01 01
2 wiring diagram
CleanCut Cuttings Blower remote pushbutton stations 1 –
P35445D-01 01
3 wiring diagram
CleanCut Cuttings Blower remote pushbutton stations –
P35519D-01 01
block diagram.
CleanCut Cuttings Blower Typical remote pushbutton
P35520D-01 01
stations – wiring diagram
CleanCut Cuttings Blower remote pushbutton station 4 –
P35521D-01 01
wiring diagram

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P34838D NOTES

ON SETTING UP OF PX1-10
CLYDE CUTTINGS I/S CABLE

BLOWER ( 3 x 1.5mm ) LEVEL (2 x 1.5)

LEVEL
(FLYING LEAD
FROM ELEMENT) LEVEL 8mA - ALARM <
SEE NOTE
DRAWING No

CONTROL PANEL SWITCH TRANSMITTER ELEMENT 16mA - OK >

LSH01 LTH01 LEH01 0mA - ALARM
LOSS OF SIGNAL SIMULATE HIGH

16/11 50 51/2 LOOSE ITEMS, TO BE MOUNTED BY YARD

X4 25 X4 26 X4 28

E 25 26 27 (TERMINALS) PROBE
OVERRIDE
(GREEN PUSHBUTTON) LEVEL SWITCH LSH01
60/1 61/1 62/1

60/2 61/2 64/1 63/1 63/2 64/2 60/3 61/3 61/4 62/2

12 11 7 8 Y1 Y2 A2 A1 15 18 21 22
- +

I/S BARRIER LEVELMONITOR

KFD2-CR-EX1.30.200 1 3 PXL 10.338.4115

I/S CIRCUIT HIGH LEVEL

IN THE
FEED HOPPER

(BLUE) + -
(FLYING LEAD BLUE
FROM ELEMENT)

(RED)
TRANSMITTER
RED EXTERNAL

SCREEN TERMINATED
LEVEL IN THE GLAND
ELEMENT

LEH 01

Issue: Revision: Date: Client:

MATERIALS
02 LSH01 Contact N/C and additional notes 28-01-02 **** HANDLING
CONFIDENTIAL 03 Additional notes 02-24-09
Title:
CLYDE CUTTINGS BLOWER LEVEL SWITCH
SHAW LANE INDUSTRIAL ESTATE
This print and all information thereon is the
property of Clyde Materials Handling Limited LSH01-WIRING DETAILS DONCASTER
Doncaster, England and must be kept
Date: 02-18-09 Checked by: Drawing No: Issue:
confidential and not be made public or
copied unless so authorised by them Drawn: T.H. Date:
SOUTH YORKSHIRE DN2 4SE
and is subject to return upon demand. 91
02-18-09
Scale: Project No: Telephone: 01302 321313
N.T.S. P34838D-00 03 Facsimile: 01302 369055
 Revision No: 06
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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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Section 9

NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

99
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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

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NOTE:

REMOTE PUSH-BUTTON STATIONS

AND EMERGENCY STOPS ARE
OPTIONS, NOT INCLUDED IN
DELIVERY

101