985 22647-R02 Installation Manual ORCA Offshore Part1

Created by ALFALAVAL Copenhagen
Installation Manual

Fresh Water Maker
ORCA Offshore
Document No.: 985 22647 Rev. 02

Project Name :
Project No. :
Serial No. :

985 22647-R02 Installation Manual ORCA Offshore Part1.doc Page 2 of 21

Generally most of the items installed in the ORCA can be found in the equipment,
valve or the instrument list in the appendix.

Additionally Part Lists and drawings can also be found in the appendix.

All items on the lists refer to a tag number in the PID.

Equipment, valves or instruments for which Alfa Laval supplies spare parts, can
be found with article numbers in the Spare Parts Manual.

Spare parts for the electrical control panel as well as parts for the separator
vessel which cannot be found in the equipment, valve or the instrument list are
included separately in the Spare Parts Manual.

When requesting or ordering spare parts from Alfa Laval please always state:

The ORCA serial number
(Please see name plate mounted on the equipment, current front page or footer)
Article number & item description
Tag number (if relevant).

Alfa Laval Service

The Alfa Laval group is represented in all major parts of the world.

DO NOT hesitate to contact your local Alfa Laval Sales Company if you have any
questions, problems or require spare parts. Find us at www.alfalaval.com

Alfa Laval reserves the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for
improvement of this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval Sales
Company.

Published by:

Alfa Laval Copenhagen A/S
Maskinvej 5
DK-2860 Sborg
Copenhagen) Denmark

Copyright Alfa Laval Copenhagen A/S.

This document and it content must not be copied, reproduced, transmitted or disclosed
to any third party without consent of Alfa Laval Copenhagen A/S.

Installation Instructions

1 SAFETY INSTRUCTIONS AND WARNINGS 4
1.1 Safety Instructions and Warnings 4
1.2 General Safety Precautions 4
2 ENVIRONMENT DECLARATION 5
3 STORAGE AND TRANSPORTATION 7
3.1 Storage 7
3.2 Preservation Procedure for control panels 8
3.3 Preservation Procedure for Solenoid Valves 8
3.4 Preservation Procedure for Motors 8
3.5 Preservation Procedure Compressor 9
3.6 Transportation 10
4 PERFORMANCE CRITERIA 11
4.1 Sea water Design water Analyses 12
5 INSTALLATION 12
5.1 Installation description 12
5.1.1 Electrical Equipment 12
5.1.2 Seawater Supply 13
5.1.3 Brine and Seawater Discharge 13
5.1.4 Distillate Discharge 13
5.1.5 Space Requirements 13
5.1.6 Ambient Conditions 13
5.1.7 Vibrations 13
5.1.8 General Safety Precautions 13
5.1.9 Scale Inhibitor Dosage Equipment for Feed Water 13
6 SYSTEM DESCRIPTION 14
6.1 System Description 14
6.2 Working Principle 15
6.3 Distillate Quality/Salinity 16
6.4 Main Components 16
6.5 Optional Equipment 18
7 ELECTRICAL SPECIFICATION 19
7.1 Environment conditions 19
7.2 Local Control Panel (LCP) 19
7.3 Cabinet 19
7.4 Power Supply 19
7.5 Installed Power 20
7.6 Earting System 20
7.7 PLC 20
7.8 HMI 21

1 Safety Instructions and Warnings

1.1 Safety Instructions and Warnings

The following symbols in this manual point out safety precautions. It means your
attention is needed and your safety is involved.

Warning

This symbol is used to indicate the presence of a hazard, which can
cause severe personal injury if the warning is ignored.

Caution

This symbol indicates the presence of a hazard, which can cause
property damage if the instructions are not observed.

Note

This type of instruction indicates a hazard, which could cause
damage to equipment.

1.2 General Safety Precautions

It is the responsibility of both operator and owner to ensure that all personnel
involved in the use or operation of this equipment follow all safety instructions.

Read all safety instructions carefully and insist that they be followed by those
working with you and for you.

Not following the instructions may cause severe personal injury or damage the
equipment beyond repair.

Do not allow this equipment to be used if it is faulty or the operator does not
understand the proper use.

Warning

The ORCA is not to be operated in polluted water.
The produced water can be unsuitable for human consumption.


Warning

Noise hazards
Use ear protection in noisy environments.

Crush hazards
Use correct lifting tools.
Do not work under hanging load.

Caution

Burn hazard
Wear gloves to avoid burns by hot surfaces.

Cut hazards
Wear gloves to avoid cuts by sharp edges when handling machined
parts.
Wear helmet to avoid cuts by sharp edges when maintaining the
machine.

Note

Max. ambient temperature for ORCA is 50C
Min. ambient temperature for ORCA is 2C
( if nothing else is mentioned in the Technical Specification)

Always handle the equipment with great care. Take precautions not to damage
the parts during transportation and installation.

Warning

Before start-up: Check that your main supply cable size, voltages,
frequency and maximum error current agrees with the electrical
specifications.

Warning

Before start-up: Check that all connections are properly earthed
(grounded) in accordance with local regulations, and properly
isolated.

2 Environment Declaration


Type:
ORCA freshwater generator

Manufacturer:
Alfa Laval Copenhagen A/S, Maskinvej 5, 2860 Sborg, Denmark

Product:
ORCA Offshore

Production site:
Alfa Laval Copenhagen A/S, Maskinvej 5, 2860 Sborg, Denmark

Local environment legislation or regulation to consider:
The ORCA must be installed and operated with respect to any local environment
legislation. It is the purchaser / owner of the ORCA responsibility to follow any
legislation or regulation.
It is the purchaser / customers responsibility to make sure that all necessary
approval from the environmental authorities is obeyed, before installing and
operating the ORCA.

Handling of waste:
In relation to maintain the ORCA, it is necessary to dispose cip-, dechlorination-
and anti scale fluids and oil-soil from the compressor
All waste shall be stored in safe approved containers and be handled and
disposed after the local environmental regulations.

Handling of hazardous materials:
Cip-, dechlorination- and anti scale fluids shall be stored in safe approved
containers before and after use. All handling of hazardous materials shall take
place after present local environmental regulations. Schemes for correct dosing
chemicals are located under the Feed Water Treatment section in this manual.

Noise:
The ORCA has a noise emission of maximum 81dBA. It is necessary to use ear
protection when operating the ORCA.

Discharge of process water:
The salinity in the process water from the ORCA can have an impact on the local
environment if it is channelled into the ground or areas near freshwater. If the
ORCA is placed offshore, the process water is harmless when it is lead back to
the sea. It is the purchaser / customers responsibility to make sure that the
ORCA installation has no impact on the local environment.

Emission to air:
There is no emission to air from the ORCA.

Risk of soil and ground water pollution:
Following the instructions in this manual, there is no risk for soil and ground water
pollution.

Disassembling and disposal of the ORCA:
Disassembling and disposal of the ORCA shall be executed after the present
local environmental regulations regarding all separate materials.

3 Storage and Transportation

3.1 Storage
Alfa Laval standard packing(seaworthy) is suited for transportation and for up to 6
months indoor storage in a vibration free area at a temperature ranging between
15 to 45
o
C (59 to 113
o
F) and with a humidity around 70%. For crate storage up
to 8 months from date of delivery it is only necessary to check the crate for
external physical damage and view humidity levels at two weeks intervals.

Records of date for inspection and results shall be maintained.

Should the humidity level be high it can be assumed that the bag is breached.
The crate should be opened desiccant replaced and the bag evacuated and re-
sealed. For security the crate should be re-closed.

Should it be necessary to remove the original packing for pre-commissioning, the
following should apply for up to six months prior to commissioning.

Turn rotating equipment by hand once per week leaving in a different resting
position.
Keep equipment protected against rain, dust, sand etc. stored under a secured
polythene sheet.
Repair paints damage promptly.
Change electrical desiccant once per month.
Permanently energise anti-condensation heaters for electrical equipment.
Post notice prohibiting climbing or abuse of equipment.

In the event of physical damage or queries contact Alfa Laval Copenhagen.

There are no lubrication requirements for the equipment during storage.

Releasing of flanges and unions shall be permitted for draining low and dead
parts of the system.

Note

There should ABSOLUTELY NOT be any OZONEPRODUCING
equipment in the room, like operating electric motors or arc-welding,
since ozone destroys many rubber materials.

Do not store organic solvents or acids in the room.

Avoid heat and ultraviolet radiation.

The Alfa Laval standard packing is NOT suited for outdoor storage, Alfa Laval
can therefore not be held responsible for any damage to the ORCA under these
conditions.
In case it is needed to unpack the ORCA the yard is responsible for protecting
the equipment as Alfa Laval can not be held responsible for any damage when
stored under these conditions.


3.2 Preservation Procedure for control panels

The panels have to be disconnected from the main supply and kept clean and dry
during the long-term standstill period.

The panel is kept dry inside either by an anti-condensation heating element or by
use of a desiccant.
Warning

If anti-condensation heater is used, prominent warnings of live
terminals inside the panel must be posted inside and outside the
panel.

The electric panel normally includes motor starters with thermal relays,
transformer, contactors and salinometer.

Remove the salinometer sensor in the distillate pipe after the distillate pump,
clean the sensor and store it in the electric panel or in a dry place.

3.3 Preservation Procedure for Solenoid Valves

The solenoid valves and the associated on/off valves should be activated every 6
months with the normal operating air pressure. The valves are operated using the
control switches on the relevant control panel.
The solenoid valves should be removed, flushed with warm freshwater and
stored in a clean dry ozone free area.
Before replacing, the valves should be flushed again with warm freshwater and
the valve functions are to be checked by energising the coil.

3.4 Preservation Procedure for Motors

Factory fitted bearings use a lithium-based grease with a recommended shelf life
of two years. If stored for a longer period, grease may need to be replaced.

Shielded bearings have a storage life of five years and a further two years
operational life following the installation.

To avoid static indentation during long term stand still, the area should be
vibration free.

Where exposure to some vibration is unavoidable, the shaft should be locked.
Roller bearings may be fitted with a shaft-locking device, which should be kept in
place during long term stand still.

Shaft should be rotated by hand, one quarter of revolution weekly.


Warning

Where anti-condensation heaters have been fitted, it is
strongly recommended that they are energised.

In such case, prominent warnings of live terminals inside
the terminal box must be posted inside and outside the
motor terminal box.

Where anti-condensation heaters are not fitted, the use of desiccant is
recommended.

3.5 Preservation Procedure Compressor

Remove the belt and store it in a clean dry ozone free area.

Turn the compressor rotor twice a week.

Stuffing boxes, shaft passages at shaft seals should be wrapped in Denso-
Bindings (wax-permeated J ute bindings). The running surfaces and bushings
should be coated with Molycote.

Labyrinth shaft seals must be treated with long-term protective material such as
Tectyl No. 505.

Anti-corrosive wax should be applied to the running surfaces on the pulleys.

3.6 Transportation

All transportation of the ORCA must be in accordance with local regulations.

Always handle the equipment with great care. Make sure not to damage the parts
during transportation.

After transportation the crates should be visually inspected for physical damage.
In the event that the packing is damaged the following action shall be taken:

Remove sufficient packing to verify that there is no physical damage to the
goods.
On finding no damage replace and repair packing.

In the event of physical damage to the goods Alfa Laval Copenhagen inspection
shall be requested.

Any damage to paint shall be repaired promptly in accordance with the approved
paint repair procedure.

The ORCA must be lifted using the lifting points indicated on the ORCA, hooked
where the following label is placed:

Warning

The ORCA is very heavy. Lifting the ORCA or parts therefore may
be hazardous to personnel.

Ensure that safe working load of the lifting equipment is sufficient to
lift the ORCA.

Remember to lift simultaneously at all lifting points indicated to
ensure an even load.

Warning

Make sure that the lifting equipment has the required breaking
strength to lift the unit. See weight in General Arrangement drawing.


4 Performance criteria

The desalination system has been designed according to the parameters outlined
in the end of the installation manual; however, the performance of the system is
also subject to the following criteria:

a) Raw water supply shall be seawater with a concentration of no more than
3.5%, unless otherwise stated. The seawater shall be pre-filtered by the
customer to remove suspended solids larger than 0.5 mm. Further, the seawater
used shall not contain pollutants, such as oil, fat, detergents, organic matters,
micro-organisms, algae, humic matter, mud, clay, sand, etc. Generally the al-
lowance of such undesirable matter shall not surpass content in the raw water
supply that results in a fouling factor of the heat transfer surfaces higher than
15% of the normal practice within international desalination engineering practice.
Moreover, the seawater supply shall not contain corrosive substances or gases
such as H2S, free Chlorine, Fluorine, etc. higher than stated in the specification
or other substances, which can alter the physical-chemical properties of the raw
water.

b) Supply of Utilities and consumables such as: Air, electric power shall be
provided on a constant basis and at the values for voltage, Phases and
Frequency required and specified in this quotation, and not presenting
fluctuations of more than 5 %.
The pre-treatment chemicals shall be dosed in the correct amount and type
recommended by Alfa Laval. The raw water shall be supplied constant and
without variations at the required flow and pressure.

c) The equipment shall be properly operated in accordance to the instruction
manuals provided by Alfa Laval for this purpose. Critical parameters shall be kept
within the design values for: flows, pressures, temperatures, chemicals dosage,
evaporating temperature, water recovery factor, maximum allowed brine
concentration etc. plus proper observance of the maintenance procedures
included in the manuals. Recording of the operation parameters plus written
logging of the preventive and corrective maintenance will be the only valid
documentation for evaluation of performance of the equipment delivered.
Improper physical handling of the equipment and components will cause
immediate invalidation of guarantees of performance.

4.1 Sea water Design water Analyses
....................
TSS ............. <2,00 p.p.m. (mg/l)
pH ............... 8,26
TDS ............ 35.175,00 p.p.m. (mg/l)
Calcium Ca
++
408,1 p.p.m. (mg/l)
MagnesiumMg
++
1.297,50 p.p.m. (mg/l)
Sodium ...Na
+
10.767,80 p.p.m. (mg/l)
Potassium K
+
387,6 p.p.m. (mg/l)
Barium ... Ba
+
0 p.p.m. (mg/l)
BicarbonateHCO3
-
142,5 p.p.m. (mg/l)
Chlorides Cl
-
19.360,50 p.p.m. (mg/l)
SulphatesSO4
-
2.701,70 p.p.m. (mg/l)
Fluoride ....F
-
1,3 p.p.m. (mg/l)
Bromium Br
-
65,9 p.p.m. (mg/l)
Iridium ....... I
-
0,05 p.p.m. (mg/l)
Silica .... SiO2 2,4 p.p.m. (mg/l)
....................
Spec. densityy at 20
o
C 1.024.0 kg/m3
...................
Ref. Standard Sea Water according to OSW 3

Note: The seawater supplied shall, by proper design of seawater intake and
proper filtration be free of impurities, such as mud, clay, silt, algae etc. which
could cause fouling and/or blockage in the unit.

5 Installation

5.1 Installation description

The ORCA is delivered as a unit that can be either bolted or welded to the floor
plate. See attached Foundation Plan drawing.
When the Fresh Water Maker is complete and fastened to the floor plate all
terminal points shall be connected to supply seawater, service water, instrument
air and electrical power. Secure free access for discharge of drain water and
distillated water.

The terminal points for hook-up are detailed on the general arrangement drawing
and on the P&IDs. The hook-up does not require the presence of Alfa Laval
personnel.

5.1.1 Electrical Equipment
A control panel with starters for electric motors is delivered mounted on the units.

Check all connections and cables to make sure that the frequency and voltage
agrees with the electrical specifications

Check that all connections are properly earthened (grounded) in accordance with
local regulations, and properly insulated.

All electric installations must be carried out by a professional electrician in full
accordance with local regulations.

5.1.2 Seawater Supply
The seawater supplied to the unit has to pass a filter (customer supply) in the sea
water line before the feed water line and ejector pump.
Please refer to the P&IDs for recommended pipe dimensions.

5.1.3 Brine and Seawater Discharge
This line is and open line.
Please refer to the P&IDs for recommended pipe dimensions

5.1.4 Distillate Discharge
Please refer to the P&IDs for recommended pipe dimensions

5.1.5 Space Requirements
The space requirements are indicated on the service area drawing of the ORCA
unit. See attached service area drawing.

5.1.6 Ambient Conditions
When determining where to place the ORCA, consideration must be paid to a
number of ambient conditions such as vibrations, service space, allowable back
pressure, and pressure loss.

5.1.7 Vibrations
The ORCA cant be placed in an area known to be subject to frequent and high
vibrations.

However, under normal conditions no further precautions are necessary.

5.1.8 General Safety Precautions
Always handle the ORCA with great care. Make sure not to damage the parts
during transportation or installation.
During erection all inlets and outlets must be covered to be protected from dirt
and particles.

5.1.9 Scale Inhibitor Dosage Equipment for Feed Water
The Anti scale tank with pump and safety valve shall be positioned max. 2 m
from the ORCA.
Fittings and hose is supplied with the tank. Installation is to be done by Yard.


FreshWaterTo
Tank
Brine
Overboard
SeawaterFrom
Sea
Seawater
Overboard
Compressor
8
7
6
3
2
5
9
10
13
14
4
Condenser
Evaporator
11
12
1

6 System Description

6.1 System Description

1. Vent condenser
2. Circulation pump
3. Brine pump
4. Compressor
5. Air ejector
6. Distillate pump
7. Brine heat exchanger
8. Distillate heat exchanger
9. Electrical heater
10. Filter
11. Sight glass
12. Filter
13. Evaporating chamber
14. Condenser chamber


6.2 Working Principle

Numbers in the text below refer to the drawing above:

Seawater is supplied to the ORCA where it is divided into two streams, one as
feed water and one as jet water for the ejector (5). The feed water stream is
divided into two equal streams to the plate heat exchangers (7, 8). One stream
passes through the distillate / feed water pre-heater (8) and the other stream
through the brine / feed water pre-heater (7). The ingoing feed water is heated in
the plate heat exchangers by the outgoing brine and distillate flows obtained
during the process.

After the pre-heaters, the feed water stream from the distillate cooler is led
through a vent condenser (1) into the evaporation chamber (13).

In the vent condenser the temperature of the feed water is increase slightly. This
is caused by condensing vapour and the cooling down of the non-condensable
gasses vented to the atmosphere by means of the Ejector (5).

The other stream is led directly into the evaporation chamber (13) where it is
mixed with brine. Approx. 90% of this blended mixture is circulated by the
circulation pump (2) and discharged into the evaporator/condenser for
evaporation. The remaining 10% is extracted by the brine pump (3) and led
through the brine / feed water pre-heater (7) in order to heat up the incoming feed
water, and then finally discharged overboard.

The blended feed and brine flow, circulated by pump (2), is discharged into the
evaporator where it flows through the distribution channels of the plates and
down in an even and controlled falling film. While flowing down, the brine film is
heated up and partially evaporated by the heat obtained from the condensation
of vapour on the other side of the plates. The released vapour in chamber (13) is
then sucked through a demister by the centrifugal vapour compressor (4) which
compresses the vapour and thereby increases its temperature with approx. 3-
5C. The vapour is then led back into the condensation chamber (14) where the
evaporator/condenser plate stack is situated. Here the vapour condenses into
pure distillate yielding its latent heat and thereby evaporating the brine on the
other side of the plates.

The distillate produced in the condenser is extracted by the distillate pump (6)
which pumps it through the distillate / feed water pre-heater (8) in order to heat
up the incoming feed water, and then to the storage tank.

The evaporation process normally takes place around 75C. The evaporation
effect is done at sub-atmospheric conditions, where the vacuum is created by
means of the ejector (5), which initially evacuates the air from the system, and
afterwards maintains the vacuum by extracting the non-condensable gases and
venting them to the atmosphere.

The electrical heater (9) is primarily for starting up the process.

6.3 Distillate Quality/Salinity

To continuously check the quality of the produced distillate, a salinometer
(measuring conductivity) is provided together with an electrode unit fitted on the
delivery side of the distillate pump.

If the salinity of the produced distillate exceeds the chosen maximum value, the
dump valve and alarm are activated to automatically dump the produced water to
open drain.

If there are no special requirements from the authorities, the produced distillate
can be used directly as drinking water. Otherwise the distillate should be post-
treated in suitable equipment.

6.4 Main Components

The ORCA consists of the following main components:

1. Evaporator/Condenser section
The evaporator/condenser section consists of a titanium plate heat exchanger
and is mounted inside the separator vessel. It generates the distillate by
evaporating the feed water on one side of the plate and condensing it on the
other. The evaporator and the condenser section are internally separated with a
partition plate.

2. Feed water pre-heaters
The pre-heaters are two titanium heat exchangers (one brine cooler and one
distillate cooler) where the incoming feed water is pre-heated by the excess heat
obtained during the process in the outgoing brine and distillate flows.

3. Separator vessel
The separator vessel is made by stainless steel and contains the plates as well
as other interior construction parts. Further anodes are mounted in the vessel.

4. Air ejector
The ejector evacuates the air to create vacuum inside the vessel. During
operation, the ejector maintains the vacuum by extracting the non-condensable
gases from the separator vessel. Maximum backpressure at seawater outlet is
normally 0.6 bar g, due to the performance of the Air Ejector.

5. Brine pump
The brine pump is a single-stage centrifugal pump. The brine pump extracts part
of the brine from the bottom of the vessel to ensure a constant brine level and
concentration, and pumps the water through the brine/feed water pre-heater to
discharge. The brine discharge is internally connected to seawater outlet.

6. Distillate pump
The distillate pump is a single-stage centrifugal pump. The distillate pump
extracts the produced distillate from the vessel and pumps the water through the
distillate/feed water pre-heater to a tank or post treatment equipment, if any.

Normally discharge pressure at is 0.6 bar g. (If nothing else is mentioned in the
technical specification).

7. Circulation pump
The circulation pump is a single-stage centrifugal pump. The circulation pump
circulates the brine/feed water mixture into the evaporator/condenser to ensure a
constant flow of feed water to the evaporating channels in the plate stack
As the brine is heated as part of the process inside the plate heat exchanger in
the vessel, its latent heat is used to pre-heat the cold incoming seawater.

8. Control panel / HMI
The control system is for operating monitoring the ORCA unit. This includes
starting up and stopping components as well as the continuous monitoring of
ORCA performance.
The panel contains of motor starters with thermal relays, running lights,
salinometer, as continuously checks the salinity of the produced water. Besides
of the PLC and HMI, where all action and monitoring of performance and
parameters are performed. The ORCA is entirely operated from the touch panel
on the HMI.

9. Electrical heater
The electrical heater is primarily used for starting up the process and will
automatically shut off when the process is on its specified values. The electrical
heater also switches on during actual operation, if the heat exchanger
temperature falls below adjustable set points.

10. Vapour compressor
The vapour compressor is a single-stage centrifugal vapour compressor. The
compressor compensates for the loss of energy in the heat exchangers, the heat
radiating from the vessel during operation, and loss of energy through the air
ejector. The performance of the centrifugal compressor is vital to the process. It
supplies the energy required to drive the process inside the ORCA .
The vapour compressor is a single-stage centrifugal vapour compressor which
rise the pressure of the produced vapour and thereby increases the temperature
of the vapour with approx. 3-5C, this temperature increase keep the process
running.

11. Vent condenser
The vent condenser is a small plate heat exchanger (PHE). The hot vapour from
the evaporation phase is cooled by incoming feed water, yielding its heat to the
feed for pre-heating. The vent condenser cools the vented vapour before it
reaches the ejector. The ejector may function less efficiently, if the entering feed
water temperature is too high.

12. Separator
The demister is a small-meshed filter in stainless steel. The demister filters off
droplets in the produced vapour before the vapour enters the compressor.

13. Anti scalant dosing unit
The anti scalant dosing unit consist of a dosing pump mounted on a tank with
manual agitator and low level switch. The anti scalant is dosed to the feed water.


All the above equipment is mounted and internally wired on the ORCA.

6.5 Optional Equipment

14. Seawater pump
The seawater pump is a single-stage centrifugal pump. This pump supplies the
ORCA with seawater for the air ejector as well as feed water for evaporation.

15. Distillate Booster Pump
A distillate booster pump with a backpressure valve can be added as loose
supply to the ORCA. A motor circuit breaker for the distillate booster pump is
installed in the control panel. The distillate booster pump starts simultaneously
with the distillate pump.
This option can be needed if the distillate discharge pressure is more than 0.6
bar g.

16. De-chlorination dosing unit
If the feed water (seawater) contains more than 0,5% ppm of Chlorine *, it is
recommended to inject de-chlorination agent into the feed water, in order to
minimize corrosion.

17. Mineralisation Filter
Water produced from any freshwater generator, reaches a pH-value of 5 to 7.0.
To bring the pH-value back to neutral ( 7 8.5 ) a pH-adjustment filter is to be
installed after the freshwater generator. Drinking water should have a minimum of
carbonate hardness for human healthcare and beside this, the carbonate
hardness is helping to form protective layers against corrosion on all wetted
surfaces for instance within the pipe manifolds.

* Free chlorine ions.

7 Electrical Specification

7.1 Environment conditions
As a standard the plant is designed to operate in the following conditions:

Ambient
Temperature
2 C to 50 C
Seawater
Temperature
18 C to 32 C
Humidity <90 % Non-
Condensing

Location Indoor & Non-
Hazardous

7.2 Local Control Panel (LCP)
The LCP is designed as a combined control and MCC (Motor Control Center)
panel in a common cabinet.

The LCP is installed directly on the ORCA frame.

7.3 Cabinet
The cabinet material is (CS) sheet steel with the below specified thickness:
Enclosure 1.5 mm
Door 2.0 mm
Mounting Plate 3.0 mm
The cabinet has the following surface finish:
Enclosure & Door Dip coat primer and powder coated
Mounting plate Zinc plated

The standard cabinet color is light grey, RAL 7035.

The cabinet is protection class IP54.

7.4 Power Supply
A single power supply is needed for the LCP. The following power supplies are
standard:

Voltage Frequency
3x380V 50Hz
3x400V
3x415V
3x690V
3x440V 60Hz

3x460V
3x480V

The following permanent variation in voltage and frequency can be accepted:

Permanent
Variation
Voltage 10%
Frequency 2 %

Typically a 200 A circuit breaker (or fuse) shall be installed on the main power
supply for the ORCA.

7.5 Installed Power
The typical rated power installed on the ORCA is specified in below table:

Plant size 50Hz 60Hz
ORCA 20
ORCA 30
ORAC 40
ORCA 50
71 kW

78 kW

ORCA 60
ORCA 70
80 kW 87 kW

The standard LCP is designed for a short circuit level of 30 kA.

7.6 Earting System
The earthing system is IT. The earth bar is divided in 2 earth bars in the LCP.
Instrument Earth Bar IE
Protection Earth Bar PE

Instrument Earth Bar
The instrument cable screen is connected to the instrument earth bar in LCP.
The instrument screen is standard not connected to the earth terminal on the
instrument.

The instrument earth bar is insulated from the LCP cabinet.

Protection Earth Bar
The earth conductor in all power cables (yellow/green insulation) are connected
to the protection earth bar in LCP and the equipment (motors and heater).

The protection earth bar is connected to the LCP cabinet.

Earth bonding is installed between ORCA freshwater maker skid and:
Vessel Frames
LCP
Motors

16mm
2
yellow/green insulated earth conductor is standard installed on all
bonding, bonding on small motors (<5kW) is, however, 6mm
2
.

7.7 PLC
The operation of the freshwater maker is controlled by a Programmable Logic
Controller (PLC) with automatic start-up / stop and automatic production.

7.8 HMI
A touch screen operator panel (HMI) is installed on the front of LCP. The
freshwater maker can be operated from the HMI only, however the plant can also
be started and stopped from remote (hardwired signals).

985 22647-R02 Installation Manual ORCA Offshore Part1

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985 22647-R02 Installation Manual ORCA Offshore Part1

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Created by ALFALAVAL Copenhagen

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