Manual Gs500cic-Tg5-201403

« S H I P _ N AM E »
Instruction Manual
TeamTec Incinerator
GS500CIC
GS500CIC 1
GS500CIC
Copyright © 2003 TeamTec AS. All rights reserved.

No part of this manual may be reproduced, transmitted, stored in a database or translated into
any language or in any form without explicit and written permission of TeamTec AS.
Version Date Purpose Written

Rev 0 20.12.2010 KK
Updated Hour counter, alarm list, test of control functions,
Rev A 31.03.2011 KK
test of safety and alarms.
Rev B 16.06.2011 Updated sludge displays, and added burn-in KK
Added date to guarantee certificate, and updated SW,
Rev C 07.07.2011 KK
Sludge and Burn-in menu.
Rev D 12.10.2011 Corrected small text errors. KK
Added change of Sludge dosage pump from RDCZ441 to
RDCZ432. Changed settings according to new pump.
Rev E 23.01.2012 Reorganized the instruction book layout. Removed KK
Frequency controlled FGF. Made small text corrections.
Added top logo to guarantee certificate.
Small text corrections. Updated incinerator 10
Rev F 22.03.2012 KK
commandments.
Rev G 05.12.2012 Steam/air supply for sludge and water was 20Kg/h KK
2 GS500CIC
TABLE OF CONS
Addendums, corrections and notes

This document describes, from a user point of view, how to operate and maintain the GS500C incinerator.
The incinerator type is GS500C, but some of the drawings might have additional letter codes that
describe the extra equipment on your incinerator.
All TeamTec incinerators are made according to EC Type-Examination Certificate MED-B, and are
found to comply with the requirements in the following regulations/standards:
Annex A.1, item NO. A1/2.7 and Annex B, Module B in the Directive. Marpol 73/78 as amended, Annex
VI Regulation 16(2)(a), IMO Res. MEPC.76 (40).
Generally, for a design or type approval certificate, it is allowed to make minor modifications to the
equipment. Minor modifications are changes that will not affect the incinerators function or design. The
incinerator type is still the same, and all main functions are identical to the type approved unit and will be
covered by the certificates. The type stamped on the incinerator is the same as we have on the certificate,
but some of the drawings might have letter codes to describe the extra equipment (minor modification) on
your incinerator. All possible letter codes are:
Code Feature description

A Ampere meter for flue gas fan
B Diesel oil booster pump
C Standard - Computerized automation/control (PLC)
D Dual sludge tank
F Auto feeding of solid waste (Stoker, Shredder)
G Stirrer for solid waste
I Water injection
K Cooling of control cabinet
L Sludge tank level readout in display panel
M Flue gas fan motor heater
P Sludge transfer pump
R Roof mounted sluice
S Sluice for solid waste
T Diesel oil transfer pump
W Incinerator for solid waste only
X Large single door opening
Z CCS - centr. Control station twin display
GS500CIC 3
TABLE OF CONTENTS
4 GS500CIC
TABLE OF CONTENTS
Table of contents
ADDENDUMS, CORRECTIONS AND NOTES .................................................................................... 3
LIST OF DRAWINGS............................................................................................................................. 11
Project: «Project_No» ........................................................................................................................................ 11
INCINERATOR .............................................................................................................................................. 11
FLUE GAS .................................................................................................................................................... 11
SLUDGE TANK ............................................................................................................................................. 11
ELECTRICAL DIAGRAMS .............................................................................................................................. 12
ACRONYMS AND TERMS ................................................................................................................... 13
THE INCINERATOR “10 COMMANDMENTS” ............................................................................... 15
GARBAGE MANAGEMENT................................................................................................................. 17
INCINERATION OF SOLID AND LIQUID WASTE ............................................................................................... 17
SOLID AND LIQUID WASTE THAT IS PROHIBITED TO BE BURNED ................................................................... 17
SOLID WASTE HANDLING ............................................................................................................................ 18
BATCH LOADING ......................................................................................................................................... 18
SLUICE FEEDING .......................................................................................................................................... 18
SLUDGE CAPACITY ...................................................................................................................................... 18
INTRODUCTION.................................................................................................................................... 19
INSTRUCTION MANUAL, PURPOSE AND SCOPE .............................................................................................. 19
SERVICE NETWORK FOR TEAMTEC (GOLAR) INCINERATORS....................................................................... 19
MAIN DATA ............................................................................................................................................ 21
PERFORMANCE DATA .................................................................................................................................. 21
Incinerator (combustion chamber). ....................................................................................................... 21
Burner (fixed on combustion chamber) ................................................................................................. 21
Diesel oil booster pump (optional) ........................................................................................................ 22
Flue gas fan (bulkhead mounted)........................................................................................................... 22
Flue gas damper. ................................................................................................................................... 22
Sluice (fixed on top of incinerator unit) (Optional) ............................................................................... 22
Sludge tank............................................................................................................................................. 23
Water tank (Optional) ............................................................................................................................ 23
Sludge circulating pump. (installed on sludge tank).............................................................................. 23
Sludge filling pump (if dual sludge tank system)(Optional)................................................................... 23
Sludge transfer pump (optional on dual sludge tank system)(Optional) ............................................... 23
Sludge dosing pump (fixed on combustion chamber) ............................................................................ 23
Water dosage pump (Optional).............................................................................................................. 24
Diesel oil preheater (fixed on combustion chamber)............................................................................. 24
Electrical control panel incinerator ( fixed on combustion chamber)................................................... 24
SHIPS SYSTEM INTERFACE REQUIREMENT.................................................................................................... 25
Electrical................................................................................................................................................ 25
Diesel oil. ............................................................................................................................................... 25
Flue gas duct.......................................................................................................................................... 25
Sludge and Steam or Air. ....................................................................................................................... 25
Water and Steam or Air. (Optional)....................................................................................................... 25
Sludge tank. (1100 / 1700 / 2000 / 3000 l option).................................................................................. 25
Water tank. (435 l) (Optional) ............................................................................................................... 26
GUARANTEE CERTIFICATE ........................................................................................................................... 27
TECHNICAL DESCRIPTION ............................................................................................................... 29
OVERALL SYSTEM FUNCTION DESCRIPTION ................................................................................................. 29
Water injection (Optional) ..................................................................................................................... 29
Combustion chamber ............................................................................................................................. 29
GS500CIC 5
TABLE OF CONTENTS
Flue gas fan ........................................................................................................................................... 30

Sludge service tank with heater ............................................................................................................. 30
Sludge settling tank with heater (optional). ........................................................................................... 30
Water tank (Optional). ........................................................................................................................... 30
SLUDGE CONTROL ....................................................................................................................................... 31
Introduction ........................................................................................................................................... 31
Temperature limits ................................................................................................................................. 31
Burner stage........................................................................................................................................... 32
Control ................................................................................................................................................... 32
OPERATOR PANEL............................................................................................................................... 33
General .................................................................................................................................................. 33
Structure................................................................................................................................................. 34
POP-up select program ......................................................................................................................... 35
Description of the program selection alternatives are given in chapter program description.............. 35
Pop-up Start -Stop ................................................................................................................................. 35
Information pop-up ................................................................................................................................ 35
Burner .................................................................................................................................................... 36
Setting tanks ........................................................................................................................................... 36
Hour counters ........................................................................................................................................ 37
Setup....................................................................................................................................................... 37
Login ...................................................................................................................................................... 38
Wrong user pop-up ................................................................................................................................ 38
Change values........................................................................................................................................ 38
Settings burner ....................................................................................................................................... 39
Settings alarms....................................................................................................................................... 39
Settings sludge (1/4)............................................................................................................................... 40
Settings sludge (2/4)............................................................................................................................... 41
Settings sludge (3/4)............................................................................................................................... 43
Settings sludge (4/4)............................................................................................................................... 44
Settings solid waste (1/2) ....................................................................................................................... 45
Settings solid waste (2/2) ....................................................................................................................... 46
Settings solid waste and sludge.............................................................................................................. 47
Settings sludge with water...................................................................................................................... 48
Settings loading/slagging and stop ........................................................................................................ 49
Burn-in ................................................................................................................................................... 50
Incinerator configuration....................................................................................................................... 51
Backlight ................................................................................................................................................ 51
Time and date......................................................................................................................................... 51
Program information ............................................................................................................................. 52
Consumption .......................................................................................................................................... 52
Consumption setup................................................................................................................................. 52
Alarm system.......................................................................................................................................... 53
The alarm Screen ................................................................................................................................... 53
Alarm List .............................................................................................................................................. 54
Setting list............................................................................................................................................... 56
Settings frequency inverter ALTIVAR 31 ............................................................................................... 59
Settings frequency inverter ALTIVAR 12 ............................................................................................... 60
PROGRAM DESCRIPTION .................................................................................................................. 61
OVERALL PROGRAM FUNCTION DESCRIPTION .............................................................................................. 61
General .................................................................................................................................................. 61
Flue Gas Fan ......................................................................................................................................... 62
Function Sludge program ...................................................................................................................... 62
Function Sludge program with water Injection ..................................................................................... 64
Function solid waste program ............................................................................................................... 65
Function Solid waste and sludge program ............................................................................................ 66
Function Sluice operation...................................................................................................................... 66
MAINTENANCE INSTRUCTION ........................................................................................................ 67
6 GS500CIC
TABLE OF CONTENTS
PREVENTIVE MAINTENANCE ........................................................................................................................ 67

Service hours: ........................................................................................................................................ 67
Daily....................................................................................................................................................... 67
Weekly (100 hours) ................................................................................................................................ 67
Monthly (400 hours) .............................................................................................................................. 68
6 monthly (2500 hours).......................................................................................................................... 68
Yearly (5000 hours) ............................................................................................................................... 68
INSPECTION ................................................................................................................................................. 69
Combustion chamber:............................................................................................................................ 69
Diesel oil pump:..................................................................................................................................... 69
Flue gas fan: .......................................................................................................................................... 69
Sludge dosage pump: ............................................................................................................................. 69
Water dosage pump: .............................................................................................................................. 69
CLEANING AND LUBRICATION ..................................................................................................................... 71
Ashes:..................................................................................................................................................... 71
Photo resistor: ....................................................................................................................................... 71
Diesel oil burner:................................................................................................................................... 71
Diesel oil pump:..................................................................................................................................... 71
Flue gas fan: .......................................................................................................................................... 71
Door hinges: .......................................................................................................................................... 71
Sluice: .................................................................................................................................................... 71
Pusher:................................................................................................................................................... 71
Sludge burner: ....................................................................................................................................... 71
Water injection: ..................................................................................................................................... 71
DISASSEMBLY, REPAIR, REPLACEMENT AND REASSEMBLY .......................................................................... 72
Flue gas fan ........................................................................................................................................... 72
To replace the impeller:...................................................................................................................................... 72
Disassembly................................................................................................................................................... 72
Repair ............................................................................................................................................................ 72
Replacement .................................................................................................................................................. 72
Reassembly.................................................................................................................................................... 72
To adjust the clearance between impeller and fan house............................................................................... 72
Performance verification ............................................................................................................................... 73
Mounting of bearings with tapered bore............................................................................................................. 73
SPARE PARTS......................................................................................................................................... 75
RECOMMENDED MINIMUM SPARE PARTS ..................................................................................................... 75
RECOMMENDED SPARE PARTS FOR 1 YEAR SERVICE .................................................................................... 76
RECOMMENDED ONBOARD REPAIR PARTS ................................................................................................... 77
STORAGE AND INSTALLATION ....................................................................................................... 78
PREPARATION FOR SHIPMENT ...................................................................................................................... 78
STORING AT YARDS WAREHOUSE ............................................................................................................... 78
PRESERVATION FROM INSTALLATION TO START UP OF EQUIPMENT ............................................................. 78
PRESERVATION IN CASE OF LONG TIME STORING AFTER INSTALLATION....................................................... 78
PRE-COMMISSIONING .................................................................................................................................. 79
Mechanical completion check list. ......................................................................................................... 79
Pre-check of live equipment................................................................................................................... 79
TEST OF FUNCTION AND SAFETY DEVICES.................................................................................................... 80
TEST OF CONTROL FUNCTIONS..................................................................................................................... 86
OPERATION INSTRUCTIONS ............................................................................................................ 91
PRIOR TO START .......................................................................................................................................... 91
SLAGGING ................................................................................................................................................... 91
SOLID WASTE.............................................................................................................................................. 91
SLUDGE ....................................................................................................................................................... 91
SOLID WASTE SLUDGE ................................................................................................................................ 92
SLUDGE AND WATER .................................................................................................................................. 92
EMERGENCY STOP ....................................................................................................................................... 93
In the incinerator room.......................................................................................................................... 93
GS500CIC 7
TABLE OF CONTENTS
Outside the incinerator room................................................................................................................. 93

When emergency stop is used, or at black out. ...................................................................................... 93
EMERGENCY GENERATOR....................................................................................................................... 93
TROUBLE SHOOTING .................................................................................................................................... 94
APPENDIX A: PLC ................................................................................................................................ 99
GENERAL .................................................................................................................................................... 99
BASE UNIT ................................................................................................................................................ 100
INSTALLING A MEMORY MODULE ............................................................................................................. 101
REPLACING THE BATTERY ......................................................................................................................... 102
DIN RAIL MOUNTING ............................................................................................................................... 103
DIAGNOSTICS ............................................................................................................................................ 104
APPENDIX B: OPERATOR PANEL ................................................................................................. 107
GENERAL .................................................................................................................................................. 107
TECHNICAL DATA ...................................................................................................................................... 108
APPENDIX C: OIL BURNER............................................................................................................. 109
SERVICING AND ADJUSTMENT ................................................................................................................... 109
Dismantling.......................................................................................................................................... 109
Cleaning and adjustment ..................................................................................................................... 109
Re-assembly ......................................................................................................................................... 109
DIESEL OIL PRESSURE ADJUSTMENT .......................................................................................................... 109
AIR ADJUSTMENT. ..................................................................................................................................... 110
DO NOZZLES ............................................................................................................................................. 110
Standard nozzle.................................................................................................................................... 110
Maintenance......................................................................................................................................... 110
Capacities ............................................................................................................................................ 111
APPENDIX D: OIL PUMP .................................................................................................................. 112
APPLICATIONS ........................................................................................................................................... 112
PUMP OPERATING PRINCIPLE ..................................................................................................................... 112
Bleed .................................................................................................................................................... 112
Cut-off:................................................................................................................................................. 112
TECHNICAL DATA ...................................................................................................................................... 113
General ................................................................................................................................................ 113
Hydraulic data ..................................................................................................................................... 113
PUMP DIMENSIONS .................................................................................................................................... 114
PIPE DIMENSIONS....................................................................................................................................... 114
INSTALLATION .......................................................................................................................................... 115
START UP .................................................................................................................................................. 115
PRESSURE REGULATION ............................................................................................................................ 115
SYSTEMATIC MAINTENANCE ..................................................................................................................... 115
PARTS LIST ................................................................................................................................................ 116
APPENDIX E: FREQUENCY INVERTER ATV12.......................................................................... 117
SPECIFICATION .......................................................................................................................................... 117
Teamtec H055M2................................................................................................................................. 117
TECHNICAL CHARACTERISTICS .................................................................................................................. 118
ACCESSING TERMINAL BLOCKS ................................................................................................................. 119
Power Terminals.................................................................................................................................. 119
Control Terminals................................................................................................................................ 120
Programming ....................................................................................................................................... 122
TeamTec Control Settings.................................................................................................................... 124
FAULTS – CAUSES – REMEDIES ................................................................................................................. 129
Drive does no start, no fault displayed ................................................................................................ 129
APPENDIX F: SLUDGE BURNER .................................................................................................... 134
CLEANING OF SLUDGE BURNER ................................................................................................................. 134
8 GS500CIC
TABLE OF CONTENTS
PROCEDURE FOR ADJUSTING THE SLUDGE BURNER ................................................................................... 134

APPENDIX G: SLUDGE VALVE. ..................................................................................................... 135
A 6324/1101/7003. 0-1 bar. G 3/4" ..................................................................................................... 135
Valve .................................................................................................................................................... 136
APPENDIX H: SLUDGE DOSAGE PUMP ....................................................................................... 137
DIMENSION ............................................................................................................................................... 137
DISMANTLING AND ASSEMBLY DIAGRAM, ................................................................................................. 138
MOTOR FOR PUMP. .................................................................................................................................... 138
PARTS LIST ............................................................................................................................................... 139
INSTALLATION .......................................................................................................................................... 140
Installation and Safety Recommendations ........................................................................................... 140
General ................................................................................................................................................ 140
STORAGE ................................................................................................................................................... 140
Short-term storage ............................................................................................................................... 140
Long-term storage................................................................................................................................ 140
IMMEDIATELY PRIOR TO INSTALLATION AND STARTING. ........................................................................... 140
ELECTRICAL .............................................................................................................................................. 141
IMPORTANT ............................................................................................................................................... 141
General safety ...................................................................................................................................... 141
Start-up procedure ............................................................................................................................... 141
DRY RUNNING ........................................................................................................................................... 141
Mechanical seals, all pumps. ............................................................................................................... 142
Guards ................................................................................................................................................. 142
Warning/control device........................................................................................................................ 142
Pump operating temperature ............................................................................................................... 142
MAINTENANCE OF WEARING COMPONENTS ............................................................................................... 142
Rotor and stator ................................................................................................................................................ 142
DIAGNOSTIC CHART .................................................................................................................................. 143
APPENDIX I: SLUDGE CIRC. PUMP ............................................................................................... 145
APPENDIX J: WATER DOSAGE PUMP ......................................................................................... 151

DIMENSION ............................................................................................................................................... 151
DISMANTLING AND ASSEMBLY DIAGRAM, ................................................................................................. 152
MOTOR FOR PUMP. .................................................................................................................................... 152
PARTS LIST ART. NO. 2007740.......................................................................................................... 153
INSTALLATION .......................................................................................................................................... 154
Installation and Safety Recommendations ........................................................................................... 154
General ................................................................................................................................................ 154
STORAGE ................................................................................................................................................... 154
Short-term storage ............................................................................................................................... 154
Long-term storage................................................................................................................................ 154
IMMEDIATELY PRIOR TO INSTALLATION AND STARTING. ........................................................................... 154
ELECTRICAL .............................................................................................................................................. 155
IMPORTANT ............................................................................................................................................... 155
General safety ...................................................................................................................................... 155
Start-up procedure ............................................................................................................................... 155
DRY RUNNING ........................................................................................................................................... 155
Mechanical seals, all pumps. ............................................................................................................... 156
Guards ................................................................................................................................................. 156
Warning/control device........................................................................................................................ 156
Pump operating temperature ............................................................................................................... 156
MAINTENANCE OF WEARING COMPONENTS ............................................................................................... 156
Rotor and stator ................................................................................................................................................ 156
DIAGNOSTIC CHART .................................................................................................................................. 157
GS500CIC 9
TABLE OF CONTENTS
DRAWINGS……………………………………………………………………………………………..15
8
10 GS500CIC
LIST OF DRAWINGS
List of drawings
Project: «Project_No»
Incinerator
Dwg.no. Name of drawing.
2007803 Piping & Instrument Diagram GS500CS/CIC w/Steam Heating
1009062 Combustion Chamber Main Dimension. GS500CS/CIC
1009068 Combustion Chamber GS500CS Main Assy.
1009121 Combustion Chamber Mounting Drawing
1009132 Oil Burner F-50-45-T, 220V with Sludge Burner
1009107 Oil Burner F-50-45-T, Sub. Assy.
1009129 Refractory and Insulation GS500CS
1009274 Sludge Oil Dosage Valve Assembly.
1009059 Sluice Assembly
1009064 Inspection Door Assembly
1009035 Arrangement Piping, Fuel, Sludge, Steam
Flue gas
Dwg. no. Name of drawing.
4006932 Main Dimensions Flue Gas Fan DN 400 H2.
1006994 Flue Gas Fan Assembly DN 400 H2
1008634 Flue Gas Fan DN 400 Sub Assy. w/Motor
1007012 Flue Gas Fan Sub. Assy. DN 400, H2
3007253 Main Dimensions Flue Gas Damper DN400
1007004 Flue Gas Damper Assembly DN 400.
1007002 Flue Gas Damper Sub. Assy. DN 400.
AS400-5 Expansion compensator DN 400
Sludge Tank
1006028 Main Dimensions 2000L Sludge Tank with Steam Heating
1007038 Sludge Tank Assembly 2000 L Net Steam Heating
GS500CIC 11
ACRONYMS AND TERMS
Electrical diagrams
4008138 Cable Arrangement for GS500CS
1009890 Control Panel 380/440V - 220V for GS500CICS
1009891 Mounting Plate with El.Components 380/440V-220V, GS500CICS
3010463 Electric Diagram 380/440V-220V Teamtec Incinerator GS500CICS
2006520 Junction Box on Sluice GS500C
4006469 Electric Diagram Junction Box for Sluice GS500C
4007918 Terminal Diagram Diesel Oil Burner F-50-45-T with Analog motor
2006948 Control Panel Sludge Tank w/Steam Heating
2006949 Mounting Plate w/El.Components Sludge Tank w/Steam Heating
3007895 El. Diagram380/440V-220V Sludge Tank w/Steam Heating
3006996 Thermocouple with Transmitter for Flue Gas
12 GS500CIC
ACRONYMS AND TERMS”
ACRONYMS AND TERMS

Acronym/term Description
ACK Acknowledge
CCP Combustion chamber pressure
CCT Combustion chamber temperature
D.O. Diesel Oil
DEC Decrease
EMC Electro Magnetic Compatibility
ESC Escape
FGF Flue gas fan
FGT Flue gas temperature
HMI Human machine interface
HYS Hysteresis
INC Increase
LCD Liquid crystal display
LED Light emitting diode
MAX Maximum
MIN Minimum
PID A proportional–integral–derivative controller
PLC Programmable logic controller
PREV Previous
RPM Revolutions per minute
SAF Secondary air fan
SCP Sludge circulation pump
SDP Sludge dosing pump
SFP Sludge Filling Pump
SLT Sludge settling tank
SST Sludge service tank
STP Sludge transfer pump
SW Solid Waste
USR User
WDP Water Dosage Pump
Acronym/term Definition
Hysteresis The difference noted in a sensor's output as a
response to an increasing or decreasing
input signal of the same value
GS500CIC 13
ACRONYMS AND TERMS
14 GS500CIC
GARBAGE MANAGEMENT
The incinerator “10 commandments”
• Keep the incinerator chamber inlet outlet and burner parts clean. Inspect daily before start
in the morning, and clean as required.
• Do never throttle the air/steam needle valve more than ¾ turn closed. If the pressure
increases above green area, clean the sludge burner nozzle.
• Do never turn off the main power before the chamber temperature is down below 170°C.
• If experiencing any problem with high temperature in combustion chamber, flue gas or
control of sludge dosing, replace the dosing pump stator.
• Do not transfer sludge to the service tank during sludge burning in a single tank system
(can damage the refractory).
• As a minimum, heat the sludge over night, without starting the circulating pump. Next
morning drain off the free water and start the sludge program.
• Never load glass, lithium batteries or large quantities of spray cans in the incinerator –
nor large quantities of oily rags or filter cartridges. This may damage the flue gas fan.
• Inspect the cooling jacket every 6 months (open the cover plates) and clean as required
with steam or hot water.
• Read the instruction manual, and never change any settings unless instructed by TeamTec,
Norway
• In case of abnormal operation, contact TeamTec.
GS500CIC 15
INTRODUCTION
Garbage management
TeamTec recommend working out guidelines for an onboard garbage management plan.
Personnel responsible for operation of the incinerator shall be trained and capable of
implementing the guidance follows by the instruction manual.
Waste incineration on board sea going ships and offshore platforms is world wide regulated by
IMO MARPOL 73/78, RESOLUTION MEPC 76(40), STANDARD SPECIFICATION FOR
SHIPBOARD INCINERATORS, adopted on 25.september 1997, and IMO MARPOL ANNEX
VI REGULATION 16 and APPENDIX IV adopted on 26. September 1997.
Incineration of solid and liquid waste

In accordance with the above regulation the following solid and liquid waste can be burned in
an IMO certified shipboard incinerator:
Plastic, Cardboard, Wood

Rubber, Cloth, Oily Rags, Lub. Oil Filters,
Diesel Engine Scavenge Scraping
Paint Scraping
Food waste, etc.
Sludge Oil, Waste Lub. Oil
Hospital Waste, Female Hygienic Binds
Destruction of Contaminated water
Solid and liquid waste that is prohibited to be burned

Material, which contains more than traces of HEAVY METAL and of refined petroleum
products containing halogen compounds is prohibited to be incinerated. Light bulbs contain
heavy metal and are prohibiting incinerating.
Under shipboard operational waste the following materials have a density placing them in the
category of HEAVY METAL:
MERCURY
LEAD
NICKEL
VANADIUM
ZINC
IMO Annex VI regulation 16 prohibits incineration on ship of certain products, such as

contaminated packaging materials and polychlorinated biphenyls (PCBs).
Do not incinerate metals as soda and food can plates, flatware, serving spoons/tray,
hardware (nuts & bolts), structural pieces, wire rope, chains etc, glass such as bottles, jars,
drinking glasses etc., flammable materials such as bottles or cans containing flammable
liquids or gasses and aerosol cans. Do not incinerate heavy load with plastics or bulk food
waste. Read instruction/warning label on garbage door.
Loading of glass will result in a rock hard slag, which is difficult to remove from the refractory
lining.
GS500CIC 17
GARBAGE MANAGEMENT
Solid Waste handling

GS500C is intended for incineration/burning of sludge and solid waste onboard ships or other
marine installations. For batch loading the incinerator capacity is 400l/charge IMO class 2
wastes.
Class 2 refuse, consists of approximately even mixture of rubbish and garbage by weight. This
type of waste is common to passenger ships occupancy, consisting of up to 50% moisture, 7%
incombustible solids and has a heating value of about 10.000 kJ/kg as fired.
Be aware that plastics has high calorific value, about 36.000 kJ/kg and must only be incinerated
in small amounts at the same time.
Batch loading
Do not attempt to clean the combustion chamber without activating the slugging mode on the
touch screen display, to prevent injury to personnel due to insufficient ventilation.
Each morning, providing that the combustion chamber temperature is lower that 170°C, slag
and ashes should be removed. Partly burnt garbage shall remain in the chamber. This garbage
will be fully incinerated at the next sequence of incineration. The air inlet openings in the
bottom of the combustion chamber must be regularly cleaned. This is important in order to let
the combustion air come into the chamber.
Load the combustion chamber with garbage of type IMO class 2. If high calorific garbage is
loaded, a smaller quantity must be loaded per charge.
Sluice feeding
If sluice is installed, solid waste can be fed into the 125 litre sluice at temperatures between
700/900°C and 1050°C depending on program running. Sluice is available at 700°C running
solid waste program, and 900°C running Solid waste/Sludge. A green feeding push button
indicates that sluice feeding is ready when lit. Fill the trash in a garbage paper bag, open the
sluice lid/sluice door and put the bag into the sluice. Do not jam the trash bag into the sluice or
overfill it. Close the lid / sluice door and rotate the sluice by the handle on the right side of the
sluice. The maximum waiting time between each time the sluice can be operated is 210 seconds
if temperature is above 750°C, or if temperature is below 750°C the temperature must be above
the temperature the sluice was activated. After the waiting time has elapsed, the push button
lights up again and the sluice is ready for a new load. Check out operator panel sluice menu for
information about the waste burning.
Sludge Capacity
The incinerator is certified according to MEPC 76(40) which determines the sludge to contain
20% water.
A high water content up to 50% water content will result in a higher capacity than what is
mentioned in the certificate. As an example, the sludge with 40% water content will have lower
calorific value than IMO sludge, hence higher hydraulic capacity.
A water content higher than 50% requires a pilot burner (support burner). This reduces the
available capacity for burning of sludge.
18 GS500CIC
INTRODUCTION
Introduction
Instruction manual, purpose and scope
This user manual is made according to guidelines in the Norwegian Standard NS 5820
The manual will guide the reader/user gradually to an understanding required for safe operation
and maintenance of the incinerator system.
It is important for the user to have a good understanding of the incinerator function, to avoid
malfunction caused by operational errors.
The guarantee will be invalid if problems and/or caused by operational errors or mistreatment.
Service network for TeamTec (Golar) incinerators.

Please note that our office is the single point of contact for your service, spares and
upgrading requirements:
TeamTec AS
Nyvei 41
P.O.Box 203
4902 Tvedestrand
Norway
Tel.: +(47) 37 19 98 00
Telefax: +(47) 37 19 98 90
E-mail: office@teamtec.no
Please note that our main strategy is to offer our customers the best service and quality
spare parts wherever and whenever they need them. To reach this goal we have
established a stock of spare parts and trained service personnel in major ports throughout
the world.
For more information please visit our web pages: www.teamtec.no
GS500CIC 19
MAIN DATA
20 GS500CIC
MAIN DATA
Main data
Performance data
Incinerator (combustion chamber).
Type: GS500CIC
Capacity: 800 000 Kcal/h (930KW)
Corresponding to: 105 l/h IMO sludge oil IMO sludge (20% water)
Solid waste max. 135kg/h continuous feeding IMO class 02 waste
Combustion chamber Max. 1200 °C

temperature: Working. 870-1150 °C
Flue gas temperature: Max. 350°C
Working. 250 - 340 °C
Surface temperature: 15°C above ambient temperature.
Electrical power, rated 32 kW (Flue gas fan included.) From ship distribution
consumption: system.
Flue gas fan El. power 22 / 251.3 kW From incinerators electrical

consumption. control panel
Negative pressure: 10-35 mmWC In combustion chamber
Total weight: 4545kg
Outline dimension: 2416 x 1944 x 2097 (L x W x H) See dimension drawing.
Burner (fixed on combustion chamber)

Capacity: 16-43 l/h Two nozzles: 3.5 gph 60° and
5.5 gph 45°
Diesel Oil viscosity Max. 13 cSt at 40°C
Burner air blower each: Max. 1,500 m2/h
Oil pump: Working press. 16 bar

Max 21 bar.
El. Motor 2800/3400 rpm.

Rated current: 1.43/1.38 Amp.
380/440 V 50/60 Hz, 0.55/0.63kW
Ignition transformers: 230V / 10,000V
Weight (each): 30 kg
GS500CIC 21
MAIN DATA
Diesel oil booster pump (optional)

Capacity: 110 l/h At 14 bar.
El.motor: See Burner motor
Connections: 1/4"
Weight: 12 kg.
Outline dimension: 422x170x200(L x W x H) See dimension drawings.
Flue gas fan (bulkhead mounted)

Type: One stage centrifugal fan. Designed to withstand max
temperature of 450°C
Capacity: 12,500 std. m³/h at 300°C At 200 mmWC total back

pressure.
Flue gas duct dimensions DN 400/400
El.motor: 380/440V, 18/21.3kW 1465/1768 rpm variable

Current rating 36.8/36.6A
Weight: 563 kg
Control speed: 0-1800 rpm
Flue gas damper.

Type: Welded steel damper with actuator
Size: DN 400
Actuator motor: Drive force 20Nm. Travel

time for 90° is 150/125sec
50/60Hz.
Weight: 76 kg
Dimension between flanges: 300 mm See dimension drawing.
Sluice (fixed on top of incinerator unit) (Optional)

Purpose: Feeding of solid waste
Opening / volume 400 x 500 mm / 125 litres
22 GS500CIC
MAIN DATA
Sludge tank
Volume: Net: 1,100/1,700 or 2,000/3,000 litres.
Test pressure: Cylindrical tanks 1 bar

Rectangular tanks 0.2 bar
Corrosion Protection: Internal coated with one layer of Carboline

E-19 primer, thickness 40 microns
Flange rating: NP 16
Weight: 490 / 566 or 605/750 kg.
Outline dimension: (L x W x H) See dimension drawing.
Water tank (Optional)

Volume: Net: 435 litres.
Test pressure: Rectangular tanks 0.2 bar
Corrosion Protection: External coated with one layer of Carboline

E-19 primer,
thickness 70-80 μ. and one top coat Carboline
Carboxane 2000, Colour: RAL 6019 (light
green) Dry film thickness: 70 - 100 μ.
Internal coated with one layer of Carbozinc
858 primer 40 μ thikcness, and top layer of
Carbomastic 18 FC 175 μ thickness.
Flange rating: NP 16
Weight: 424 Kg
Outline dimension: (826 x 1026x 2188) See dimension drawing.
Sludge circulating pump. (installed on sludge tank)

Type; 40WYXH-6-20
Capacity: 6 m3/h at 1.9 bar discharge pressure.
El. motor: 4.8/4.7 Amp 2880/3480 rpm

Current rating 380/440 V, 50/60 Hz, 2.2/2.55 kW,
Sludge filling pump (if dual sludge tank system)(Optional)

Type; See sludge circulating pump
Sludge transfer pump (optional on dual sludge tank system)(Optional)

Type; See sludge circulating pump
Sludge dosing pump (fixed on combustion chamber)

Type: TeamTec RDCZ 432 screw pump
El. Motor: 0.37kW IP55 885/1062 rpm

Current rating 1.9A 220V 50/60Hz
Control speed: 0 – 1200 rpm
GS500CIC 23
MAIN DATA
Water dosage pump (Optional)

Type: TeamTec 432 screw pump
El. Motor: 0.55kW IP55 1380 rpm

Current rating 1.6A 380V 50Hz
Control speed: 0 – 1000 rpm
Diesel oil preheater (fixed on combustion chamber)

Rating: 380/440V, 50/60Hz, 1.5/2.0 kW
2.3/2.6 Amp
Electrical control panel incinerator ( fixed on combustion chamber)

Type: A Sarel panel of protected steel. 800x600x300mm
Enclosure rating IP 55
Weight: 67 kg
24 GS500CIC
MAIN DATA
Ships system interface requirement.

Electrical.
Refer to Cable Arrangement drawing.
Diesel oil.
Diesel oil supply line Equipped with a closing valve.
Connection. DN 15 flange, max pressure
Recommended filter, mesh 1.5 bar
40µm
Max. suction lift 3500mm
Diesel oil return line Connection. DN 15 flange, max pressure
1.5 bar
Flue gas duct.

Incinerator to flue gas fan Duct DN 400
Flue gas fan to open air. Duct DN 400
Sludge and Steam or Air.

Steam /air supply line for burner atomising. Connection DN 15 flange
Pressure 6 - 8 bar
Consumption: Steam approx. 20kg/h
Comp. air approx. 20kg/h
Drain from spill collector. Connection DN 25
Water and Steam or Air. (Optional)

Steam /air supply line for water injection Connection DN 15 flange
atomising. Pressure 6 - 8 bar
Consumption: Steam approx. 20kg/h
Comp. air approx. 20kg/h
Drain from spill collector. Connection DN 25
Sludge tank. (1100 / 1700 / 2000 / 3000 l option)

Filling Connections. DN 50 flange
Overflow line Connection. DN 65 flange
Supply and return line for incinerator Connections. DN 25 flange
Air vent. Connection. DN 65 flange
Drain. Connection. DN 32 flange
Sample points. Connections. 1/2" BSP
Heating: Steam Connection. 1/2" BSP
Consumption. approx. 50kg/h
Max. pressure. 10 bar
Heating: Thermal oil Connection DN 15 flange
Consumption. 2 m³/h
Max. pressure. 10 bar
Max. temperature. 180°C
GS500CIC 25
MAIN DATA
Water tank. (435 l) (Optional)

Filling Connections. DN 32 flange
Overflow line Connection. DN 40 flange
Supply line for incinerator Connections. DN 15 flange
Air vent. Connection. DN 50 flange
Drain Connection DN 50 flange
Detailed information regarding the system is found on the Piping & Instrument Diagram given in the
Drawings section.
26 GS500CIC
MAIN DATA
Guarantee certificate
TEAMTEC - GOLAR INCINERATOR

TYPE: GS500CIC
The incinerator plant consist of:
1. Combustion Chamber
2. Flue Gas Fan
3. Electric Panel
4. Spare parts
5. Sludge tank
6. Water tank (Optional)
7. Diesel Oil Booster Pump (optional)
We hereby confirm that the ordered equipment is guaranteed against faulty manufacturing for a
period of 12 months from approved start-up on board ship, but limited to 18 months from
shipment date of equipment.
Any faulty parts with proven manufacturing defects will be supplied free of charge, ex. works,
including packing, during the guarantee period. Possible travelling and accommodation
expenses for Service Engineer are not included.
The guarantee does not cover wear and tear parts. The guarantee is valid only if our operation-
safety- and maintenance instructions are properly followed, and start-up approved by signature
from ship owner's representative.
Tvedestrand,
Willy T. Morka
GS500CIC 27
TECHNICAL DESCRIPTION
28 GS500CIC
Technical description
Overall system function description
The TeamTec Incinerator type GS500C is designed for on board incineration of ship's waste oil, solid refuse
and destruction of bilge water. The system consists of 5 main parts:
• Combustion chamber with diesel oil burner, sludge burner, pilot fuel heater and electric control panel.
• Flue gas fan with flue gas damper
• Sludge service tank with circulating pump and heater.
• Sludge settling tank with filling pump and heater (Optional).
• Water injection (Optional).
Water injection (Optional)

The incinerator is equipped with a separate water injection unit including a frequency controlled water dosage
pump. The purpose of this pump is to inject water, containing small quantities of oil remnants, into the
combustion chamber by a special designed TeamTec nozzle system.
When burning sludge with injected water, the sludge burning capacity increases, NOx in flue gas duct reduces
and it is an easy way to get rid of problem water. Dumping oily water directly into the sea can harm marine life,
and is illegal. Various ports are facing new local regulations on ship emissions, including discharges of ballast
water, gray water, bilge water, and deck runoff, among others. Disposal of the contaminated water in the
incinerator is an easy and effective solution to a complex problem.
Combustion chamber
The combustion chamber consists of two cylindrical chambers with connecting openings. The right chamber is
for loading solids. The trash is ignited by burner in the chamber. The combustion chamber is equipped with an
inspection door and a ash door, which can be opened only while the incinerator is not burning. The control
system will prevent the doors from being opened before the set temperature for cooling is reached.
The flue gas outlet is located at the top of the left chamber for most efficient use of the flames. The flames
from the burners follow a corkscrew pattern towards the bottom and continue rotation upwards in the centre of
the combustion chamber. Remnants of particulate matters in the gas flow are neutralised by the burner, making
the combustion ecologically safe. As the fumes exits the chamber, cooling air drawn from the lower part of the
casing is mixed with the flue gas to bring the temperature down to approx. 330°C before it pulled out by the
flue gas fan and blown out the stack to atmosphere.
The burning process is monitored by the PLC and scanned by a photo resistor in the burner. The temperatures
are also monitored/regulated automatically by the PLC control system.
Two sight glasses are equipped, one at the end of the incinerator, for the operator to be able to inspect the
amount of trash in the chamber and the function of the system, and one in the inspection door .
The combustion chamber is of steel construction, lined with specially designed refractory blocks. Between the
steel and refraction there is a 50mm layer of insulation. The refractory material is made of a low cement/high
alumina quality being slag resistant and having very good thermal shock resistance. A double steel casing with
a cooling air jacket forms the outside of the combustion chamber.
The combustion chamber is equipped with a, three-stage diesel oil burner and a steam/air atomising nozzle for
sludge burning. Under the burner assembly, a bracket/drip tray for sludge burning equipment is mounted.
The Diesel Oil burner has 3 stages, automatically controlled by the PLC. In addition there are four stages for
sludge burning, using steam or compressed air for atomising. The sludge burner allows particles up to 4 mm to
pass through. The D.O. burner is monitored by the PLC and has a built in primary air fan and diesel oil pump.
The main electrical control panel is normally fitted on the incinerator and it contains circuit breakers, starters,
frequency inverters, PLC and operator panel. The electric panels are built according to international standards
for marine equipment. The operator panel, which is located at the front of the control panel, has a LCD display
touch screen for selecting burner program modes and for monitoring the burning process.
GS500CIC 29
Flue gas fan

The purpose of the flue gas fan is transportation of the flue gas from the combustion chamber and the fan
creates negative pressure in the furnace. The same fan draws ambient air through the cooling jacket on the
combustion chamber and the hot gas from the furnace is diluted with the cooling air at the flue gas outlet on the
combustion chamber in order to reduce the temperature below 350°C. The cooling air drawn trough the cooling
jacket will keep the surface temperature of the combustion chamber lower than 15°C above ambient
temperature
Sludge service tank with heater

The TeamTec Sludge tank is meant to function as a daily service tank for sludge to the incinerator. A heater,
controlled by a thermostat, will keep the sludge temperature around the set point (80 to 90°C). (With
temperatures above 60°C, regulations require tank to be insulated or guarded with metal screen).
Drain valves (sample points) are mounted on the tank to check the sludge level in the tank. A level transmitter
on the tank provides PLC to generate a animated tank level readout on operator panel (display on incinerator
control panel), and right amount of sludge burned.
A circulating pump is mounted on the tank. The pump transports the sludge to the incinerator and a return line
to the tank is provided, a god mixing of the sludge and water is guaranteed. A low level switch on the tank will
stop the incinerator, the circulating pump and heating when the level has reached a minimum. An indicating
light for heating is placed on the junction box on the tank.
Do not transfer sludge to the service tank during sludge burning
Sludge settling tank with heater (optional).

The TeamTec Settling tank is meant to function as a daily tank to heat, separate and drain water from the
sludge. A transfer pump can be used to fill the tank, and be connected to the "high level" switch, which stops
the pump when the tank is full.
A heater, controlled by a thermostat, will keep the sludge temperature around the set point (80 to 90°C). (With
temperatures above 60°C, regulations require tank to be insulated or guarded with metal screen).
Drain valves (sample points) are mounted on the tank to check the sludge level in the tank. The lowest one is
meant to use for draining off the water. A level transmitter on the tank provides PLC to generate a tank level
readout on operator panel (display on incinerator control panel).
A filling pump is mounted on the tank. The pump transports the sludge to the sludge service tank. A low level
switch on the tank will stop the filling pump and heating when the level has reached a minimum. It is not
possible to transfer sludge to the service tank during sludge burning
An indicating light for heating is placed on the junction box on the tank.
Water tank (Optional).

As an option to use the ships bilge/grey water tank, it is possible use a water service tank. The Water tank can
be filled from either the bilge holding tank or the gray water tank. This system is utilizing the existing water
discharge pumping system in order to fill a water tank to be located adjacent to the incinerator.
The water tank has filling, overflow and ventilation connection. The incinerator has frequency controlled water
dosing pump unit, with suction lift at 3500mm. The water is connected to the incinerator with DN 15 flange
connection.
The water tank has two level switches. A high level switch to stop the filling pump and a low level switch, with
dual contact set, to start the filling pump and to stop the water injection if switch is activated for more than two
minutes. This is to prevent the water dosage pump to run dry. A suitable tank is available from TeamTec.
30 GS500CIC
Sludge control
Introduction
The automatic sludge control logic is designed for burning a maximum amount of sludge, consuming a
minimum amount of diesel, and maintaining a combustion chamber temperature above 870°C (CCT stop burner
diesel oil), see operator panel - settings sludge program page 2/4. Sludge quality is an important factor for the
sludge burning process. The system is capable to handling sludge with a high content of water, but this might
however result in a higher consumption of diesel oil.
Temperature limits
680°C Start sludge burner.
640°C Temperature decrease to this level stop sludge burner and increase sludge quality
counter with 2(see slugde quality control Page 30).
660°C Temperature decrease to this level, after temperature have been above 690°C,
decrease the sludge dosage pump rpm with 70/401 and increase sludge quality counter
with 2.
690°C Temperature increase to this level increase the sludge dosage pump rpm with 70/402.
700°C Alarm level for low combustion chamber temperature, if combustion chamber
temperature has been above 850°C. Sluice is available in Solid waste program.
840°C Starts a diesel support burner in addition to the condition at 870°C and increase the
sludge quality counter with 2. Decrease the sludge dosage pump rpm with 140/1003.
870°C Temperature allowing burning sludge alone. Temperature increases to this level an
increase of the sludge dosage pump rpm with 140/1004.
890°C Above this temperature the sludge quality counter will step down by one every
minute.
900°C Sluice is available in Sludge & Solid waste program.
1000°C Temperature increase to this level and above, decrease the sludge dosage pump rpm
with 4 rpm every 30 second if Sludge & Solid waste program is running.
1050°C Sluice is not available in Sludge & Solid waste or Solid waste program.
1050°C Water injection control temperature. Water amount injected to combustion chamber
will increase if CCT is above this level, and decrease if CCT below this level.
1110°C Water injection starts.
1150°C Temperature increase to this level and above, decreases the sludge dosage pump rpm
with 4 rpm every 30 second.
1
For PLC program PLS0203D or later.
2
3
4
GS500CIC 31
Burner stage
• STAGE NO 3 Diesel oil nozzles no. 1 + 2.
• STAGE NO 4 Diesel oil nozzle no. 1 and sludge.
• STAGE NO 5 Diesel oil nozzle no. 2 and sludge.
• STAGE NO 6 Diesel oil nozzles no 1 + 2 and sludge
• STAGE NO 7 Sludge burner alone.
Control
At first start up a sludge burner program, the sludge burner start when combustion chamber temperature rise
above 680°C, the operator panel will indicate burner stage 5, the sludge dosage pump will be given start speed
150/2005 rpm, and will run at this speed for 60 seconds. During the 60 seconds, burner step 5 will be fixed.
Figure: Sludge quality control.
Assuming the sludge is of a good quality the temperature will start to rise. If the temperature raise is >=0°C
over 30 seconds, the sludge dosing pump increase 2 rpm. There will be a sampling of temperature each 30 sec.
and provided there is a temperature raise, a new step of 2 rpm will take place.
If the sludge quality is still good, the sludge dosing pump will be given a new step increase of 70/1406 rpm
when temperature rises above 690°C. The burner stage will be 4. When temperature raise above 870°C the
sludge dosing pump will again be given a new step increase 140/1007 rpm and the burner stage will be 7.
If the sludge contain too much water or chemicals, the temperature is likely to fall below 640°C and the sludge
dosing pump stop. Burner will change to stage 3, and the sludge quality counter will increase with 2 (after an
attempt to stage 5). When temperature rises above 680°C the sludge burner will start again. The burner stage
will then depend of sludge quality number. The sludge quality number is an indication of the quality of the
sludge. A high sludge quality number indicates a sludge with high water content, and burner will use more
diesel oil.
The low temperature alarm, 700°C, will first be activated if temperature has been above 850°C.
5
6
7
32 GS500CIC
PROGRAM DESCRIPTION
Operator Panel
General
The operator panel is a touch sensitive screen enabling the operator to enter information to the incinerator
control system. The screen is also displaying information from the control system to the operator. The panel is
connected to A PLC, controlling the combustion process. A description of the screens follows. The main
picture is displayed at start up and is possible to access by pressing “main” from most other screens. The screen
will display equipment according to scope of delivery from TeamTec AS
The Main picture has animated feedback to

the operator. The pumps and fans turn green 1
when running. The level switches are 2
animated up or down according to the level.
A level indication is animated at the sludge 3
tanks. There are written numbers displaying
4
actual measured values positioned
approximately according to physical
position at the incinerator. In addition to the
buttons at the lower part of the panel, it is
possible to press on an item on the screen to
5
open a different screen or dialogue box. The
list below describes the possible options: 6
10
11
12
1: Press in the middle of burner to access screen “Burner”

2: Press either of the two figures to access screen “Setting tanks”
3: Press heating symbol to access pop-up screen for start/stop heating sludge service tank.
4: Press heating symbol to access pop-up screen for start/stop heating sludge settling tank.
5: Press pump symbol to access pop-up screen for start/stop sludge filling pump (SFP).
6: Press pump symbol to access pop-up screen for start/stop sludge circulation pump
(SCP).
7: Press “Stop” button to stop incinerator.
8: Press “Alarm” button to access alarm screen.
9: Press “Hour” button to access screens for hour counting (2 pcs).
10: Press “Slag” button to start loading / slagging program.
11: Press “Setup” button to access screen “Setup” for selection of specific setup screen.
12: Press “Start” button to access pop-up for start / change program.
(The appearance of the screen may differ based on the choice of optional equipment)
GS500CIC 33
PROGRAM DESCRIPTION
Structure
Logic control system consists of an “Overview” screen and several sub-screens in the order as described below:
Main
Burner Hour counters
Settings tanks Consumption Setup consum.
Start/stop pumps Water tank

and heating
Select/start
programs
Setup Burner
Hour counters Alarms
Alarm Service Trend
Sluice Sludge I/O
Solid waste
Information
The control system Pop-up
will activate these SW Sludge
screens. Service
Pop-up
Sludge and Water
Load/slag & stop
Conf. Setting Water tank

Tanks
Login
Restore
Factory
Burn-in Settings
Display backlight
Date time
Prog. info
Consumption Setup consum.
Water tank
Hour
General: From all screens it is possible to stop the incinerator by pressing “Stop” It is also possible to access
“Main”, Setup” and “Alarm from all screens.
34 GS500CIC
PROGRAM DESCRIPTION
POP-up select program

Select program to start. The pop-up will close
after selection of program. Select “Cancel” to
close pop-up if you don’t want to start or
change program.
Description of the program selection

alternatives are given in chapter program
description.
Pop-up Start -Stop

To start and stop equipment press the actual
icon on the main screen and a pop-up window
will allow you to start or stop pumps and
heaters. The following figure shows an
example for heating service tank. The pop-
up’s will close after selection of “Start” or
“Stop”. Select “Cancel” to close pop-up if you
don’t want to change status of the equipment.
Start – stop heating sludge service tank:

Low level switch in sludge service tank must
be activated.
Start – stop heating sludge settling tank:
Low level switch in sludge settling tank must
be activated.
Start – stop sludge filling pump: Low level switch in sludge settling tank must be activated and high level in
sludge service tank can not be activated. Sludge burning program must not be activated.
Start – stop sludge circulation pump: Low level switch in sludge service tank must be activated. If a program
burning sludge is activated it is not possible to stop the pump by this control. In that case choose a program not
burning sludge or stop the incinerator
Start – stop sludge transfer pump: High level switch in sludge settling tank must not be activated.
Information pop-up
An information pop-up gives information to the
user about irregularities between user actions and
incinerator status. Read the message and press
“Ack”.
The following messages may appear as
information messages:
• High temperature sludge settling tank
• Not possible to start heater low level in

sludge settling tank
• Not possible to start sludge transfer

pump high level in sludge settling tank
• Not possible to start sludge filling pump low level in sludge settling tank
• Not possible to start sludge filling pump high level in sludge service tank
• Not possible to start sludge filling pump when sludge program is running
GS500CIC 35
PROGRAM DESCRIPTION
• Not possible to start sludge circulation pump low level in sludge service tank
• Not possible to start heater low level in sludge service tank
• Not possible to start sludge program - low level sludge service tank
• Not possible to start sludge with water program - low level sludge service tank
• Not possible to start solid waste - sludge program - low level sludge service tank
• Not possible to start program - Door not closed - please close door
• Not possible to start program – Alarm is active - please check Alarms
• Waiting.... flame in chamber
• High temperature water tank
• Sludge dosage pump is worn out – stator must be replaced
• Low level water tank – check water tank
• Sludge service tank level decreases too fast – Stop draining
• Low level sludge service tank – cooling
• Heating of refractory is finished. Let the incinerator cool down for 10 Hours8
Burner
Display actual values and status on motors,
actuators and sensors. No adjustments or
settings on this screen – view only.
Setting tanks
Displays tanks physical attributes and sludge
mass for correct sludge consumption.
8
Program revision C or later
36 GS500CIC
PROGRAM DESCRIPTION
Hour counters
Display last run and total hours. Press “Next”
button to access screen “Hour counters 2”
Setup
Some functions require the operator to login in
order to access a screen or to alter a value in
the setup. This normally indicates that the
operator needs training in order to be aware of
the consequences of his actions.
Select the setup screen you want to access. If
not logged in as user “usr”, values on different
setup screens are “view only”.
GS500CIC 37
PROGRAM DESCRIPTION
Login
Pressing “Setup” will give access to “Login”.
Wrong user pop-up

All screens can be accessed by all users. To
change settings, the user has to log in as user
“usr” with password “2468”. To log in, select
“Setup” and then “Login”. If the user tries to
change a value without logging in to the
operating terminal, this screen will pop-up:
Press “Login” to activate the login sequence: An

alphanumeric keyboard will pop-up:
Press “User” button and type in user name usr

and press “return” to accept user name. Press
“Password” button and type in password 2468 and press return to accept password.
Press return to close Login pop-up. The user is now logged in as user “usr” and is allowed to change settings.
Settings will automatically change back to factory settings every 15 minutes, regardless if logged in as usr.
Change values
Plot the value that should be changed. A numeric pop-up will appear:
The present value is displayed on the line. Type in a new value and press return to
accept, or press “ESC” to cancel.
38 GS500CIC
PROGRAM DESCRIPTION
Settings burner
If not logged in as user “usr”, values on different
setup screens are “view only”. Buttons “Prev.”
and “Next” is used in a circular shift function
between a number of setting screens.
Text Description
Burner damper burner Burner damper opening. Adjusts the amount of air supplied to the
step x combustion process by the burner motor fan.
Factor CCP burner Correction of burner damper opening related to combustion chamber
damper reg. pressure (CCP). Used internally in the control system.
Factor SDP burner Correction of burner damper opening in related to sludge dosage pump
damper reg. (SDP) speed. Used internally by the control system.
Settings alarms
If not logged in as user “usr”, values on
different setup screens are “view only”.
GS500CIC 39
PROGRAM DESCRIPTION
Text Description
Alarm max time The maximum time the dieselheater is activated the first time after start
dieselheater start incinerator. The dieselheater requires extra time at start-up.
Alarm max time The maximum time the dieselheater is activated during incinerating.
dieselheater run
Alarm max. CCT Maximum combustion chamber temperature (CCT).
Min. operating CCT Minimum combustion chamber temperature (CCT). Used as reference to
“Alarm CCT below min. oper.”
Alarm CCT below Maximum temperature drop combustion chamber temperature (CCT).
min. oper. Related to “Min. operating CCT”.
Alarm max. FGT Maximum flue gas temperature (FGT).
Alarm min. CCP Minimum combustion chamber pressure (CCP).

(Draught failure)
Settings sludge (1/4)

Buttons “Prev.” and “Next” is used in a
circular shift function between a number
of setting screens.
Text Description
Set burning time9 Set total burning time for sludge program
Sludge alone10 Yes - if sludge burning without diesel oil support burner is allowed
No - if sludge burning with diesel oil support burner is required
CCP start sludge Setpoint combustion chamber pressure (CCP) when starting a sludge
program
9
Can be changed by user
10
40 GS500CIC
PROGRAM DESCRIPTION
Max. CCP run sludge Maximum combustion chamber pressure (CCP). Used internally as a limit
in the control system
Min. CCP run sludge Minimum combustion chamber pressure (CCP). Used internally as a limit in
the control system
Min. sludge temp run Minimum sludge temperature before starting sludge program. This value is
sludge also calculating alarm sludge temperature. See alarm settings.
Alarm sludge temp. The maximum temperature drop in sludge temperature. Related to “Min
low sludge temp run sludge”.
Alarm sludge temp. The maximum temperature increase in sludge temperature. Related to “Min
high sludge temp run sludge”.
Min. CCT run sludge Minimum combustion chamber temperature (CCT) before starting sludge.
CCT low hysteresis – Maximum drop combustion chamber temperature (CCT) – stop sludge
stop sludge. dosage system.

Text Description
Time start sludge Time after start sludge dosage pump (SDP) before making adjustments – to
before adjust ensure a stable process before adjusting sludge.
Time check CCT after Time between reading combustion chamber temperature (CCT) and making
adjust adjustments to the process
CCT inc between The minimum increase in combustion chamber temperature (CCT) needed
adjust – inc sludge at time check before making adjustment to process.
CCT inc sludge – dec Minimum combustion chamber temperature (CCT) before decreasing diesel
diesel oil oil and increasing sludge.
Hys dec sludge – inc Maximum drop combustion chamber temperature (CCT) before decreasing
diesel oil sludge and increasing diesel oil.
CCT stop burner Minimum combustion chamber temperature (CCT) before stop diesel oil
diesel oil and further increase sludge.
GS500CIC 41
PROGRAM DESCRIPTION
Hys burner restart Maximum drop combustion chamber temperature (CCT) before restart
diesel oil burner diesel oil and decrease sludge.
Max. CCT Maximum combustion chamber temperature (CCT) before reducing sludge.
Hys max. CCT – stop Maximum drop combustion chamber temperature (CCT) before stop
dec sludge reducing sludge.
Set CCP running Step Set point for Combustion Chamber Pressure (CCP) is -12mmWC during
4&5 burner stage 4 & 5 as long as the Combustion Chamber Temperature is
below 800°C
Set min CCP for Minimum set point for Combustion Chamber Pressure (CCP) as long as the
temp.regulating Combustion Chamber Temperature is above 800°C
42 GS500CIC
PROGRAM DESCRIPTION

Text Description
Max. FGT – start Maximum flue gas temperature (FGT) before decreasing combustion
adjust CCP chamber pressure (CCP)
Hys max. FGT – stop Maximum drop flue gas temperature (FGT) before stop decreasing
adjust CCP combustion chamber pressure (CCP)
Time check FGT Time between check flue gas temperature (FGT) before making further
adjust CCP increase in combustion chamber pressure (CCP)
FGT max. inc. CCP Maximum flue gas temperature(FGT), increase combustion chamber
pressure(CCP).
Max. FGT – start Maximum flue gas temperature (FGT) decrease sludge dosage pump (SDP)
adjust SDP RPM RPM.
Hys FGT – stop adjust Minimum drop flue gas temperature (FGT) before stop decreasing sludge
SDP RPM dosage pump (SDP) RPM.
Min. CCT scale CCP Minimum combustion chamber temperature (CCT) in scaling range for
run sludge adjusting combustion chamber pressure (CCP)
Max. CCT scale CCP Maximum combustion chamber temperature (CCT) in scaling range for
run sludge adjusting combustion chamber pressure (CCP)
CCP running Combustion chamber pressure (CCP) when burning both diesel nozzles and
burnerstep 6 sludge nozzle.
SDP comp. decrease Increasing sludge when changing burner step from 5 to 4, or 6 to 5.
diesel oil
SDP comp. stop diesel Increasing sludge when changing burner step from 4 to 7.
oil
GS500CIC 43
PROGRAM DESCRIPTION

Text Description
SDP RPM decrease Decreasing SDP RPM every 30 second if combustion temperature CCT >
Max. CCT run sludge – dec sludge(1/4).
SDP RPM increase Increasing SDP RPM every 30 second if combustion temperature CCT
increases or equal.
Min. RPM SDP Minimum allowed speed sludge dosage pump.
Max. RPM SDP Maximum allowed speed sludge dosage pump.
Manual setpoint SDP Adjust sludge dosage pump manually.

RPM
Sludge quality counter Sludge quality counter number.
Purging start sludge Time for purging sludge nozzle before opening sludge.
Purging stop sludge – Minimum combustion chamber temperature (CCT) for stop purging sludge
CCT below nozzle.
Setpoint heat tracing Setpoint for heat tracing temperature on sludge line.
Hystersis heat tracing Hysteresis for setpoint, heat tracing temperature on sludge line.
Alarm low level Activate if alarm is needed when sludge service tank low level switch is
Sludge service tank activated.
44 GS500CIC
PROGRAM DESCRIPTION
Settings solid waste (1/2)

circular shift function between a number of
setting screens.
Text Description
Set burning time11 On, makes it possible to program a fixed burning time
CCP start-up solid Minimum combustion chamber pressure (CCP) before start burner at start
waste program solid waste program
CCP max. solid waste Maximum combustion chamber pressure (CCP) when running solid waste
program
CCP min. solid waste Minimum combustion chamber pressure (CCP) when running solid waste
program
Maximum CCT Max combustion chamber temperature (CCT), decrease burner stage
CCT min. for start Minimum combustion chamber temperature (CCT) for burning solid waste
solid waste (sluice)12 (operating sluice)
Waiting time, new Minimum waiting time between sluice loads.

sluice load13
Set CCP sluice Setpoint combustion chamber pressure when sluice is activated
operation14
11
12
Only visible if sluice is installed
13
14
GS500CIC 45
PROGRAM DESCRIPTION
Settings solid waste (2/2)

circular shift function between a number of
setting screens.
Text Description
Time check CCT Time for checking temperature increase/decrease.

increase
Max. FGT start Maximum flue gas temperature (FGT) before start adjusting combustion
adjustment CCP chamber pressure (CCP).
Hysteresis FGT stop Minimum drop flus gas temperature (FGT) before stop adjusting
adjusting CCP combustion chamber pressure (CCP)
CCP inc when FGT Value for increasing combustion chamber pressure (CCP) when flue gas
above setpoint temperature (FGT) is above set point
CCP dec when FGT Value for decrease combustion chamber pressure (CCP) when flue gas
below setpoint temperature (FGT) is below set point
Time check FGT Time between reading flue gas temperature (FGT) before making
adjust CCP adjustments to combustion chamber pressure (CCP).
Max. FGT start adjust Maximum flue gas temperature (FGT) before start adjusting burner step.
burner step
Hysteresis FGT stop Minimum drop flue gas temperature (FGT) before stop adjusting burner
adjust burner step step.
Time check FGT Time between reading flue gas temperature (FGT) before making
adjust burner step adjustment to burner step.
46 GS500CIC
PROGRAM DESCRIPTION
Settings solid waste and sludge

Text Description
Max. CCT SW & Maximum combustion chamber temperature (CCT) – reduce sludge when
sludge running solid waste and sludge program.
Hysteresis max. CCT Minimum drop combustion chamber temperature (CCT) – stop reducing
SW & sludge sludge when running solid waste and sludge program.
Decrease SDP rpm Decrease sludge dosage pump rpm when sluice is activated.
sluice operation
Set CCP sluice Combustion chamber pressure when sluice is operated.

operation15
CCT enable sluice16 Minimum combustion chamber temperature for sluice operation
15
16
GS500CIC 47
PROGRAM DESCRIPTION
Settings sludge with water

Text Description
CCT enable Water Setpoint combustion chamber temperature for water injection to start.
injection
CCT max. for Water Maximum combustion chamber temperature when water injection is
injection enabled.
CCT min. for Water Minimum combustion chamber temperature when water injection is
injection enabled.
Max. RPM WDP Maximum Water dosage pump RPM.
Start RPM WDP Start RPM Water dosage pump.
Min. RPM WDP Minimum Water dosage pump RPM.
Increase RPM WDP Increase of Water dosage pump RPM every 60 second until “Max RPM
WDP” is reached
48 GS500CIC
PROGRAM DESCRIPTION
Settings loading/slagging and stop

Text Description
CCP running cooling Set point for combustion chamber pressure (CCP) when running “Stop”
program (cooling).
Auto start of FGF after Off – After emergency stop the flue gas fan needs to be restarted by pushing
emergency stop17 “STOP” button on display.
On – After emergency stop the flue gas fan automatically starts if

temperature is above 220°C.
Start/Stop cooling - Setpoint start and stop of cooling incinerator

hystersis
Hystersis start/stop Hystersis start and stop of cooling incinerator

cooling
17
Can be changed by user.
GS500CIC 49
PROGRAM DESCRIPTION
Burn-in
Burn-in program is used for burning in

refractory after long storage periods or
refractory replacement. It runs automatically
for 10 hours, increasing CCT from 100°C to
600°C. A message will appear when refractory
is ready.
Text Description
Temperature setpoint Setpoint for combustion chamber temperature CCT, running Burn-in
(view only) program
Hys. chang. burner Hysteresis for temperature setpoint, when changing burner step.
step
Burnerstep (view only) Actual burnerstep
50 GS500CIC
PROGRAM DESCRIPTION
Incinerator configuration
Incinerator configuration
The button “Restore factory settings” can be
used to restore settings to factory
specifications.
If assistance from TeamTec is required, you

might be asked for the incinerator
configuration listed on the screen
Backlight
No user name and password required.
Time and date

No user name and password required. Press
button “Set new time & date” after new time
and date has been entered. This will transfer
the new time and date values to the control
system.
GS500CIC 51
PROGRAM DESCRIPTION
Program information
Values are view only. If assistance from
TeamTec is required, you might be asked for
the type and version listed on the screen.
Consumption
Display consumption for this run, last run and
total. Press “Setup consumption” to access
setup screen.
Consumption setup
52 GS500CIC
PROGRAM DESCRIPTION
Alarm system
If the control system encounters any irregularities the system will give an alarm and shut down the incinerator.
When an alarm occurs, the internal audible alarm activates and the alarm signal is given to ships alarm system.
The "ALARM" screen will pop-up at the operator panel display and the most recent alarm(s) will be displayed
at the top of the list. The “ALARM” screen will display active alarms as well as the alarm history. A total of
128 alarms (active and history) can be displayed. When additional alarms occur, the oldest alarms will be
deleted from the alarm history list.
The alarm Screen

Highlighted line (yellow letters) indicates the selected line. When “Ack” button is pressed, the selected alarm is
acknowledged.
Symbols indicating alarm status

Alarms Status:
Symbol Status
! Active Not accepted
*! Active Accepted
* Not active Accepted
Buttons for handling alarm system.
BUTTON TEXT Description

Ack Acknowledge an alarm.
Double arrow up Move the line (alarm) selection to top of list or screen.
Arrow down Move the line (alarm) selection down one line. If the alarm list contains
more alarms than can be displayed on the screen, the list will move one
line at a time each time the button is pressed.
Audio Off Switch off audible alarm. The audiable alarm will not reengage until all
the alarms have been inactive and an new alarm appears
Close Leave alarm screen. If one or more alarms is still active or not
acknowledged, a red symbol is displayed on the “Alarm” button on the
“Main” screen.
GS500CIC 53
PROGRAM DESCRIPTION
Alarm List
The Alarm-list contains information about which alarms that are available. The reference refers to electrical
drawings.
ALARM TEXT Set point Active Ref. Description

Failure frequency inverter All time -U6 One or more failure(s) occurred
SDP in frequency inverter for Sludge
dosage pump.
Failure frequency inverter All time +25-U1 One or more failure(s) occurred
WDP18 in frequency inverter for Water
dosage pump
Flue gas temp. FGT high 375°C All time -U4 Flue gas temperature above
maximum setpoint temperature.
Comb. chambr. temp. CCT 1200°C All time -U2 CCT above maximum
high temperature.
Comb. chambr. temp. CCT 700°C Running -U2 CCT falling below normal
low Sludge operation temperature
Thermal failure - motor x A19 All time -F1, to – Protection relay cut out.
overload F9
Door not closed ∼ Running -Y3, -Y4 Micro switch in door lock not
closed.
Draught failure - CCP low -5 mmWC Running -A11 Combustion chamber pressure
falling below set point.
Diesel oil temp. low 600/48020 Running/ +2-S2 Heater element active more than
sec. Start up set point time
1200/60021
sec..
Diesel oil temp. high 90°C Running +2-S3 Safety thermostat released.
(Require manual reset)
Diesel oil press. Low 11 bar Running +2S1 Diesel oil pump press low.
Flame failure ~ Running +2-R1 Poor or no flame.
Voltage low – high 220V All time -K9 Control voltage more than +/-
±10% 10% out of normal.
Steam/air press. - sludge low 1,5 bar Sl. prog. -S5 Steam / air pressure sludge low.
Steam/air press. - sludge 4,5 bar Sl.prog. -S5A Steam / air pressure sludge high
high
Sludge pressure low 0.1 bar Sl. prog. -S6 Sludge pressure low.
Sludge temperature low 50°C Sl. prog. -U3 Sludge temperature low.
Sludge temperature high 95°C All time -U3 Sludge temperature high.
Sludge service tank temp. 110°C All time +3A.1-S1 Safety thermostat released.
high22 (require manual reset)
18
Only visible if water injection is installed
19
See motor rating
20
For PLC version PLS0203D or later
21
22
sludge tank w/el. heater
54 GS500CIC
PROGRAM DESCRIPTION
ALARM TEXT Set point Active Ref. Description

Steam/air press. - water 1,5/4,5 bar Sludge +25 Steam / air pressure water
low/high23 w/water S4/S5 low/high.
Prog.
Circuit failure FGT ~ All time -U4 Open circuit in sensor (broken)
or short circuit in amplifier for flue
gas temperature.
Communication failure PLC- ~ All time A1 & A2 Communication failure between
Display PLC and display
Circuit failure CCT ~ All time -U2 Open circuit in sensor (broken)
or short circuit in amplifier for
combustion chamber
temperature.
Circuit failure SDP temp. ~ All time -U3 Open circuit in sensor (broken)
or short circuit in amplifier for
sludge temperature.
Low level sludge service tank ~ Sl. Prog. +3A-S1 Sludge below low level switch in
more than 5 sec.
23
Only visible if water injection is installed
GS500CIC 55
PROGRAM DESCRIPTION
Setting list
Settings burner 50Hz 50Hz 60Hz 60Hz Sluice

Sluice
Burner damper burner step 1 32 % 32 % 27 % 27 %
Burner damper burner step 7 70/5524 70/5525 70/5026 70/5027%
% % %
Factor CCP burner damper reg. 0.150
Factor SDP burner damper reg. 0.087/0.05028
Settings alarms
Alarm max time dieselheater start 1200/60029
Sec.
Alarm max time dieselheater run 600/48030 Sec.
Alarm max CCT 1200 °C
Min.operating CCT 850 °C
Alarm CCT below min. oper. 150 °C
Alarm max FGT 375 °C
Alarm min CCP (Draught failure) -5 mmWC
Settings sludge
Sludge alone Yes
CCP start sludge -35 mmWC
Max. CCP run sludge -35 mmWC
Min CCP run sludge -10 mmWC
Min. sludge temp run sludge 80 °C
Alarm sludge temp. low, below normal 30 °C
Alarm sludge temp. high, above normal 15 °C
Min. CCT for run sludge 680 °C
CCT low hysteresis – stop sludge 40 °C
Time start sludge before adjust 60 Sec.
Time check CCT after adjust 30 Sec.
CCT inc between adjust – inc sludge 0 °C
CCT inc. sludge – dec. diesel oil 690 °C
Hys dec sludge – inc diesel oil 30 °C
CCT stop burner diesel oil 870 °C
Hys restart burner diesel oil 30 °C
Maximum CCT 1150 °C
Hys max CCT – stop dec sludge 10 °C
Set CCP running step 4 & 5 -12 mmWC
Set min CCP for temperature regulation -12 mmWC
Max. FGT – start adjust CCP 330 °C
24
25
26
27
28
29
30
56 GS500CIC
PROGRAM DESCRIPTION
Hys max FGT – stop adjust CCP 0 °C

Time check FGT adjust CCP 30 Sec.
FGT max inc CCP -3 mmWC
Max FGT start adjust SDP RPM 340 °C
Hys FGT – stop adjust SDP RPM 1 °C
Min CCT scale CCP run sludge 800 °C
Max CCT scale CCP run sludge 1200 °C
CCP running burner step 6 -35 mmWC
SDP compensation – decrease diesel oil 70/4031 rpm
SDP compensation – stop diesel oil 140/10032 rpm
SDP RPM decrease 4 rpm
SDP RPM increase 2 rpm
Min. RPM SDP 150/20033 rpm
Max. RPM SDP 1200 rpm
Manual setpoint SDP rpm * rpm
Sludge quality counter [0-18]
Purging start sludge 10 Sec.
Purging stop sludge – CCT below 300 °C
Setpoint heat tracing34 75°C
Hysteresis heat tracing35 5°C
Alarm low level Sludge service tank Off
Settings solid waste
CCP start-up solid waste program -35 mmWC
CCP max. solid waste program -28 mmWC
CCP min solid waste program -10 mmWC
Maximum CCT 1150 °C
CCT min. for start solid waste (sluice) 700 °C
Waiting time, new sluice load 210 sec
Set CCP sluice operation -32 mmWC
Time check CCT increase 40 sec
Max. FGT start adjustment CCP 330 °C
Hysteresis FGT stop adjusting CCP 2 °C
CCP inc when FGT above setpoint 1 mmWC
CCP dec when CCP below setpoint 2 mmWC
Time check FGT adjust CCP 30 Sec.
Max. FGT start adjust burner step 340 °C
Hysteresis FGT stop adjust burner step 5 °C
Time check FGT adjust burner step 60 Sec
Settings sludge with water
CCT enable water injection 1110 °C
CCT max. for water injection 1050 °C
CCT min. for water injection 840 °C
Max. RPM WDP 1000 rpm
Start RPM WDP 600 rpm
Min. RPM WDP 200 rpm
Increase RPM WDP 5 rpm
Settings solid waste and sludge
Max CCT SW & Sludge 1000 °C
Hysteresis max CCT SW & Sludge 10 °C
31
32
33
34
Visible if heat tracing installed
35
Visible if heat tracing installed
GS500CIC 57
PROGRAM DESCRIPTION
Decrease SDP rpm sluice operation 30 rpm

Set CCP sluice operation -40 mmWC
CCT enable sluice 900 °C
Settings loading/slagging & stop
CCP running cooling -18 mmWC
FGF rpm when CCT below stop 500 rpm
Auto start of FGF after emergency stop On
Start/Stop cooling – hysteresis 220 °C
Hysteresis start/stop cooling 50 °C
Setup consumption
Nozzle 1 specification 20.82 l/h
Nozzle 2 specification 24.60 l/h
Setpoint WDP capacity 0.00210 l/r
Setpoint SDP capacity 0.00295/
0.002236 l/r
SDP capacity 0.00295/
0.0022 l/r37
Accepted deviation SDP capacity 80%
Settings
Tanks
TG5
Sludge
Max tank level Volume below low level Tank area density
435 L 500000 mm² 0.96 Kg/L
703 L 217,9 L. 750000 mm² 0.96 Kg/L
1107 L 219,5 L 1020703 mm² 0.96 Kg/L
1692 L 277,0 L 1517468 mm² 0.96 Kg/L
2071 L 277,0 L 1517468 mm² 0.96 Kg/L
2938 L 277,0 L 1517468 mm² 0.96 Kg/L
3812 L 622,0 L 1985565 mm² 0.96 Kg/L
4945 L 550,0 L 1985565 mm² 0.96 Kg/L
36
37
Changes after 3 hours continious sludge burning. For PLC version PLS203D or later
58 GS500CIC
PROGRAM DESCRIPTION
Settings frequency inverter ALTIVAR 31
drC code +25-U1 (Water)38

FCS InI
bFr 50 Hz
UnS 380 V
nCr 1.6 A
nSP 1380
COS 0.82
Uft n
tUn POn*
SEt code +25-U1(Water)

ACC 1.0
dEC 0.1
HSP 50
ItH 1.6
UFr 40
FLG 33
Ctl code +25-U1(Water)

Fr1 AI3
FUn code +25-U1(Water)

AdCÆAdC no
drC Code +25-U1(Water)

SCS Str 1
Save settings before incinerator leaves TeamTec

*Press button until display changes to nO.
38
Only available if water injection is installed
GS500CIC 59
PROGRAM DESCRIPTION
Settings frequency inverter ALTIVAR 12
CONF code +1-U6 Sludge

FCS InI
bFr 50 Hz
dEC 0.1 sec
nPr 0.37 kW
nCr 1.9 A
A11t 0A
FULL - drC code +1-U6 Sludge

Ctt PErF
nPr 0.37 kW
UnS 220 V
nCr 1.9 A
nSP 885
UFr 50
FLG 33
tUn YES
CONF - code +1-U6 Sludge

SCS YES*
drC Code +1-U6 Sludge

Non rFr
Save settings before incinerator leaves TeamTec

*Press button until display changes to nO.
60 GS500CIC
PROGRAM DESCRIPTION
Program description
Overall program function description
The TeamTec Incinerator type GS500C is controlled by a Programmable logic controller (PLC) witch handles
both the operating functions and the alarm system. The Human Machine Interface (HMI) is a touch screen
operator terminal. The operator terminal allows the user to view and monitor the process and to give input to
the process by choosing appropriate program to the desired task.
The Incinerator has 5 programs to select from; “Sludge”, ”Sludge and Water39”, “Solid waste & Sludge”,
“Solid Waste” and “Slag”. Some functions are general and controlled in the same way regardless of choice of
program.
General
The diesel oil burner heats up the incinerator. The burner runs in different steps, each program calculates the
required burner step and the burner responds accordingly by controlling the diesel oil valves, the burner air
damper the burner motor and the ignition electrodes.
The airflow through the burner is adjusted by the burner damper to different air flow at different steps on the
burner. The damper opening is corrected for the actual pressure in the combustion chamber (CCP) and the
actual speed of the sludge dosing pump (SDP)
The burner has the following steps:
0 - Burner stopped.
1 – Nozzle 1
2 – Nozzle 2
3 – Nozzle 1 and 2
4 – Nozzle 1 and sludge.
5 – Nozzle 2 and sludge.
6 – Nozzle 1 and 2 and sludge.
7 – Sludge only
39
Only available if water injection is installed
GS500CIC 61
PROGRAM DESCRIPTION
The actual burner step is displayed in the operator terminal.
Combination of possible burner steps in different programs:
Program: Sludge Sludge with Solid waste Solid waste

water and sludge
Burner step 0 X X X X
Burner step 4 X X X Not possible
Flue Gas Fan

The flue gas damper (FGD) controls the combustion chamber pressure (CCP). If frequency controlled flue gas
fan is installed, the flue gas fan (FGF) speed controls the speed, the combustion chamber pressure (CCP)
changes, and thereby also alter the amount of combustion air drawn into the combustion chamber from the
outside.
The chosen program will call for different Combustion chamber pressure set points at different conditions and
stages of the program.
Function Sludge program

The incinerator is designed and approved to burn sludge according to IMO specifications. See technical
specifications for information about sludge and quantities to be handled by your incinerator.
The incinerator starts heating up using the diesel oil burner. The diesel oil burner is controlled in different steps.
See description of burner for details.
For operation instruction see page 94.
After sludge program is started there is two criteria that needs to be fulfilled before incinerating starts; Sludge
temperature above 80°C and Diesel oil temperature above 60°C and CCP must be -35mmWC.
When the combustion chamber temperature (CCT) has reached set point “min CCT for run Sludge”(680°C), the
steam line will flush for 10 seconds to drain out condensate water before starting up the sludge burner. The
sludge dosage pump (SDP) starts. If the temperature increases after 60 seconds, the diesel oil burner reduces
“CCT inc sludge – dec diesel oil”(690°C). If temperature decreases below 640°C, sludge burning stops and
retries with a higher burnerstep at “min CCT for run Sludge”(680°C) if sludge quality counter is above the
initial value for increasing sludge burner step. At set point “CCT stop burner diesel oil” (870°C), the sludge
program requires burner step 7 from the burner program and runs sludge only if selected in the sludge settings.
62 GS500CIC
PROGRAM DESCRIPTION
The sludge dosage pump (SDP) is controlled by a frequency inverter.
Sludge dosage pump (SDP) will increase sludge dosing if combustion chamber temperature (CCT) is equal or
rising, until combustion chamber temperature (CCT) has reached set point ”Max CCT run Sludge” (1150°C) or
flue gas temperature (FGT) raises above “Max FGT – start adjust SDP RPM (340°C). The control system will
then adjust sludge dosage pump (SDP) to keep combustion temperature (CCT) and flue gas temperature below
maximum setpoints.
Low sludge tank will result in a normal stop of the program or alarm if it is selected in alarm settings. When
sludge burner stops, the sludge solenoid valve closes the sludge while the steam/air solenoid flushes the sludge
nozzle until the temperature in the combustion chamber is lower than 300°C in order to avoid building up of
coke on the burner tip.
The temperature and pressure in the combustion chamber is controlled by calculations in the control system.
The calculation involves:

Set points for temperature in chamber (CCT).
Set points for pressure in chamber (CCP).
Set points for diesel oil burner.
Set points for sludge temperature.
Set points for sludge dosage pump (SDP).
Actual combustion chamber temperature (CCT).
Actual combustion chamber pressure (CCP).
Actual flue gas temperature (FGT).
Actual speed sludge dosage pump (SDP).
Actual sludge temperature.
The calculations controls:
1 – Combustion chamber pressure (CCP).
2 – Combustion chamber temperature (CCT).
3 – Flue gas temperature (FGT).
By adjusting:
1 – Flue gas fan damper(FGD)/ Flue gas speed.
2 – Diesel oil burner steps
5 – Speed sludge dosage pump (SDP).
All checks of temperature are made in time intervals. After each change in state or function, further adjustments
are not made until time interval has elapsed.
At the end of each time interval (30sec), the change in combustion chamber temperature (CCT) is calculated.
Depending of temperature raise (or drop), adjustments are made, according to calculations, to components that
will influence the combustion chamber temperature (CCT), and the present combustion chamber temperature
(CCT) is stored.
GS500CIC 63
PROGRAM DESCRIPTION
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again.
Combustion chamber pressure:

At the start of sludge program, the initial combustion chamber pressure (CCP) (app. -35 mmWC) must be
reached in order to start burner.
The CCP set point is controlled by the combustion chamber temperature (CCT), flue gas temperature (FGT)
and burner step.
Function Sludge program with water Injection

The “Sludge and Water” program is identical to the sludge program except for the addition to water injection.
If “Sludge and Water” is active the water dosage pump (WDP) is started when combustion chamber
temperature (CCT) reach “CCT enable bilge”(1110°C).
The control system will adjust the sludge dosage pump (SDP) to keep the combustion chamber temperature
(CCT) at “CCT max. for water injection”(1050°C). The maximum water dosage pump (WDP) RPM starts at
200/600 rpm and increases by “Increase RPM WDP” (5 rpm) every 60 second, until “Max. RPM WDP”
(600/1200) RPM is reached. Water dosage pump (WDP) RPM is controlled as a function of the combustion
chamber temperature (CCT), see illustration.
If combustion chamber temperature (CCT) drops below “CCT min. for water injection”(840°C), the water
dosage pump (WDP) stops.
1400
1200
1000
800
WDP [rpm]
WDP rpm(Heater)
WDP2 rpm
600
400
200
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
10 0
10 0
10
10 0
30
10 0
50
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
0
4
10
10
CCT [°C]
64 GS500CIC
PROGRAM DESCRIPTION
Function solid waste program
Note: All references to settings and values are for explanation only. The values on your incinerator or
application may be different.
The program assumes a batch load of waste in the incinerator and will have initial speed and pressure set points
to facilitate enough combustion air to handle this (CCP=28 mmWC, burnerstep 1).
All checks of temperature are made in time interval. After each change in state or function, further adjustments
are not made until time interval has elapsed.
At the end of each time interval (40 sec), the change in combustion chamber temperature (CCT) is calculated.
Depending of temperature raise (or drop), adjustments are made, according to calculations, to components that
will influence the combustion chamber temperature (CCT), and the present combustion chamber temperature
(CCT) is stored.
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again according to tabular below.
Delta CCT Delta step 1 Delta Delta Delta step Delta step
step 2 step 3 4 5
CCT < -1C°
STEP CCT -1 to + 3 to +10 to > +17C°
+3C° +10C° +17C°
> 1000C° P +1 0 -2 -4 -5
4 B 0 -1 -1 -1 -2
860 - 1000C° P +2 +1 0 -2 -4
3 B +1 0 0 -1 -1
700 – 860C° P +4 +3 +2 0 -2
2 B +1 +1 +1 0 0
< 700C° P +8 +6 +4 +2 0
1 B +1 +1 +1 +1 0
P = Combustion chamber pressure (-mmWC)
B = Burnerstep
Delta CCT = Temperature rise after 40 seconds.
The diesel oil burner heats up the incinerator. The burner starts and runs in 3 steps (burner step 1-3). Change in
burner steps are made in time intervals as described above.
When combustion chamber temperature (CCT) reaches set point 1000 °C, the diesel oil burner reduces one step,
and further increase in combustion chamber temperature (CCT), reduces burner to step 1.
At the end of time interval (see description above), corrections are made to combustion chamber pressure
(CCP), according to calculations involving a combination of actual temperature in combustion chamber (CCT)
and the temperature raise (or drop) since last correction.
Combustion chamber pressure is also controlled by the flue gas temperature (FGT). At flue gas temperature
(FGT) above set point (330 °C), the control system overrides calculations made in time interval (as described
above).
GS500CIC 65
PROGRAM DESCRIPTION
Function Solid waste and sludge program

The Solid Waste and sludge Program heats up the combustion chamber according to the solid waste program
and when the Incinerator is ready to burn sludge the functions of the sludge program is applied. The maximum
combustion chamber temperature is then reduced to app. 1000°C in order to enable the operator to feed solid
waste (if a sluice is fitted).
Function Sluice operation

Solid Waste program:
Sluice feeding is available at CCT above 700°C and below 1050°C. When sluice is
installed, an information display will be visible in the main display. This describes the
sluice status when using the sluice.
When green push button on sluice is lit, load the sluice with waste, close sluice door.
When the sluice is rotated, the Combustion chamber pressure (CCP) will increase to
“Set CCP sluice operation”(-32 mmWC) and burnerstep 2 is active. When sluice is
activated, combustion chamber pressure will be unchanged until 210 seconds has
elapsed, or combustion chamber temperature (CCT) after 60 seconds, has decreased
below combustion chamber temperature when sluice was activated. All this
information is available in sluice display. This display window also shows if waste has
high or low calorific value.
If waste is loaded when Combustion chamber temperature is below 750°C, and low
calorific waste is detected, sluice program is

deactivated until Combustion chamber temperature
has increased above combustion chamber temperature
when sluice was activated.
Solid waste and sludge program:

Sluice feeding is available at CCT above 900°C and
below 1050°C. When sluice is available, an
information display will be visible in the main display.
This describes the sluice status when using the sluice.
When green push button on sluice is lit, load the

sluice with waste, close sluice door and rotate the
sluice. . When the sluice is rotated, the Combustion
chamber pressure (CCP) will increase to “Set CCP
sluice operation”(-40 mmWC) and reduces sludge
dosage pump (SDP) with 30 rpm. When sluice is
activated, Combustion chamber pressure will be unchanged until 210 seconds has elapsed, or Combustion
chamber temperature after 60 seconds, has decreased below combustion chamber temperature when sluice was
activated. All this information is available in sluice display. This display window also shows if waste has high
or low calorific value.
66 GS500CIC
MAINTENANCE INSTRUCTION
Maintenance instruction
Preventive maintenance
Preventive maintenance periods are defined in the
control system apart from the daily checks. The
control system counts the running hours of the diesel
oil burner. Each group is connected to a list of service
points required to perform. The preventive
maintenance is divided into four groups: Weekly,
monthly, 6 monthly and yearly. Based on experience
the intervals correspond to respectively 100h, 400h,
2500h and 5000h programmed with a service interval
“Hours service”. When the actual running hours since
last performed maintenance exceeds the service
interval the control system calls for service by a pop
up screen.
6 months and yearly service banner will appear, regardless of running hours, when 180/365 days has elapsed.
It is then required to follow the appropriate procedure. When the maintenance has been carried out press
“Done” and “Hours since last service” is reset. If not logged in as user “usr”, values on different setup screens
are “view only”. Also the “Done” buttons are only visible if user “usr” has logged in.
Service hours:
When “Hours since last service” is above
setting “Hours service”, a red banner is
activated in line for the item. By pressing
“Done”, the hour counter “Hours since
last service” is reset to 0 and the red
banner is turned off.
Daily
1. Inspect the combustion chamber. Remove all ash and slag before loading and starting the incinerator.
2. NOTE: The combustion chamber air inlets in the bottom must always be cleaned.
3. Check diesel oil pressure. Normal reading 16 bar.
4. Check sludge pressure. Normal reading 0.2 bar.
Weekly (100 hours)

1. Clean photo resistor on the Diesel oil Burner. Visually inspect the flame scrod and blast tube for
deposits. Clean if necessary.
2. Check that combustion air inlets and cooling air inlets on the incinerator casing are free from
obstructions. Clean if necessary.
3. Visually inspect the flue gas outlet for deposits, clean if necessary.
GS500CIC 67
Monthly (400 hours)

1. Check fan belts and tensions. Make sure there are no abnormal vibrations, noise or bearing
temperatures.
2. Check refractory condition. Check for pieces falling out or big cracks.
3. Clean diesel oil burner, blast tube flame scrod and ignition electrodes.
4. Dismantle, clean and adjust sludge oil burner.
5. Dismantle, clean and adjust water injection nozzle40.
6. Check spark arrester (if installed) and clean if necessary.
6 monthly (2500 hours or 182 days)

1. Clean the filter in the diesel oil pump. Clean the filter in the diesel oil supply line
2. Replace the rubber stator on sludge oil dosage pump and check the rotor for wear. It should have a
smooth polished surface.
3. Grease the flue gas fan bearings.
4. Visually check the thermocouple for combustion chamber.
5. Lubricate the sluice bearings (if incinerator has sluice). See Sluice Assembly drawing.
6. Lubricate door hinges and check the door gaskets for proper sealing. Use chalk on the edges of the
door opening. Close the door. Open and check that the door gasket had contact with the edge all the
way around the opening. If not adjust the door.
7. Open the inspection hatches on the lower side of the incinerator cooling panel. Clean as required with
steam or hot water.
Yearly (5000 hours or 365 days)

1. Check paintwork. Make sure the paint is not chipped or scratched.
2. Check the control and alarm system according to "Test of function and safety devices"
3. Check all safety devices and calibrate if necessary.
4. Check all valves, pumps and solenoid valves for leakage. Repair if necessary
5. Replace nozzles for D.O. burner with new ones.
6. Replace the stator on water dosage pump41
40
If water injection is installed
41
68 GS500CIC
Inspection
ITEM ACTION
Combustion chamber: Monthly check: Check visually the refractory inside the combustion
chamber. If pieces of refractory have fallen out so the insulation or steel is
visible, then use of the incinerator must be discontinued until a repair has
been carried out. Pay attention to residue on the walls. If this is over 20 mm
thick, remove this by means of a wire brush and a paint-scraper. Do not use
a hammer!
Diesel oil pump: Daily check: Check visually for leakage. The pressure is to be checked
daily. If pressure drops below 16 bar and cannot be adjusted by means of
the adjustment screw, clean the filter. (Ref. Appendix D )
To clean the filters, proceed as follows:
Close the valves on supply and return line to D.O. pump. Remove all 8 bolts
at the end the pump opposite the drive-side. Remove the end cover and the
cover gasket.
The filter is now visible and can be pulled out without the use of tools. Clean
the filter in diesel oil and blow dry with compressed air. Reassemble and
adjust the pressure to 16 bar.
Flue gas fan: Monthly check: Check the fan belts for sufficient tightness. Correct
deflection is 10 mm using a force of approx. 3 kg. weight load.
Sludge dosage pump: Weekly check: Check visually for leakage. Turn the shaft by hand to check
it is moving freely.
Water dosage pump42: Weekly check: Check visually for leakage. Turn the shaft by hand to check
it is moving freely.
42
GS500CIC 69
Cleaning and lubrication

ITEM ACTION
Ashes: The slag must be removed daily before starting up the incinerator. Make
sure that trash has been incinerated completely and that the fire is dead and
ashes cold. Use a hoe for this purpose.
Photo resistor: The photo resistor should be cleaned by means of a damp cloth every week.
Diesel oil burner: Caution: The main switch must be in OFF position whenever working with
the burner.
For dismantling and re-assembly, see Appendix C. The blast tube, flame
scrod and diesel nozzle should be cleaned every month. This can be
cleaned with Kerosene, White Spirit or Marine Diesel Oil and a brush. The
electrodes should be wiped off with a cloth dipped in one of the above
mentioned agents.
Diesel oil pump: The filter must be cleaned every 6 month. For dismantling and re-assembly,
see Appendix D.
Flue gas fan: The grease in the bearings must be changed every six months. Make sure
the bearings are clean before they are re-greased. Pay special attention to
reinstalling of the top half of the housing to its respective base after re-
greasing. The top halves must not be mixed, each top half is made unique to
the base.
Also check the tension of the V-belts.
Door hinges: Door hinges to be greased every six months. Use ordinary ball bearing
grease.
Sluice: The sluice bearings must be lubricated every month. Use a graphite grease
type Esso Beacon Q2 or equal.
Unscrew the blinding plug and lubricate the nipple. Replace the plug. Also
lubricate the bearing on the opposite side by lubricating the nipple through
the expanded metal.
Pusher: Lubricate the bearings for the pusher with a grease gun every 6-month. Use
heat resistant type (Esso Beacon EP2 or equal).
Sludge burner: The sludge burner should be cleaned every month, if necessary.
For dismantling and re-assembly, see Appendix.
Water injection43: The water injection nozzle should be cleaned every month, if necessary.
For dismantling and re-assembly, see Appendix.
43
GS500CIC 71
Disassembly, repair, replacement and reassembly

Flue gas fan
Ref. Flue gas fan assembly drawing
To replace the impeller:

Disassembly
1. Switch off the power and make sure it cannot be switched on again while the unit is under
repair.
2. Disconnect the electrical cables to the motor.
3. Remove the 16 bolts pos. 17 (dwg. 1007012) on the cover (motor end of the fan housing).
4. Remove the 4 bolts pos. 33 for the bearing stand (fan base).
5. Slide the bearing stand assembly backwards from the fan housing till the impeller is clear of
the housing.
6. Carefully turn the bearing stand assembly to get access to the impeller.
7. The impeller is attached to the shaft with a taper lock hub. On the hub, unscrew the two
hexagon screws. By inserting one of the screws in the third hole (the one not in use), the
impeller will come off the hub when the screw is screwed in.
Repair
It is not advisable to repair an impeller unless one has access to balancing equipment.
Replacement
No special procedure is required except for cleaning the shaft and the hub before the hub is
placed on the shaft.
Reassembly
Proceed as for disassembly, in opposite manner.
To adjust the clearance between impeller and fan house

1. After working with the fan always check the proper end clearance between impeller and fan
housing.
2. Proceed as follows:
3. Unscrew the top part of both bearings.
4. Unscrew the nuts for the bearing hubs. Now the shaft is loose.
5. Pull the shaft out as far as possible. Put an ink mark on the shaft against the back bearing.
6. Push the shaft in as far as possible. Put an ink mark on the shaft against the same bearing.
7. Pull the shaft half way out so the clearance on both side of the impeller is identical (approx.
10 mm) and secure the nuts on the bearing hubs.
8. Replace the bearing tops.
72 GS500CIC
Performance verification
1. Run the fan in cold and hot condition and listen for noise.
2. Inspect that the fan is able to provide at least 100 mm WC negative pressure in the
combustion chamber. (Cold gas.)
Mounting of bearings with tapered bore

Shaft, hub and Taper-Lock bushings must be complete clean before mounting. These elements
are normally supplied light oiled.
At mounting, make sure the tightening torque is of correct level.
The mounting torque for the various hubs shall be as shown in this table:
Bushing type Set screw type Torque in NM Allen wrench Fan type
type
1210 / ø30 3/8” x 5/8” 20 5,0 DN 200

1610 / ø40 3/8” x 5/8” 20 5,0 DN 250
2012 / ø50 7/16” x 7/8” 31 6,0 DN 300/350
2517 / ø60 ½” x 1” 49 6,0 DN 400
For re-lubrication of the bearings, the caps must be demounted. The housing base and cap are
matched during manufacture and are not interchangeable. To prevent mixing, the same
consecutive number is marked on the cap and base of each individual housing.
The bearings are mounted with an adaptor sleeve. The bearings have a small internal clearance
and an accurate mounting is very important. When the bearing is properly mounted, the outer
ring can be easily turned, but there should be a slight resistance when the ring is swivelled out.
When mounting a new bearing to the fan’s shaft, the following procedure should be followed:
Before mounting the threads of the nut and the side face of the nut witch is about the bearing
should be greased and the outside diameter of the sleeve should be lightly oiled. The bearing is
then pushed on to the sleeve and the nut screwed on by hand. Check that the bearing is correctly
located on the shaft. Use a hook spanner and turn the nut an angle of 90°. By turning the nut
through this given angle of 90° the bearing will be pressed up on the tapered seating of the
sleeve. Re-position the hook spanner and apply a light hammer blow to the spanner. The bearing
will straighten up on its seating and is correctly fastened to the shaft. Lock the nut but bending
down one of the tabs on the locking washer. The residual clearance of the bearing should be
checked.
GS500CIC 73
74 GS500CIC
OPERATION INSTRUCTIONS
Spare parts
Recommended minimum spare parts
Article: 17561 / Minimum Spare Parts, GS500C TG5
Art. no. Art. name Quantity Unit
15748 Bonded Stator 1 stk
7587 Photo resistor, QRB 1 A 1 stk
GS500CIC 75
OPERATION INSTRUCTION
Recommended spare parts for 1 year service

Article: 18309 / One year wear and tear parts GS500C, TG5
11260 Nozzle, 5,5 gph 45 B 2 stk
12324 Nozzle, 3.5 gph 60S 2 stk
13530 Glassfibre Rope 15x20 2.5 M
15684 Rotor 1 stk
15688 Universal Joint 1 stk
15748 Bonded Stator, black mark 2 stk
17168 Stuffing Box Gasket 1 stk
17691 Sealing Compound 1 stk
1896 V-belt, SPB 1700 3 stk
6996 Cover gasket 2 stk
76 GS500CIC
Recommended onboard repair parts, GS500C, TG4/5

Article / Name 18250 / Recommended on board repair parts, GS500C, TG4/5
10863 Flue Gas Restriction Brick Ø200 4 stk
11632 Flame Scrod 1 stk
12500 Thermocouple Type "N-300" Assembly 1 stk
12501 Thermocouple Type "K" Assembly 1 stk
12806 Repair kit for sludge valve A6324 1 stk
15556 Solenoid Valve, G1/4",220V, 3-way 1 stk
15687 Seal Plate Gasket 2 stk
15741 Mechanical Seal 2 stk
17168 Stuffing Box Gasket 2 stk
2678 Bearing, 2213-K 2 stk
6154 Sludge Burner Assembly 1 stk
6438 Thermocouple with Pocket 1 stk
6567 Blast Tube, F-50-45-T 1 stk
6568 Ignition Cable Compl. L=380 2 stk
6981 Nozzle Line 1 stk
6987 Press. regulator kit, 10-21 bars 1 stk
7587 Photo resistor, QRB 1 A 1 stk
8126 Solenoid Valve, G1/4",220V 1 stk
8153 Ignition Electrode 2 stk
8454 Solenoid Valve, 1/8", 220V 1 stk
8563 Spline Coupling Compl. 1 stk
9272 Shaft seal kit 1 stk
GS500CIC 77
Storage and installation
Preparation for shipment

The incinerator Unit, Flue Gas Fan, damper and motors are packed for overseas shipment.
Storing at Yards Warehouse

The incinerator Unit must be stored only indoor in a dry warehouse. Sensitive electronic unit and refractory
segments might be damaged if stored outdoor in wet conditions.
For long time storage, TeamTec recommend to place Silica Gel inside the Control Panels.
Once a month, check visually that the Control Panels are not damaged. Special attention must be paid to the
silica gel inside the panels. If there has been humidity in the panel, the Silica Gel must be replaced.
Check that the coating of the steel work is OK. If the coating is damage and the steel is exposed to the
atmosphere, it must be touched up with new paint according to paint spec.
Monthly the fan, pumps and electrical motors must be rotated.
Preservation from installation to start up of equipment

After installation the equipment should be preserved and protected for hostile
environment like welding, grinding, handling of heavy equipment, insulation work, water spray washing and
paint spraying.
The equipment is delivered with plastic sheet, the plastic sheeting does not offer protection against hot work.
If the incinerator is exposed to high humidity for a period of time, silica gel must be placed inside the control
panel.
Preservation in case of long time storing after installation

In addition to the item mention above check that coating is in good condition.
Grease exposed parts of the burner.
Remove slag and ashes from combustion chamber.
Turn the electrical motors for fan, pumps and burner slightly.
If possible, the power should be switched on to the control panel in order to keep the panel dry.
78 GS500CIC
Pre-commissioning
Mechanical completion check list.
Prior to function testing at first start up, the following mechanical completion must be checked.
1. Check that the foundation support and the deck strength are adequate for the incinerator unit. (5. ton)
2. Check that flue gas fan foundation is of a sturdy design for fan to run without vibration.
3. Check that the air inlet to the incinerator room has sufficient capacity.
4. Check that the necessary drainpipe are installed and connected.
5. Check that the incinerator door can be fully opened and locked in the installed locking mechanism.
6. Check that the insulation, flue gas duct and flue gas fan is installed and fixed.
7. Check that the flue gas duct is not welded direct into painted wall penetration. (fire hazard)
8. Check that the refractory brickwork has been dried out with a portable heater for 48 hours at
approximately 100°C.
9. Check the diesel oil line for correct hook up, and make sure that no valve is closed on the return line.
(A blocked return line will result in a leak in the diesel oil pump shaft seal)
10. Check the electrical power supply for correct rated protection at the ship distribution board.
11. Check that all pipes (sludge, steam and water) ducts and cables hooked up have been correctly
completed according to arrangement drawings.
12. Check that the “Burn In” program has been run for 10 hours. The “Burn In” program starts with a
combustion chamber temperature at 100°C and runs for 10 hours. The Burn In Program is available
from the set up menu in the operator panel when logged in as user.
Pre-check of live equipment.

Prior to function test, the following live equipment should be tested.
1. Start the flue gas fan and check for correct rotation direction.
2. Start the diesel oil burner and check for correct rotation direction, and that normal diesel oil pressure
is reached.
3. Check that the operator control panel is live, and indicating normal.
4. Make sure that sludge is filled in the sludge tank to a level above the low level switch before starting
the pump. Start the sludge pump and check for correct rotation direction, and normal pressure
indication.
5. Make sure that water is filled in the water tank to a level above the low level switch.
After having checked out the above items, a function test according to this manual can take place
GS500CIC 79
Test of function and safety devices

No. Test procedure. Observation Accept
ed
1. FLAME FAILURE Alarm activates and the burner stops.
Start a burner program.
Pull the photo resistor out and Flame failure
blind off.
2. FLUE GAS TEMP. HIGH At flue gas temperature above alarm set point,
Adjust alarm set point the alarm will activate and the burner stops.
[Alarm max. FGT]
Flue gas temp. high
below operating temp.
3. COMB. CHAMBER TEMP. At combustion chamber temperature above set

HIGH Adjust alarm set point point alarm will activate and the burner stops.
[Alarm max. CCT]
below operating temperature. Comb. chmbr. temp. CCT high
4. COMB. CHAMBER TEMP. At combustion chamber temperature below set

LOW point and the alarm will activate and the burner
stops.
Start SLUDGE program.
Wait for burner to start.
Comb. chambr. temp. CCT low
Adjust alarm set point[Min.
operating CCT] below actual
temperature,
then above (actual CCT +
[Alarm CCT below min.
oper.])
5. MOTOR OVERLOAD The motor stops, the alarm will activate and the
Activate test button at front of burner stops.
the motor circuit breaker.
Thermal failure - motor overload
80 GS500CIC

ed
6. DOOR NOT CLOSED Alarm activates and the burner stops.
Unlock the waste door by
tightening the torx screw.
(Allen Bradley device) Door not closed
7. DRAUGHT FAILURE At pressure below alarm set point

Start a burner program. [Alarm max. CCP (Draught failure)]
When fan is running
disconnect the sensor tube and after 10 sec. the alarm activates and the
from vacuum controller. burner stops.
Draught failure - CCP low
8. DIESEL OIL TEMP HIGH At release of safety thermostat-S3 the alarm will
Start a burner program. activate and the burner stops
Adjust down the safety
thermostat -S3 to below set
Diesel oil temp. high
point for working thermostat -
S4. The safety thermostat require manual reset.
9. DIESEL OIL TEMP LOW At start of heating the alarm activates and the
Adjust alarm set point burner stops.
[Alarm max. time dieselheater
start]
Diesel oil temp. low
to "0".
10. DIESEL OIL PRESSURE At pressure switch +2-S1 set point, the alarm
LOW activates and the burner stops.
Reduce the fuel oil pressure
by adjusting the pump. Diesel oil press. low
11. VOLTAGE LOW/HIGH Relay deactivates at voltage above or below set

Adjust upper/lower setpoint point after a time delay (normally 5 sec.). Alarm
down/up at relay (-K9) until activates.
red LED flash. When the relay is deactivated, the yellow LED
goes off, and the red LED goes on.
Voltage low - high
GS500CIC 81
No. Test procedure. Observation Accepte

d
12. STEAM/AIR PRESSURE After 10 sec. alarm activates and the burner
SLUDGE LOW stops.
Adjust the steam/air pressure
sludge alarm switch to 1.5
bar. Steam/air press. - sludge low
Start a sludge program.

When running sludge, close
off steam-air supply.
SLUDGE HIGH stops.
Adjust the steam/air pressure
high sludge alarm switch to
Steam/air press. - sludge high
4.5 bar.

Close test valve steam/air
supply.
When running sludge, close
off steam-air supply.
14. SLUDGE PRESSURE LOW After 10 sec. alarm activates and the burner
Adjust the sludge pressure stops.
low alarm switch to 0.1 bar.
Sludge pressure low
Close the sludge supply.
15. SLUDGE TEMP LOW Alarm activates and the burner stops.
Adjust set point
[Min. sludge temp run sludge] Sludge temperature low
above actual temperature and
adjust [Alarm sludge temp
low] to 0.
82 GS500CIC
16. SLUDGE TEMP HIGH Alarm activates and the burner stops.
Adjust set point
Sludge temperature
[Min. sludge temp run sludge] high
below actual temperature and
adjust [Alarm sludge temp
high] to 0.
WATER LOW/HIGH44 stops.
Adjust the steam/air water
pressure low alarm switch to
1,5 bar. Steam/air press. - Water
high/low
Start sludge with water.
Close steam/air supply.
18. FREQUENCY INVERTER After 10 second delay, alarm activates and the
FAILURE SDP burner stops.
Start a sludge program. Frequency inverter failure SDP

Disconnect the wire at
terminal RC on the inverter.
19. FREQUENCY INVERTER After 10 second delay, alarm activates and the
FAILURE WDP45 burner stops.
Start a sludge program. Frequency inverter failure WDP

Disconnect the wire at
terminal RC on the inverter.
44
45
GS500CIC 83

ed
20. SLUDGE SERVICE TANK Alarm activates and the burner stops.
TEMP HIGH46
Start a sludge program Adjust
Sludge service tank temp. high
down safety thermostat +3.1-
S1 below operating The safety thermostat requires manual reset.
temperature.
21. LOW LEVEL SLUDGE After 5 sec. delay the Alarm/Warning activates
SERVICE TANK and burner stops
Low level sludge service tank

Activate test lever if
mounted or disconnect
cable.
22. CIRCUIT FAILURE FGT Alarm activates and the burner stops.
Disconnect wire terminal
Circuit failure FGT
+1–X1-114
23. CIRCUIT FAILURE CCT Alarm activates and the burner stops.
Disconnect wire from U2
Circuit failure CCT
terminal 4
24. CIRCUIT FAILURE SDP Alarm activates and the burner stops.
TEMP
Disconnect wire from U3
Circuit failure SDP Temp
terminal 4
25. COMMUNICATION FAILURE Alarm activates after 40 sec. and the burner
PLC-DISPLAY stops.
Disconnect cable between A1 Communication failure PLC-Display
& A2
46
Only available if El.heater installed
84 GS500CIC

ed
26. OVERLOAD SETTINGS: Flue gas fan motor :_______Amp.
Burner motor :_______Amp.
Sludge circ. pump :_______Amp.
Diesel oil booster pump :_______Amp.
Diesel oil transfer pump :_______Amp.
Sludge filling pump :_______Amp.
Sludge transfer pump :_______Amp.
27. IGNITION ELECTRODES

28. CENTRING OF FLAME-
SCROD
29. PROGRAM BASED
FUNCTIONS
30. ALL SETTINGS
ACCORDING TO LIST.
31. UNDERPRESSURE ON
DISPLAY SET TO 0
32. OVERALL INCINERATOR
VISUAL CONTROL
33. TERMINAL CLAMPS
34. FREQUENCY INVERTER
SETTINGS
GS500CIC 85
Test of control functions

No. Test procedure. Observations Display main menu
1. LOADING SLAGGING Flue gas fan start.
Test at low chamber Loading/Slagging
temp. Open the waste
door and push key
"Slag" from main menu.
2. DOOR NOT CLOSED The burner will not start until the door is closed. Not possible to
Open the door and start start program –
a burner program. Door not closed –
please close door
3. SOLID WASTE a) Diesel oil heater activate for a time of 2-5 Damper closing…
If available, load solid min. prior to start of burner. DISPLAY:47
waste in combustion The main menu display
b) Flue gas fan starts, and after app. 30 sec. the indicates flue gas
chamber and close the
diesel oil burner starts, indicated visualised in temperature and
door. Push the key
main menu display. running indication.
"Solid Waste" from the
start menu display.
a) Program will automatically control burner The main menu display
stage by the temperature rise, and indicates combustion
chamber temperature,
temperature level.
combustion chamber
pressure, burner
damper opening and
burner stage.
CCP start-up solid

waste program
-35 mmWC
Burner stage 1
4. SLUICE When burning solid waste, sluice feeding is Sluice display

Start “Solid waste” available when combustion chamber shows the status of
program or “solid waste temperature is above 700/900°C and less than incineration of
sludge” program from 1050°C. waste.
the start menu display.
5. SL. CIRC PUMP (SCP) Pressure gauge should read approx. 0.2 bar. Not possible to
Check sludge tank level. start sludge
If low level on sludge tank :
Start circulation pump by circulation pump
pushing the motor low level in sludge
symbol for SCP in main service tank
menu display.
6. SL. TRANSFER PUMP Start the sludge transfer pump by pump by Not possible to start
(STP) pushing the motor symbol for STP in main menu sludge transfer pump
display. high level in sludge
If applicable settling tank
If high level sludge settling tank:
47
Display is text at main menu
86 GS500CIC

7. SL. FILLING PUMP Start the sludge filling pump by pump by pushing
(SFP) the motor symbol for SFP in main menu display.
If applicable
If low level sludge settling tank: Not possible to start

sludge filling pump
low level in sludge
settling tank
If high level sludge settling tank:
Not possible to start

sludge filling pump
high level in sludge
service tank
8. SL TANK HEATER The heater element symbol will turn red

indicating that the sludge tank heater is active Not possible to start
Start the heater element
(ON). Thermostat in the tank control switching on heater low level in
by pushing the picture of sludge
/off the heater.
the sludge tank heater service/-settling
element in the main If low level on sludge tank: tank
menu display or start the
sludge circ pump.
9. SLUDGE a) If not started manually, the sludge circulation Waiting for correct
Check that level in pump and sludge heater will start. Pressure sludge temperature
sludge tank is above low indicator for sludge pressure should read
level. Push the key approx. 0.2 bar and the sludge temperature
"Sludge" from the start must be above start temp. 80°C (Min. sludge
menu display. temp. run sludge)
b) Diesel oil heater will operate 2-5 min. until Damper closing…
the oil temperature has reached normal level.
c) Flue gas fan starts, and after app. 30 sec. the CCP start sludge
burner starts, visualized indicated in main -35mmWg
menu. Burner stage 3
d) At chamber temperature above 680°C

(Min.sludge temp run sludge) and the given
flushing time, the sludge dosing pump start at The main menu display
150 rpm (Min.RPM SDP). indicates flue gas
Diesel oil nozzle 2 and sludge nozzle will temperature,
burn. combustion chamber
temperature,
combustion chamber
pressure, sludge
temperature, sludge
e) After sludge flush time, the burner will step dosing pump rpm,
burner damper opening
down to stage 4. Diesel oil nozzle 1 and
GS500CIC 87

sludge nozzle. and burner stage.
f) The logic control is now monitoring

temperature increase or decrease, and
controlling burner and sludge speed (60 sec
fixed start – to ensure a stable process
before adjusting sludge [Time start sludge
before adjust]).
g) At combustion chamber temperature above The main menu display

870°C burning sludge alone is allowed indicates burner step
provided the sludge is sufficient inflammable. 7 at the burner
picture.
If low level sludge service tank:
sludge program – low
level sludge service
tank.
10. SLUDGE WITH WATER
Check that level in
a) Control will be the same as for item 9 a
sludge tank is above low
to g.
level. Push the key
"Sludge with water" from
the start menu display. b) At combustion above 1110°C water
injection is enabled (CCT enable water).
Check level water tank.

Start “Sludge with water” c) If low level water tank during Low level water tank.
from the start menu incinerating, the program changes to The incinerator
display. “Sludge” and a warning will occur: automatic change to
sludge program.
88 GS500CIC

11. SW SLUDGE a) If not started manually, the sludge Waiting for correct
Check that level in circulation pump and heater will start. sludge temperature
sludge tank is above low Sludge pressure gauge should read
level. approx. 0.2 bar, and the sludge
If applicable load waste temperature must be above start temp.
in the chamber and at 80°C(Min. sludge temp. run sludge)
close the door. Push Heating up :
the key
"Solid Waste Sludge"
from the start menu b) Flue gas fan start, burner damper open
display. and after app. 30.sec. the diesel burner The main menu display
start. Check flame through the indicates flue gas
inspection glass in door. temperature,
combustion chamber
temperature,
c) Program will automatically control burner combustion chamber
stage by the temperature rise, and pressure, sludge
temperature level. Secondary air fan will temperature, sludge
start at 690°C, or if batch load is dosing pump rpm,
detected by the program burner damper opening
and burner stage.
d) Control will be the same as for item 9 c
to f. Program Solid Waste
and Sludge:
Burner is controlled
by solid waste
program until
combustion chamber
temperature (Min. CCT
for run sludge) is
above 680°C. From
here burner is
controlled by sludge
program but will try
to not exceed 1000°C.
If low level sludge service tank:

solid waste – sludge
program – low level
sludge service tank
GS500CIC 89

12 FLAME IN CHAMBER Start a burner program when there is flame in Waiting... flame in
chamber or pull out the photo resistor if chamber
incinerator is in ready state. Start a burner
program.
13 STOP a) Will stop any selected program.
At combustion chamber temperature > 170°C Cooling. Combustion
Push the key "Stop" all function will stop, but. chamber pressure
from the start menu the flue gas fan will run for cooling down. -18mmWg
display.
b) Combustion chamber above 300°C flushes

the sludge nozzle after sludge burner stops. The steam/air
sludge solenoid
turns green,
indicated in the
c) At combustion chamber temperature < 170°C
burner display.
the flue gas fan stop. The waste door can be
opened. Incinerator ready
14 ALARM IN SYSTEM Start a program when there is incinerator is in Not possible to start
Alarm state. program – Alarm is
active – please check
Alarms
15 CLEANING OF WATER 1. After testing is completed with water

INJECTION SYSTEM injection, system must be preservated
with diesel oil.
2. If system has water booster pump,
attach diesel hose to both inlet and
return on the booster pump.
3. If system has water tank, attach diesel to
the water inlet flange on incinerator.
4. Latch terminal clamp +1X1-
129&130(Low level water tank).
5. Start “sludge with water” and wait for
water pump to inject diesel oil into
combustion chamber. Stop when the
diesel oil has been injected(1-2 minutes).
6. Remove latch on terminal clamps.
7. This procedure is to prevent corrosion
and internal damage on pipes and
nozzle.
90 GS500CIC
Operation instructions
Prior to start
1. Main switch on the control panel is switched to position "ON" .The operator panel is
energised and the Process picture will show in the display.
Slagging
1. Check that there are no flames in the incinerator.
2. Push the "SLAG" key, the flue gas fan starts and flue gas damper will open. The
temperature (CCT) must be below 170°C (+50 hysteresis).
3. Open the ash door and remove ashes and slag, partly burned cans, can remain. These will
burn out eventually.
NOTE! Combustion air inlet openings at "floor" level must be cleaned.
This is important for a free airflow to the combustion chamber.
Solid Waste
1. Fill the combustion chamber half full with waste (max 400l)
NOTE: The Solid waste program start up sequence assumes a batch load. If the incinerator
is to be heated up without a batch load, choose the sludge program.
2. Close the door.
3. Push the key "START" and choose "SOLID WASTE" from the menu. The flue gas fan will
start and the flue gas damper will control the pressure in the chamber. If there are conditions
not met required for starting the incinerator, the operator panel will display a message
explaining the condition.
4. When the key "STOP" is pushed, the burner will stop, and the cooling down sequence
starts.
5. When the temperature in the combustion chamber has decreased to 170°C, the flue gas fan
will stop and door locks energized.
6. Sluice will be available to use when CCT reaches 700°C.
Sludge
1. Fill up the sludge tank and activate the heater. This is done by the pressing the heater
symbol on the operator panel. Choose start heater and the heater symbol will change colour
to indicate that the heater is on and the temperature is controlled locally by the thermostat
2. Drain off water from the settling tank. (The sludge should be settled overnight before water
is drained off) . Remember, longer settling time, better settling!
3. Start the filling pump by pressing the pump symbol and choose start pump. The symbol will
change colour to green to indicate that the pump is running. The pump will stop
automatically if the service tank level is high or the settling tank level is low.
4. Start the service tank circulation pump by pressing the pump symbol and choose start pump.
The symbol will change colour to green to indicate that the pump is running. Check the
sludge pressure on the pressure indicator to be in the range of 0.2 bar, adjust if required,
GS500CIC 91
using the by regulation valve. Run the circulation pump for at least 1 hour prior to burning
sludge!
5. Check the atomising -air /-steam supply pressure to be 6 - 8 bar. If steam is used, the
condensate must be drained off by use of the valve located at sludge equipment drip tray.
6. Push the key "START" and choose "SLUDGE" from the menu. The flue gas fan will start
and the flue gas damper control the pressure in the chamber. If there are conditions not met
required for starting the incinerator, the operator panel will display a message explaining
the condition.
7. The manual regulating valve for air / steam atomising located at sludge equipment drip tray
should be from ¾ to 1 turn open. The pressure should be shown in the upper half of the
green area (3.3 bar or 48 PSI) when the sludge burner/nozzle is clean. If pressure rises, do
NOT adjust the valve, but clean the sludge burner.
8. If the low level in sludge tank, or the key "STOP" is pushed, the burner will stop, and the
cooling down sequence starts.
9. When the temperature in the combustion chamber has decreased to 170°C the flue gas fan
will stop and door locks will be energized.
Solid Waste Sludge

1. Make settling according to the routine described in the sludge program.
2. Follow the Solid waste procedure, but choose “Solid Waste Sludge” program instead of
“Solid Waste” program.
3. Sluice will be available to use when CCT reaches 900°C.
Sludge and Water

1. Make sure the manual valves in the bilge water system are open.
2. Make sure there are water available and that the water tank is filled with water.
3. Follow the sludge procedure, but choose “Sludge and Water” program instead of “sludge”
program.
4. The manual regulating valve for air / steam atomising located at water equipment drip tray
should be from ¾ to 1 turn open. The pressure should be shown in the upper half of the
green area (3.3 bar or 48 PSI) when the water injection nozzle is clean. If pressure rises, do
NOT adjust the valve, but clean the water injection nozzle.
92 GS500CIC
Emergency stop
In the incinerator room.
Turn the main switch at the control panel "OFF".
Outside the incinerator room.

Activate the emergency stop. (The switch normally requires manual reset).
When emergency stop is used, or at black out.

Warning: If the combustion chamber temperature is above 220°C, it is important to start the
flue gas fan as soon as possible in order not to damage the incinerator by accumulated heat in
the refractory lining. If setting “Auto start of FGF after emergency stop” is set to “off”, a
manual restart of Flue gas fan is needed. This is done by pressing “Stop” button.
NOTE! Careful heating-up and cooling-

down is required for preventing
damage to the refractory.
Emergency generator
If the emergency generator is running starts running, the incinerator stops burner, and running
cooling program if CCT is above 220°C. An indication in the operator display will be visible
saying “Incinerator not ready – Emergency power”. When emergency generator is running no
program can be started. This is done to save energy consumption on the emergency generator.
GS500CIC 93
Trouble shooting
Symptom Probable cause Checkout procedure
1. OPERATOR PANEL 1. Faulty main power supply. Check main switch -Q1
DEAD. Check power supply from main
switchboard.
2. Emergency stop switch Check switch -S1.
open.
3. Faulty fuse for pilot Check fuses –F11 and –F12
transformer.
4. Faulty fuse -F13. Check fuse.
5. -T2 is broken Check 24VDC.
2. Alarms 1. Described in section Described in section "Alarm

"Alarm system". system".
3. Poor flame / smoke 1. The nozzles could be Change the nozzles.

when burning on blocked or damaged.
diesel oil.
2. Malfunction of burner air Check the damper function and
damper. position.
3. Burner dirty. Clean burner flame scrod and
blast tube.
4. Poor flame / smoke 1. Damaged or blocked Check the nozzle and if

when burning sludge. sludge nozzle. necessary clean and adjust it.
2. Closed or incorrect Adjust valve. (1/2 to 1/1 turn
adjusted air/steam control open) NB! only to be performed
valve. with a clean sludge burner.
Change stator.
3. Damaged sludge dosing
pump stator.
Adjust to correct setting.
4. Sludge pressure to high. (0.2 bar)
5. Malfunction of flue gas Check the damper function and
damper position.
6. Malfunction of burner air Check the damper function and
damper. position.
5. Temperature raising 1. Loaded too much waste Stop loading, and tray to block
"uncontrolled" with high calorific value. lower four corner ventilation
slots.
2. Damaged sludge dosing Change stator.
pump stator.
3. Sludge speed control not Check sludge speed.
working.
4. Leaking diesel oil solenoid Change the valve.
valve.
94 GS500CIC
6. FLAME FAILURE. 1. Flame sensor dirty. Take out and clean.

2. Flame sensor defect. Replace flame sensor.
3. The nozzles could be Clean or change the nozzles.
blocked or damaged.
4. Incorrect opening Check opening at closed
of burner air damper. damper and correct.
5. Ignition failure. Adjust spark electrodes.
6. Poor flame See section above
7. Defect solenoid valve or
Replace valve or coil
coil
8. Worn out stator/rotor. Replace stator/rotor.
7. FLUE GAS TEMP. 1. Blocked air cooling inlet. Clean inlet. (Bottom grating)
HIGH
Burning sludge 2. Panel cooling slot Clean panel slot
clogged with dirt.
3. Throttling bricks fallen Put the missing brick back in

out or worn out. place.
4. Negative pressure to low. See Draft Failure
5. Faulty temp. sensor. Replace sensor
6. Faulty temp. transmitter. Check transmitter mV input.

Replace, DO NOT ADJUST
7. Faulty frequency inverter. Check frq. inverter circuit

Burning solid waste Stop loading, and tray to block
8. Loaded too much waste
lower four corners
with high calorific value.
9. Worn out stator/rotor. Replace stator/rotor
8. COMB. CHMBR. TEMP. 1. Same as flue gas temp See FLUE GAS TEMP HIGH
HIGH high.
2. The outlet blocked with Clean outlet

slag. (Top of chamber)
3. Blocked slot at chamber Clean slots

floor level
9. STEAM/AIR PRESS. 1. To low steam/air Check steam/air supply

LOW/HIGH. pressure <1,5 bar. pressure.
2. To high steam/air Clean the sludge burner. Do not

pressure > 4.5 bar adjust the regulation valve
unless the sludge burner is
clean (3/4-1 turn open).
3. 3. Test valve is closed Open test valve.
GS500CIC 95
10. DRAUGHT FAILURE 1. Leaking sensor tube. Check sensor tube for damage
(low under pressure) and fixing.
2. Defect pressure sensor Check and replace, DO NOT

ADJUST.
3. Door gasket damaged. Check door gasket
4. Broken flue gas fan belts. Tighten or replace.
5. Flue gas fan motor

running in wrong Check direction
direction.
6. Clogged spark arrestor.

Take out and clean.
11. LOW/HIGH VOLTAGE 1. Input voltage to low or to Check supply voltage.

high (+10% to –13%) If this alarm occur and has
been reset, but supply voltage
is still low/high, the incinerator
will not start.
12. LOW CAPACITY 1. Blocked air cooling inlet. Clean inlet. (Bottom grating)
2. Panel cooling slot Clean panel slot

clogged with dirt.
3. Throttling bricks fallen Put the missing brick back in

out. place.
4. Deposits at flue gas Clean the Flue Gas outlet

outlet
5. Damaged or blocked Check the nozzle and if

sludge nozzle. necessary clean and adjust it.
13. Incinerator stops 1. Burning time is set to Set burning time to “OFF”
without alarm. “ON”
2. Low level sludge tank. Fill the sludge tank.
3. One of the diesel oil
Replace the solenoid.
solenoid is burned.
4. Sludge or steam Replace the solenoid.
solenoid burned.
5. Sludge dosage pump is Turn the axle on the sludge
stuck. dosage pump.
14. FREQUENCY 1. Sludge dosage pump is Turn the axle on the sludge
INVERTER FAILURE stuck. dosage pump.
2. Settings is incorrect on
frequency inverter. Return to factory settings.
96 GS500CIC
GS500CIC 97
APPENDIX A
98 PLC
APPENDIX A
Appendix A: PLC
General
The Standard PLC contain of 4 units. See Figure 11 and 12.
1 2 3 4
Figure 11
1. Base unit (20 Digital Inputs / 12 Digital outputs)

2. Extension unit, relay output module (16 Digital outputs)
3. Extension unit, analogue input module (4 analogue inputs)
4. Extension unit, analogue (2 analogue inputs / 2 analogue outputs)
PLC 99
APPENDIX A
Base Unit
Figure 12
1. Comm port 2 -9-pin D-Shell RS-232C connector

2. Memory Module connector
3. User 24V
4. Input terminal block
5. LCD Display Keypad (ESC, OK, Up, Down, Left, Right)
6. Battery compartment
7. Expansion bus connector
8. Battery connector
9. Output terminal block
10. LCD Display
11. LED Indicator
12. Comm port 1 – RJ45 connector
13. Comm port 0 – 8-pin mini DIN RS-232C/RS-485 connector
100 PLC
APPENDIX A
Installing a Memory Module
1. Remove the memory module port cover.
2. Align the connector on the memory module with the connector pins on the controller.
3. Firmly seat the memory module into the controller.
PLC 101
APPENDIX A
Replacing the battery

The PLC main unit is equipped with a replaceable battery. The Battery Low indicator on the
LCD display of the controller shows the status of the replaceable battery. When the battery is
low, the indicator is set (displayed as a solid rectangle). This means that either the battery wire
connector is disconnected, or the battery may fail within 2 weeks if it is connected.
IMPORTANT. Replacing the battery when the controller is powered down will lose all user
application memory. Replace the battery when the controller is powered on.
Follow the procedure below to connect the battery wire connector to the battery connector.
1. Insert the replaceable battery wire connector into the controller’s battery connector.
2. Secure the battery connector wires so that it does not block the expansion bys connector
as shown below.
102 PLC
APPENDIX A
DIN Rail Mounting
Dimension:
A – 90mm (3.5 in.)
B – 27.5mm (1.08 in.)
C – 27.5mm (1.08 in.)
1. Hook the top slot over the DIN rail

2. While pressing the controller down against the top of the rail, snap the bottom of
the controller into position.
3. Leave the protective debris shield attached until you are finished wiring the
controller and any other devices.
To remove your controller from the DIN rail:

1. Place a flat-blade screwdriver in the DIN rail latch at the bottom of the controller.
2. Holding the controller, pry downward on the latch until the latch locks in the open
position.
3. Repeat step 1 and 2 for the second DIN rail latch.
4. Unhook the top of the DIN rail slot from the rail.
PLC 103
APPENDIX A
Diagnostics
LED Colour Indicates

POWER Off No input power, or power
error condition.
Green Power on
RUN Off Not executing the user
program
Green Executing the user program in
run mode
Green flashing Memory module transfer
occurring
FAULT Off No fault detected
Red flashing Application fault detected
Red Controller hardware faulted
FORCE Off No forces installed
Amber Forces installed
104 PLC
APPENDIX A
Status Indicators on the LCD
Input status indicators (20)
Output status indicators (12)
Indicator Colour Indicates

COMM 0 Off (empty rectangle) Not transmitting via RS-
232/485 port (Channel 0)
On (solid rectangle) Transmitting via RS-232/485
port (Channel 0)
COMM 1 Off (empty rectangle) Not transmitting via Ethernet
port (Channel 1)
On (solid rectangle) Transmitting via Ethernet
port (Channel 1)
COMM 2 Off (empty rectangle) Not transmitting via RS-232
port (Channel 2)
On (solid rectangle) Transmitting via RS-232 port
(Channel 2)
DCOMM Off (empty rectangle) Configured communications
(Channel 0)
On (solid rectangle) Default communications
(Channel 0)
BAT.LO Off (empty rectangle) Battery level is acceptable
On (solid rectangle) Battery low
U-DISP Off (empty rectangle) Default display mode
On (solid rectangle) Customized display mode
PLC 105
APPENDIX A
I/O Status Indicators on the LCD
Indicator Colour Indicates

INPUTS Off (empty rectangle) Input is not energized
On (solid rectangle) Input is energized (terminal
status)
OUTPUTS Off (empty rectangle) Output is nor energized
On (solid rectangle) Output is energized (logic
status)
Error Conditions
If the LEDS The Following Probable Cause Recommended Action

indicate: Error Exists
All LEDs off Not input power No line power Verify proper line voltage and
or power supply connections to the controller
error
Power Supply This problem can occur
Overloaded intermittently if power supply is
overloaded when output loading
and temperature varies
Power and Hardware faulted Processor Hardware Cycle power. Contact TeamTec if
FAULT Error the error persists
LEDs on
solid Loose Wiring Verify connections to the controller
Power LED Application fault Hardware/Software Contact TeamTec

on and Major Fault
FAULT LED Detected
flashing
RUN FORCE Operating system Missing or Corrupt Contact TeamTec
FAULT fault Operating System
LEDs all
flashing
106 PLC
APPENDIX B
Appendix B: Operator Panel

General
The operator panel is a user friendly operator panel with touch screen. Applications are
controlled by touching screen objects. The panel is connected to the PLC.
Touch screen
Figure 14.
The function of the panel is:

• Selecting of burner mode, setting of all variables as temperature and time etc.
• Display running condition, temperature, pressure, alarm, oil consumption, timer etc.
See also chapter Operator Panel, page 21, for user functions.
OPERATOR PANEL 107

APPENDIX B
Technical data
COMM and
FAULT LEDs
RESET Button Figure 15
The operator panel is a RS-232 only display with 1 USB port, and consist of a colour (320X240)
graphics display. Colour terminals support a fixed palette of 32 standard EGA colours. All
colours in an application is defined when the application is created, and not selectable at the
terminal.
The compact flash slot is used to program the display. Normally this will be done by TeamTec
personnel.
The operator panel is connected to the PLC with RS-232 serial communication.
The terminal requires 24VDC.
Reset Button resets the terminal.
Display temperature should be less than 55°C. The CPU temperature should be less than 95°C.
The terminal has two LED indicators isolate operating problems:
• COMM indicator (green) for communications
• FAULT indicatior (red) for hardware faults
Red LED Green LED Indication
Blinking Off Last firmware download failed. Reload firmware.
Blinking Blinking Boot loader firmware failed or is missing. Reload firmware.
Blinking On Windows CE OS firmware failed or is missing. Reload
firmware.
On Off Fatal hardware error occurred. Contact TeamTec to replace
terminal
On Blinking Fatal hardware error occurred in Display. Contact TeamTec to
replace terminal
Product certification compliance with European Union Directives. EMC tests satisfies EN
50081-1-2:1993 and EN 61000-6-2:1999
108 OPERATOR PANEL

APPENDIX C
Appendix C: Oil burner

Servicing and adjustment
Air damper motor
DO press. adjustment screw 1
Dismantling DO pump
DO pressure gauge
2
5
1. Pull out the photo cell.
3
2. Remove the cover on top of the burner .
3. Disconnect the ignition cables.
4. Disconnect and pull out the sludge burner.
5. Disconnect and pull out the nozzle line.
Cleaning and adjustment Ignition electrode

(Figure 1)
Clean the blast tube, flame scrod, ignition Flame scrod

electrodes and sludge burner. Replace
the diesel oil nozzle if necessary. Blast tube
Note: The smallest nozzle is stage one.
Check the spark gap and the position of
the flame scrod.
Nozzle 2
Nozzle 1 Sludge burner
Re-assembly
Figure 1
Re-assembly the burner in reverse order.
Diesel oil pressure adjustment

The oil pressure is adjusted on the oil pump. Remove end cap nut from pump for access to pressure setting
screw.
Turning the regulator screw clockwise increases the pressure setting.
Normal pressure is 16 bar.
OIL BURNER 109

APPENDIX C
Air adjustment.
The Burner damper motor is analogue, and will open the damper proportionally to the control voltage applied
by the control system. The only two checks necessary is Closed position and that it operates freely.
To check that the damper is closed make sure that the damper blade is vertical to the opening when the control
system shows 0% opening (after power up, flue gas fan not running).
To check that the damper operates freely, wind up the actuator by using a 4mm hex key on the top of the
damper motor, then release and observe that the damper closed by the spring action.
DO nozzles
Standard nozzle
Incinerator Nozzle 1 Nozzle 2 Std. pressure DO temp.
OG 200C 2.5 GPH 60° 4.5 GPH 45° 16 bar 50°C
OG 400C 2.5 GPH 60° 4.5 GPH 45° 16 bar 50°C
GS 500C 3.5 GPH 60° 5.5 GPH 45° 16 bar 50°C
GS1000C 4.5 GPH 45° 6.5 GPH 45° 16 bar 50 °C
For special cases other nozzles can be used.
Maintenance
Burner nozzle cannot be repaired.
110 OIL BURNER

APPENDIX C
Capacities
Oil burner nozzle capacities in l/h at various pressures.48
Rated flow 49 Pressure in bar
G.P.H. l/h 10 11 12 13 14 15 16
1,50 5,68 6,82 7,12 7,41 7,71 8,00 8,24 8,47
1,65 6,25 7,41 7,82 8,24 8,53 8,82 9,29 9,76
1,75 6,62 7,88 8,29 8,71 9,06 9,41 9,71 10,00
2,00 7,57 9,06 9,47 9,88 10,29 10,71 11,06 11,41
2,25 8,52 10,24 10,71 11,18 11,59 12,00 12,41 12,82
2,50 9,46 11,29 11,82 12,35 12,88 13,41 13,88 14,35
3,00 11,36 13,53 14,18 14,82 15,47 16,12 16,65 17,18
3,50 13,25 15,88 16,65 17,41 18,06 18,71 19,35 20,00
4,00 15,14 18,12 19,00 19,88 20,65 21,41 22,18 22,94
4,50 17,03 20,35 21,35 22,35 23,24 24,12 24,94 25,76
5,00 18,93 22,59 23,71 24,82 25,82 26,82 27,71 28,59
5,50 20,82 24,82 26,06 27,29 28,35 29,41 30,47 31,53
6,00 22,71 27,18 28,47 29,76 30,94 32,12 33,24 34,35
6,50 24,61 29,41 30,59 31,76 33,53 35,29 36,47 37,65
7,00 26,50 31,76 33,53 35,29 36,47 37,65 38,82 40,00
7,50 28,39 34,12 35,88 37,65 38,82 40,00 41,76 43,53
8,00 30,28 36,47 38,24 40,00 41,18 42,35 44,12 45,88
48
Sp gr 0,85 @ 25°C and viscosity 1,3°E @ 20°C
49
Pressure = 100 P.S.I.
OIL BURNER 111

APPENDIX D
Appendix D: Oil pump

The oil pump incorporates a regulating valve with cut-off function.
Applications
• Light and medium oil
• Nozzle flow up to 110 l/h (2850 rpm, 5 cSt, 10 bar)
• Normally associated with in-line solenoid valve.
• One or two-pipe system
Pump operating principle

The gear-set draws oil from the tank through the built-in filter and
transfers it to the valve that regulates the oil pressure to the nozzle
line. All oil, which does not go through the nozzle line, will be
dumped through the valve back to the return line. The valve also as
a cut-off and bleed function as follows: Figure 2
Bleed
• Two pipe operation
During starting period when the gear-set speed is increasing, all the oil passes through a
special flat on the piston, back to the return.
Once the speed reaches a certain value and the flow can no longer pass through this flat,
then the pressure increases rapidly overcoming the valve spring force and opens the valve
Cut-off:
During the stop sequence, the gear-set speed slows down and the valve closes when the gear-set capacity is
lower than the flow.
The cut -on and cut-off speed depends on the set pressure.
Figure 3
112 OIL PUMP

APPENDIX D
Technical data
General
Mounting Flange according to DIN 24220
Connection:
Inlet 1/4" NPTF
Return 1/4 " NPTF
Nozzle outlet 1/8" NPTF
Pressure gauge port 1/8" NPSF
Vacuum gauge port ¼" NPTF
Valve function Pressure regulating cut-off.
Strainer 45 cm² open area 120 μ opening size.
Shaft ∅11 mm according to DIN 24220
By-pass plug Inserted for 2 pipe system. To be removed with
3/16" allen key for 1 pipe system.
Weight 4 kg
Rotation Anti-clockwise rotation. Left hand nozzle.
(seen from shaft end).
Hydraulic data
Nozzle pressure range. 10 to 21 bar.
Delivery pressure setting. 16 bar
Viscosity range. 2.8 to 200 cSt
Inlet and return pressure. 1.5 bar max.
Suction height. 0.45 bar max. vacuum to prevent air separation
from oil.
Rated speed. 3600 rpm max.
Oil temperature. Max. 90°C in the pump.
Starting torque. 0.4 N.m
Pump capacity Power consumption
Figure 4 Figure 5
OIL PUMP 113

APPENDIX D
Pump dimensions
Pipe dimensions
The tables below give the maximum length (in meters) of suction line as function of 3 variables:
• Lift between fuel unit and tank (H).

• Nozzle capacity.
• Pipe diameter (d)
For normal atmospheric pressure (sea level) and 0.45 bar vacuum.
Only mentioned diameters can be used, bigger pipes are not suitable.
The length indicated (intersection of horizontal lines and columns) assumes the fitting of 4 right
angle bends, 1 stop valve, 1 non return valve. If additional restrictions exist, the length must be
reduced accordingly.
From these tables, the maximum length for other viscosity's can be calculated by simple ratio of
viscosities i.e., multiply the length shown in the table by 20 and divide by the value of the new
viscosity in cSt.
Rated speed: 2850 rpm
Viscosity: 20cSt
Pressure: 12 bar
Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 12 27 51 90
1 14 30 57 99
2 17 36 68 118
3 20 42 79 136
4 22 48 90 155
Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 9 21 41 71
1 8 18 35 61
2 5 12 24 42
3 2 6 13 24
4 0 0 2 5
Installation
The pump is ready for use with 2 pipe systems (i.e. with by-
Figure 6 pass plug fitted, in the return port.)
114 OIL PUMP

APPENDIX D
The inlet and return pressures must not exceed 1.5 bar.
The vacuum must not be more than 0.45 bar to prevent air separation from oil.
It is recommended to use a separate filter upstream of the pump.
The pump is to be used with cylindrical fitting or conical fittings as appropriate and sealing washers. Other
sealants are not recommended.
Start up
Check that the sense of rotation for pump and motor are the same (an arrow is stamped on the pump body).
In order to purge pumps used on 1 pipe systems, loosen one of the high pressure connections. On 2 pipe
systems, purging is automatic.
Pressure regulation
Remove end cap nut from pump for access to pressure stetting screw. Turning the regulator screw clockwise
increases the pressure.
Systematic maintenance
1. Check the stop valve and in line filters.
2. Check the pump filter.
This filter should be cleaned with a soft brush and fuel oil.
Each time, the cover gasket should be changed.
3. Check the tightness of all couplings and unused plugs.
4. Check the shaft coupling.
5. Check the pump pressure.
Fit a pressure gauge in the fitting provided and run the pump in normal manner.
If the pressure required cannot be obtained, check that the pump is completely purged. If
air bubbles are found in the fuel, check all connections for tightness.
6. Check the pump vacuum.
Fit a vacuum gauge in fitting provided and run the pump in the normal manner, making sure
to fully purge the pump.
The vacuum should not exceed 0.45 bar. If this is the case, check condition of all
components (non return valve, stop valves, filters....).
If the pump does not suck correctly, check for any leaks in the line by retightening all
fittings.
OIL PUMP 115

APPENDIX D
Figure 7
Parts list
Pos. no. Description Article no.
1 Pressure adjusting plug assy "C" 10-21 bars 6985

1.1 Protecting nut + washer 6986
2 Pressure regulator kit, 10-21 bars 6987
3 Drilled nozzle plug and washer (J 1002) 6988
4 Shaft seal kit 9272
4.1 Seal face kit 6439
5 J 3 shaft 6999
5 J 4 shaft 6989
6 Seal cap 6990
7 By-pass plug 6991
8 1/4 NPTF plug (J 1000) 6992
9 1/8 NPTF steel plug (J 1000) 6993
10 J 3 rot. A gear kit 7000
11 Filter 6995
12 Cover gasket 6996
13 Cover + filter kit 6997
* Spanner wrench for shaft seal 6998
116 OIL PUMP

APPENDIX E
Appendix E: Frequency inverter ATV12

Specification
Teamtec H055M2
Power supply 200/240 V -15% +10%
50/60Hz ±5Hz
Motor power rating 0.37kW / 0.5HP
Line current 50 6.7 A
Permanent output 3.5 A

current
Maximum transient 5.3 A
current 51
Power dissipated 41 W
(loss) at normal
load
Dimension (WxHxD) 72x145x122 mm
Weight 1.05 kg
50
Line current: Typical value without additional inductance.
51
Transient current: for 60seconds
FREQUENCY INVERTER ATV12 117

APPENDIX E
Technical characteristics
Degree of protection IP 20 without protective vent cover. IP31 other areas.
Vibration and shock 1 gn from 13 to 150 Hz, 15 g for 11 ms
resistance
(EN60068)
Degree of pollution Degree 2 according to UL840. Protect the drive against dust,
corrosive gases, and falling liquid.
Relative maximum 96% without condensation or dripping water (if there is a risk
humidity of condensation provide a heating system).
Ambient air temp. in Operating: -10°C to +60°C (with vent cover removed)
acc. with EN50178 Storage: -25°C to +70°C
Maximum operating 1000 m. without derating. Above this, derate the current by
altitude 1% for each additional 100 m.
Output voltage Maximum voltage equal to mains voltage.
Frequency range 0 Hz to 500 Hz.
Maximum transient 150% of nominal drive controller current for 60 seconds

current
Breaking torque 100% of the nominal motor torque without break resistor
(typical value). Up to 150 % with braking resistor as an
option.
Frequency - Display: 0.1 Hz
resolution
- Analog inputs: 0.1 Hz for 100 Hz maximum
Switching frequency Can be adjusted from 2.0 to 16 kHz
Speed controller - Galvanic isolation between power and control circuits
protection and (inputs,
safety outputs, supplies)
- Protection against short-circuits:
• within internal power supplies
• between output phases
• between the output phases and earth
- Protection against input phase loss
- Thermal protection from excessive overheating and
overcurrents
- Under and overvoltage supply
- Overvoltage safe on braking
Motor protection Thermal protection integrated into the drive controller by
calculating I²t. Protection against motor phase loss.
118 FREQUENCY INVERTER ATV12

APPENDIX E
Accessing terminal blocks
Control
terminals
Power
terminals
Figure 31
Power Terminals
The power terminals must be connected before connecting the control terminals!
Maximum connection capacity: AWG 10 / 5 mm2
Tightening torque: 1.2 Nm
Figure 32

APPENDIX E
Characteristics and functions of power terminals

Terminal Function For ATV12
t Ground terminal All ratings
R/L1 - S/L2/N Power supply 1-phase 100…120
V
R/L1 - S/L2/N 1-phase 200…240
V
R/L1 - S/L2 - T/L3 3-phase 200…240
V
PA/+ + output (dc) to the braking module DC Bus (visible part on wiring All ratings
trap)
PC/- – output (dc) to the braking module DC Bus (visible part on wiring All ratings
trap)
PO Not used
U/T1 - V/T2 - W/T3 Outputs to the motor All ratings
Control Terminals
Figure 33

APPENDIX E
Terminal Function Electrical characteristics

R1A NO contact of the relay Min. switching capacity: • 5 mA for 24 V c Maximum switching
R1B NC contact of the relay capacity: • 2 A for 250 V a and for 30 V c on inductive load (cos ϕ
R1C Common pin of the relay = 0.4 and L/R = 7 ms) • 3 A for 250 V a and 4 A for 30 V c on
resistive load (cos ϕ = 1 and L/R = 0) • response time: 30 ms
maximum.
COM Common of analog and logic I/Os
AI1 Voltage or current analog input • resolution: 10 bits • precision: ± 1% at 25°C (77°F) • linearity: ±
0.3% (of full scale) • sampling time: 20 ms ± 1 ms Analog voltage
input 0 to +5 V or 0 to +10 V (maximum voltage 30 V) impedance:
30 kΩ Analog current input x to y mA, impedance: 250 Ω
5V +5 VDC power supply for reference potentiometer • precision: ± 5% • maximum current: 10 mA
AO1 Voltage or current analog output (collector) • resolution: 8 bits • precision: ± 1% at 25°C (77°F) • linearity: ±
0.3% (of full scale) • refresh time: 4 ms (maximum 7 ms) Analog
voltage output: 0 to +10 V (maximum voltage +1%) • minimum
output impedance: 470 Ω Analog current output: x to 20 mA •
maximum output impedance: 800 Ω
LO+ Logic output • voltage: 24 V (maximum 30 V) • impedance: 1 kΩ, maximum 10
mA (100 mA in open collector) • linearity: ± 1% • refresh time: 20
ms ± 1 ms.
LO- Common of the logic output (emitter)
LI1 Logic inputs Programmable logic inputs
LI2 • +24 VDC power supply (maximum 30 V)
LI3 • impedance: 3.5 kΩ
LI4 • state: 0 if < 5 V, state 1 if > 11 V in positive logic • state: 1 if < 10
V, state 0 if > 16 V or switched off (not connected) in negative
logic • sampling time: < 20 ms ± 1 ms.
+24V + 24 VDC supply provided by the drive + 24 VDC -15% +20% protected against short-circuits and
overloads. Maximum customer current available 100 mA

APPENDIX E
Programming

APPENDIX E

APPENDIX E
TeamTec Control Settings

APPENDIX E

APPENDIX E

APPENDIX E

APPENDIX E

APPENDIX E
Faults – Causes – Remedies

Drive does no start, no fault displayed
• If the display does not light up, check the power to the drive and check the wiring of input AI1.
• The Assignment of the “Fast stop” or “Freewheel stop” functions will prevent the drive from starting
if the corresponding logic inputs are nor powered up. The ATV12 then displays “nSt” in freewheeel
stop mode and “FSt” in stop mode. This is normal since these functions are active at zero so that the
drive will be stopped safely if there is a wire break.
• Check that the run command input(s) have been actuated in accordance with the chosen control mode
(tCC parameter in the I-O menu).
• If an input is assigned to the limit switch function and this input is zero, the drive can only be started
up by sending a command for the opposite direction, see ATV 12 programming manual.
• If the LED on the DC bus is lit and nothing appears on the display, check that there is no short-circuit
on the 24 V power supply.
• If the drive displays “rdY” and refuses to start, check that there is not short circuit on the 24 V power
supply and check the wiring of input AI1 and LI1.

APPENDIX E

APPENDIX E

APPENDIX E

APPENDIX E

APPENDIX F
Appendix F: Sludge burner
Cleaning of sludge burner

Check the sludge burner frequently, minimum every month, and if necessary clean it.
• Loosen setscrews (A), and nut (B) and pull out the external pipe (C).
• Clean the external (C) and internal (D) pipes.
• After cleaning, re-assemble the sludge burner in reverse order.
• Check that internal pipe (D) is centred (concentric) in the external pipe (C), adjust with set-
screw (A) according to the adjustment procedure below.
Procedure for adjusting the sludge burner

• Attach fresh water supply to the Steam/Air connection
• Apply moderate water pressure until water flows steadily trough the nozzle
• Adjust the setscrews (A) until the water forms an even shape that does not bend away from
the centre line.
134 SLUDGE BURNER

APPENDIX G
Appendix G: Sludge valve.

A 6324/1101/7003. 0-1 bar. G 3/4"
Figure 34
SLUDGE BURNER 135

APPENDIX G
Valve
Valve housing Brass
Cove Red brass
Inner parts AISI 430F
Sealing device Teflon, Viton and Silicone
Control medium Steam 180°C, max 7 bar. Inlet 1/8 BSP
Medium Oil 90°C, max 1 bar. Inlet/Discharge 3/4 BSP
Repair kit for sludge valve article no. 12806 consist of:
Pos. no. Nos. Description

1 (101) 1 Arm
2 (301) 1 Base plate
3 (302 1 Spindle
4 (303) Piston
5 (304) 1 Disc washer
6 (305) 1 Washer
7 (306) 1 Seal
8 (307) 1 Cylinder
9 (308) 1 Tube bearing
10 (309) 1 Bolt
11 (311) 2 Ring
12 (312) 1 O-ring
13 (313) 1 O-ring
14 (314) 1 Safety ring
15 (315) 1 Nut
16 (316) 1 Deflector
17 (317) 1 Face plate
18 (318) 1 Spring
Figure 35
136 SLUDGE BURNER

APPENDIX H
Appendix H: Sludge Dosage Pump
Dimension
Weight:19,5 kg
Figure 36
SLUDGE DOSAGE PUMP 137

APPENDIX H
Dismantling and assembly diagram,
Figure 37
Motor for pump.

0.37Kw- 1.26A - 50Hz -885 Rpm.
Figure 35
138 SLUDGE DOSAGE PUMP

APPENDIX H
Parts list Art. No. 2007672

Pos.No Art.nr. Description Qty.
1 15687 Seal Plate Gasket 1

2 17168 Stuffing Box Gasket 1
3 15679 Tie rod 4
4 15683 Mech. Seal housing 1
5 15682 Seal plate 1
6 15681 Straight through end cover 1
7 15680 Pump housing 1
8 15685 Stub shaft 1
9 15684 Rotor 1
10 15748 Bonded stator 1
11 15678 Pump lantern 1
12 15677 Foot 1
13 15739 Hex socket grub screw 1
14 15738 Hex socket set screw 2
15 3206 Spring washer 4
16 2541 Hex nut 4
17 15740 Stud 4
18 15749 Flange mounted geared motors 1
19 5641 Punched washer 10
22 15688 UJ 1
23 16274 Taper plug 1
25 2598 Hex nut 10
26 15735 Hex nut 2
27 15734 Stud 2
28 15690 Retaining pin 1
30 15741 Mech. Seal 1
Figure 36

APPENDIX H
Installation
Installation and Safety Recommendations
In common with other items of process plant a pump must be installed correctly to ensure satisfactory and safe
operation. The pump must also be maintained to a suitable standard. Following these recommendations will
ensure that the safety of personnel and satisfactory operation of the pump is achieved.
General
When handling harmful or objectionable materials, adequate ventilation must be provided in order to disperse
dangerous concentrations of vapours. It is recommended that wherever possible pumps should be installed with
provision for adequate lighting, thus ensuring that effective maintenance can be carried out in satisfactory
conditions. With certain product materials, a hosing down facility with adequate draining will simplify
maintenance and prolong the life of pump components.
Storage
Short-term storage
Where a pump has to be stored for 6 months or less then the following steps are advised:
1. Store pump inside wherever possible or if this is not feasible then provide protective covering. Do not
allow moisture to collect around the pump.
2. Remove the drain plug, if fitted. Any inspection plates fitted should also be removed to ensure that the
suction housing could drain and dry completely.
3. Loosen the packing gland and inject sufficient grease into the stuffing box. Tighten the gland nut
hand tight. If a water flush system is to be used do not grease, a small amount of light oil is
recommended for these.
4. See Manufacturers instructions for motor/gearbox/drive instructions for storage procedures.
Long-term storage
If the pump is to be kept in storage for more than six months then in addition to the above the following
procedures should be carried out regularly (every 2 - 3 weeks if possible):
1. If practicable rotate the pump at least three quarters of one revolution to avoid the rotor setting in the
stator.
2. Note, however, that the pump is not to be rotated for more than two revolutions each time because
damage could be caused to the rotor/stator elements.
Immediately prior to installation and starting.

Before installing the pump please ensure that all plugs and inspection plates are replaced and that excess
grease/oil is removed from the stuffing box. Make sure the pump is not started in dry condition.

APPENDIX H
Electrical
Electrical connection should only be made using equipment suitable for both rating and environment. Where
any doubts exist regarding the suitability of equipment, supplier should be consulted before proceeding.
Normally the pump should be installed with starting equipment arranged to give direct on line starting.
Earthing points will be provided on electric drives (if supplied) and it is essential that these are correctly
connected. When the motor is being wired and checked for rotation, the start/stop sequence must be
instantaneous to prevent dry running or pressurising upstream equipment. (Check direction arrow on pump
nameplate). The electrical installation should include appropriate isolating equipment to ensure that the pump
unit is safe to work on.
Important
The pump must never run against a closed inlet or outlet valve, as this could result in mechanical failure.
General safety
Great care must be taken to protect all electrical equipment from splashing when hosing down.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness before operation.
To eliminate vibration, the pump must be correctly aligned with the drive unit, and all guards must be securely
flexed in position. When commissioning the plant, all joints in the system must be checked thoroughly for
leakage.
If, when starting, the pump does not appear to operate correctly, the plant must be shut down immediately and
the cause of the malfunction established before operations are recommenced. It is recommended that
depending upon plant system operation, either a combined vacuum and pressure gauge, or a vacuum gauge only
be fitted to the pump inlet port, and a pressure gauge fitted to the outlet port, these will then continuously
monitor the pump operating conditions.
Start-up procedure
Pumps must be filled with liquid before starting. The initial filling is not for priming purposes, but to provide
the necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid
will normally be trapped in the rotor/stator assembly to provide lubrication upon re-starting.
If, however, the pump has been left standing for an appreciable time, moved to a new location, or has been
dismantled and re-assembled, it must be refilled with liquid and given a few turns before starting. The pump is
normally somewhat stiff to turn by hand owing to the dose rotor/stator fit. However, this stiffness disappears
when the pump is running normally against pressure.
Dry running
Never run the pump in a dry condition even for a few revolutions, the stator will be damaged
immediately. Continual dry running could produce some harmful or damaging effects.

APPENDIX H
Mechanical seals, all pumps.

When a mechanical seal is fitted to the pump it may be necessary to provide a barrier fluid to some part of the
seal. This should be provided in line with the seal manufacturers instructions.
Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the pump.
Warning/control device
Prior to operating the pump, if any warning or control devices are fitted these must be set in accordance with
their specific instructions.
Pump operating temperature

The range of temperatures the pump surfaces will develop is dependent upon factors such as product
temperature and ambient temperature of the installation. There may be instances where the external pump
surface can exceed 50°C.
Maintenance of wearing components

Rotor and stator
The wear rate on these components is dependent on many factors, such as product abrasivity, speed, pressure
etc.
When pump performance has reduced to an unacceptable level one or possibly both items will need replacing.

APPENDIX H
Diagnostic chart
SYMPTOMS POSSIBLE CAUSES
1 NO DISCHARGE 1.2.3.7.26.28.29.
2 LOSS OF CAPACITY 3.4.5.6.7. &: 9.10. 11.13. 16.17.21.22.23.29.
3 IRREGULAR DISCHARGE 3.4.5.6.7.8.13.15.29.
4 PRIMING LOST AFTER START 3.4.5.6.7.8.13.15.
5 PUMP STALLS AT START UP 8.11.24.
6 PUMP OVERHEATS 8.9.11.12.18.20.
7 MOTOR OVERHEATS 8.11.12.15.18.20.
8 EXCESSIVE POWER ABSORBED BY PUMP 8.11.12.15.18.20.
9 NOISE AND VIBRATION 3.4.5.6.7.8.9.11.13.15. 18.s~19. 20.22.23.27.
10 PUMP ELEMENT WEAR 9.11..
11 EXCESSIVE GLAND OR SEAL WEAR 12.14.25.30.
12 GLAND LEAKAGE 13.14.
13 SEIZURE 9. 11.12.20.
LIST OF CAUSES REMEDIAL ACTIONS

1. INCORRECT DIRECTION OF ROTATION REVERSE MOTOR
2. PUMP UNPRIMED BLEED SYSTEM OF AIR / GAS
3. INSUFFICENT N.P.S.H. AVAILABLE INCREASE SUCTION HEAD OR REDUCE SPEED / TEMP
4. PRODUCT VAPORISING IN SUPPLY LINE INCREASE N.P.S.H. AVAILABLE (SEE 3 ABOVE)
5. AIR ENTERING SUPPLY LINE CHECK PIPE JOINTS / GLAND ADJUSTMENT
6. INSUFFICIENT HEAD ABOVE SUPPLY VESSEL OUTLET RAISE VESSEL / INCREASE PIPE SIZE
7. FOOTVALVE / STRAINER OBSTRUCTED OR BLOCKED CLEAN OUT SUCTION LINE / VALVES
8. PRODUCT VISCOSITY ABOVE RATED FIGURE DECREASE PUMP SPEED / INCREASE TEMP
9. PRODUCT TEMP ABOVE RATED FIGURE COOL THE PRODUCT
10. PRODUCT VISCOSITY BELOW RATED FIGURE INCREASE PUMP SPEED / REDUCE TEMP
11. DELIVERY PRESSURE ABOVE RATED FIGURE CHECK FOR BLOCKAGES IN DELIVERY LINE
12. GLAND OVERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
13. GLAND UNDERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
14. GLAND FLUSHING INADEQUATE CHECK FLUID FLOWS FREELY INTO GLAND
15. PUMP SPEED ABOVE RATED FIGURE DECREASE PUMP SPEED
16. PUMP SPEED BELOW RATED FIGURE INCREASE PUMP SPEED
17. BELT DRIVE SLIPPING RE -TENSION BELTS
18. COUPLING MISALIGNED CHECK AND ADJUST ALIGNMENT
19. INSECURE PUMP I DRIVE MOUNTING CHECK AND TIGHTEN ALL PUMP MOUNTINGS
20. SHAFT BEARING WEAR I FAILURE REPLACE BEARINGS
21. WORN PUMP ELEMENT FIT NEW PARTS
22. RELIEF VALVE CHATTER CHECK CONDITION OF VALVE / RENEW
23. R.V. INCORRECTLY SET RE -ADJUST SPRING COMPRESSION
24. LOW VOLTAGE CHECK VOLTAGE I /WIRING SIZES
25. PRODUCT ENTERING PACKING AREA CHECK PACKING CONDITION AND TYPE
26. DRIVE TRAIN BREAKAGE CHECK AND REPLACE BROKEN COMPONENTS
27. NEGATIVE OR VERY LOW DELIVERY HEAD CLOSE DELIVERY VALVE SLIGHTLY
28. DISCHARGE BLOCKED / VALVE CLOSED REVERSE PUMP/RELIEVE PRESSURE / CLEAR
BLOCKAGES
29. STATOR TURNING REPLACE WORN PARTS / TIGHTEN UP STATOR BOLTS
30. STUFFING BOX EATS - PACKING CHECK FOR WORN SHAFT AND REPLACE

APPENDIX H

APPENDIX I
Appendix I: Sludge circ. pump

1.General information
Model 40WYXH-6-20 marine sludge oil circulation pump is a motor-
driven horizontal sludge oil pump (Reference to as residual oil pump
hereinafter).
Pumps of this series are suitable for delivering heavy oil and sludge oil
with temperature up to 90℃. This is a piece of equipment optimal for
completion of incinerator in water treatment plant.
1.1Type designation
40 WY XH ─ 6 ─ 20
Pressure at rated flow0.20Mpa
Rated flow 6m3/h
Circulation pump
Sludge oil（residual oil）
Inlet and outlet dia40mm
2.Structure and Features
2.1Structure （See fig.）
A. Pump of this series is composed of casing, impeller, locking bolts,
sealing device, motor and etc.
B. Pump of this series is a horizontal pump with the motor at rear and
pump in front coupled together. The pump uses semi-open impeller
which is directly connected to motor output shaft.
C. Inlet and outlet of the pump shall be connected to external with
standard four-step four-hole flanges.
2.2 Features
Pumps of this series feature high discharge power, good sealing
performance, thermal resistance, high efficiency and energy saving.
3.Selection of Main Part and Component Materials

a. Pump casing, rear pump casing and impeller are made of ductile cast
SLUDGE CIRC. PUMP 145

APPENDIX I
iron.
b. Metal bellow mechanical sealing ring is used as shaft seal。
4.Main Technical Data

Type
Item Unit
40WYXH-6-20
Flow m3/h 6
Pressure mpa 0.2
Power supply v/Hz 380/50 440/60
Motor power kw 2.2 2.53
Motor speed r/min 2840 3470
Dia. of inlet and outlet mm 40
Weight kg
Outline（L×W×H） mm 454×225×240
5. Installation Instructions (See Fig. For dimension
The pump is a non-self-suction type and media is sludge oil with solid
granulates or heavy oil. Therefore, centerline of pump casing must be below
medium level and suction and discharge pipes must have size larger than inlet
and outlet with minimal bends. Otherwise, pumping performance shall be
affected.
Pump base plate shall be secured with bolts. There shall have four pump
casing fixing bolts at pump discharging side 90°apart, which can be undone
for adjustment.
6.Operation and Maintenance Instructions
Prior to initial start, pump motor shall be checked for conformance of
power supply to be connected with power system of the motor.
Open valves in suction and discharge pipelines and start the motor. At
start up direction of pump rotation shall be checked to see if it is in line with
that indicated on pump casing, or it shall be changed.
If there is any leakage with the pump, stop the pump immediately to make
checks and close valves so as not to burn the motor. When necessary, seal ring
shall be replaced. Normal leakage from the mechanical seal shall be less then
10ml/h.
146 SLUDGE CIRK. PUMP

APPENDIX I
The pump shall not be run empty so as not burn seal ring.
When the pump is not to be operated for al long time, it shall be
dismantled for cleaning. Special attention shall be paid when disassembling
that both faces of mechanical seal shall not be damaged. A suitable amount of
lubricant shall be applied at assembling for proper storage
7.Disassembling and assembling

7.1Disassembling
a. Removal the four securing nuts(15) and take off pump casing(1).
b. Undone lock nuts (2) and pull out impeller (4). Take out flat key (5).
c. Remove three fixing screws (14) for rear pump casing (14) and pull out rear
casing (13) together with mechanical seal ring(7). And remove the mechanical
seal ring from rear pump casing for replacement or repair.
d. Remove 3 screws (9) fixing the gland and take off the gland (10) and you
will be able to fill lubricant into the bearings.
e. Remove the retainer from motor shaft (11) by means of circlip pliers.
Remove 3 fixing screws on motor enclosure and pull out the enclosure with
bearing for replacement and cleaning.
7.2. Assembling
a. Assemble in the reverse order of assembling.
b. Both faces of the mechanical seal ring shall be cleaned up before being
installed. Never strike so as not to damage the sealing ring.。
8. Spare Parts Delivered with the pump (see packing list for details)
a. “o”-type ring each for two sizes
9. Document Delivered with the pump
a. A copy of pump inspection certificate
b. A copy of operation instructions
c. Motor operation instructions & quality certificate 1 copy each
d. Packing list 1 copy.

APPENDIX I
Packing list
S/N Description Type and size Q’ty Unit Remarks

1 Marine sludge oil
40WYXH-6-20 1 set
circulation pump
2 O seal ring 20×2.6 GB1235-76 1 pc spare
3 O seal ring 130×3.1GB1235-76 1 pc spare
4 Document
Inspection:____________ Packing:____________Date:____________

APPENDIX I

APPENDIX I

APPENDIX J
Appendix J: Water Dosage Pump
Dimension
Weight:19,5 kg
Figure 38
WATER DOSAGE PUMP 151

APPENDIX J
Dismantling and assembly diagram,
Figure 39
Motor for pump.

0.55Kw- 1.6A - 50Hz -1395 Rpm.
Figure 35
152 WATER DOSAGE PUMP

APPENDIX J
Parts list Art. No. 2007740

Pos.No Art.nr. Description Qty.
1 15689 Gland Guard 1

2 15687 Seal Plate Gasket 1
3 15679 Tie rod 4
4 15683 Mech. Seal housing 1
5 15682 Seal plate 1
6 15681 Straight through end cover 1
7 15680 Pump housing 1
8 15685 Stub shaft 1
9 15684 Rotor 1
10 15748 Bonded stator 1
11 15678 Pump lantern 1
12 15677 Foot 1
13 15739 Hex socket grub screw (for part no. 4400) 1
14 15738 Hex socket set screw (for part no. 4400) 2
15 3206 Sping washer (for part no.42) 4
16 2541 Hex nut (for part nr. 41) 4
17 15740 Stud (for part no. 40) 4
18 15749 Flange mounted geared motors 1
19 5641 Punched washer (for part nr. 16) 10
20 15736 Spring washer (for part no. 08) 2
21 15741 Mech. Seal 1
22 15688 UJ 1
23 16274 Taper plug (for part no. 5010) 1
24 2598 Hex nut (for part no. 15) 10
25 15737 Spring washer (for part no. 7710, 1200 & 5310) 10
26 15735 Hex nut (for part no. 07) 2
27 15734 Stud (for part no. 5861 & 5452) 2
28 15690 Retaining pin 1
Figure 40

APPENDIX J
Installation
Installation and Safety Recommendations
In common with other items of process plant a pump must be installed correctly to ensure satisfactory and safe
operation. The pump must also be maintained to a suitable standard. Following these recommendations will ensure that
the safety of personnel and satisfactory operation of the pump is achieved.
General
When handling harmful or objectionable materials, adequate ventilation must be provided in order to disperse
dangerous concentrations of vapours. It is recommended that wherever possible pumps should be installed with
provision for adequate lighting, thus ensuring that effective maintenance can be carried out in satisfactory conditions.
With certain product materials, a hosing down facility with adequate draining will simplify maintenance and prolong
the life of pump components.
Storage
Short-term storage
Where a pump has to be stored for 6 months or less then the following steps are advised:
1. Store pump inside wherever possible or if this is not feasible then provide protective covering. Do not allow
moisture to collect around the pump.
2. Remove the drain plug, if fitted. Any inspection plates fitted should also be removed to ensure that the
suction housing could drain and dry completely.
3. Loosen the packing gland and inject sufficient grease into the stuffing box. Tighten the gland nut hand tight.
If a water flush system is to be used do not grease, a small amount of light oil is recommended for these.
4. See Manufacturers instructions for motor/gearbox/drive instructions for storage procedures.
Long-term storage
If the pump is to be kept in storage for more than six months then in addition to the above the following procedures
should be carried out regularly (every 2 - 3 weeks if possible):
1. If practicable rotate the pump at least three quarters of one revolution to avoid the rotor setting in the stator.
2. Note, however, that the pump is not to be rotated for more than two revolutions each time because damage
could be caused to the rotor/stator elements.
Immediately prior to installation and starting.

Before installing the pump please ensure that all plugs and inspection plates are replaced and that excess
grease/oil is removed from the stuffing box. Make sure the pump is not started in dry condition.

APPENDIX J
Electrical
Electrical connection should only be made using equipment suitable for both rating and environment. Where any
doubts exist regarding the suitability of equipment, supplier should be consulted before proceeding. Normally the
pump should be installed with starting equipment arranged to give direct on line starting.
Earthing points will be provided on electric drives (if supplied) and it is essential that these are correctly connected.
When the motor is being wired and checked for rotation, the start/stop sequence must be instantaneous to prevent dry
running or pressurising upstream equipment. (Check direction arrow on pump nameplate). The electrical installation
should include appropriate isolating equipment to ensure that the pump unit is safe to work on.
Important
The pump must never run against a closed inlet or outlet valve, as this could result in mechanical failure.
General safety
Great care must be taken to protect all electrical equipment from splashing when hosing down.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness before operation. To
eliminate vibration, the pump must be correctly aligned with the drive unit, and all guards must be securely flexed in
position. When commissioning the plant, all joints in the system must be checked thoroughly for leakage.
If, when starting, the pump does not appear to operate correctly, the plant must be shut down immediately and the
cause of the malfunction established before operations are recommenced. It is recommended that depending upon
plant system operation, either a combined vacuum and pressure gauge, or a vacuum gauge only be fitted to the pump
inlet port, and a pressure gauge fitted to the outlet port, these will then continuously monitor the pump operating
conditions.
Start-up procedure
Pumps must be filled with liquid before starting. The initial filling is not for priming purposes, but to provide the
necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid will
normally be trapped in the rotor/stator assembly to provide lubrication upon re-starting.
If, however, the pump has been left standing for an appreciable time, moved to a new location, or has been dismantled
and re-assembled, it must be refilled with liquid and given a few turns before starting. The pump is normally
somewhat stiff to turn by hand owing to the dose rotor/stator fit. However, this stiffness disappears when the pump is
running normally against pressure.
Dry running
Never run the pump in a dry condition even for a few revolutions, the stator will be damaged immediately.
Continual dry running could produce some harmful or damaging effects.

APPENDIX J
Mechanical seals, all pumps.

When a mechanical seal is fitted to the pump it may be necessary to provide a barrier fluid to some part of the seal.
This should be provided in line with the seal manufacturers instructions.
Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the pump.
Warning/control device
Prior to operating the pump, if any warning or control devices are fitted these must be set in accordance with their
specific instructions.
Pump operating temperature

The range of temperatures the pump surfaces will develop is dependent upon factors such as product temperature and
ambient temperature of the installation. There may be instances where the external pump surface can exceed 50°C.
Maintenance of wearing components

Rotor and stator
The wear rate on these components is dependent on many factors, such as product abrasivity, speed, pressure etc.
When pump performance has reduced to an unacceptable level one or possibly both items will need replacing.

APPENDIX J
Diagnostic chart
SYMPTOMS POSSIBLE CAUSES
1 NO DISCHARGE 1.2.3.7.26.28.29.
2 LOSS OF CAPACITY 3.4.5.6.7. &: 9.10. 11.13. 16.17.21.22.23.29.
3 IRREGULAR DISCHARGE 3.4.5.6.7.8.13.15.29.
4 PRIMING LOST AFTER START 3.4.5.6.7.8.13.15.
5 PUMP STALLS AT START UP 8.11.24.
6 PUMP OVERHEATS 8.9.11.12.18.20.
7 MOTOR OVERHEATS 8.11.12.15.18.20.
8 EXCESSIVE POWER ABSORBED BY PUMP 8.11.12.15.18.20.
9 NOISE AND VIBRATION 3.4.5.6.7.8.9.11.13.15. 18.s~19. 20.22.23.27.
10 PUMP ELEMENT WEAR 9.11..
11 EXCESSIVE GLAND OR SEAL WEAR 12.14.25.30.
12 GLAND LEAKAGE 13.14.
13 SEIZURE 9. 11.12.20.
LIST OF CAUSES REMEDIAL ACTIONS

31. INCORRECT DIRECTION OF ROTATION REVERSE MOTOR
32. PUMP UNPRIMED BLEED SYSTEM OF AIR / GAS
33. INSUFFICIENT N.P.S.H. AVAILABLE INCREASE SUCTION HEAD OR REDUCE SPEED / TEMP
34. PRODUCT VAPORISING IN SUPPLY LINE INCREASE N.P.S.H. AVAILABLE (SEE 3 ABOVE)
35. AIR ENTERING SUPPLY LINE CHECK PIPE JOINTS / GLAND ADJUSTMENT
36. INSUFFICIENT HEAD ABOVE SUPPLY VESSEL OUTLET RAISE VESSEL / INCREASE PIPE SIZE
37. FOOT VALVE / STRAINER OBSTRUCTED OR BLOCKED CLEAN OUT SUCTION LINE / VALVES
38. PRODUCT VISCOSITY ABOVE RATED FIGURE DECREASE PUMP SPEED / INCREASE TEMP
39. PRODUCT TEMP ABOVE RATED FIGURE COOL THE PRODUCT
40. PRODUCT VISCOSITY BELOW RATED FIGURE INCREASE PUMP SPEED / REDUCE TEMP
41. DELIVERY PRESSURE ABOVE RATED FIGURE CHECK9890
FOR BLOCKAGES IN DELIVERY LINE
42. GLAND OVERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
43. GLAND UNDERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
44. GLAND FLUSHING INADEQUATE CHECK FLUID FLOWS FREELY INTO GLAND
45. PUMP SPEED ABOVE RATED FIGURE DECREASE PUMP SPEED
46. PUMP SPEED BELOW RATED FIGURE INCREASE PUMP SPEED
47. BELT DRIVE SLIPPING RE -TENSION BELTS
48. COUPLING MISALIGNED CHECK AND ADJUST ALIGNMENT
49. INSECURE PUMP I DRIVE MOUNTING CHECK AND TIGHTEN ALL PUMP MOUNTINGS
50. SHAFT BEARING WEAR I FAILURE REPLACE BEARINGS
51. WORN PUMP ELEMENT FIT NEW PARTS
52. RELIEF VALVE CHATTER CHECK CONDITION OF VALVE / RENEW
53. R.V. INCORRECTLY SET RE -ADJUST SPRING COMPRESSION
54. LOW VOLTAGE CHECK VOLTAGE I /WIRING SIZES
55. PRODUCT ENTERING PACKING AREA CHECK PACKING CONDITION AND TYPE
56. DRIVE TRAIN BREAKAGE CHECK AND REPLACE BROKEN COMPONENTS
57. NEGATIVE OR VERY LOW DELIVERY HEAD CLOSE DELIVERY VALVE SLIGHTLY
58. DISCHARGE BLOCKED / VALVE CLOSED REVERSE PUMP/RELIEVE PRESSURE / CLEAR
BLOCKAGES
59. STATOR TURNING REPLACE WORN PARTS / TIGHTEN UP STATOR BOLTS
60. STUFFING BOX EATS - PACKING CHECK FOR WORN SHAFT AND REPLACE

DRAWINGS
DRAWINGS
158 DRAWINGS

Manual Gs500cic-Tg5-201403

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« S H I P _ N AM E »

Copyright © 2003 TeamTec AS. All rights reserved.

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Code Feature description

THE INCINERATOR “10 COMMANDMENTS” ............................................................................... 15

Flue gas fan ........................................................................................................................................... 30

PREVENTIVE MAINTENANCE ........................................................................................................................ 67

Outside the incinerator room................................................................................................................. 93

PROCEDURE FOR ADJUSTING THE SLUDGE BURNER ................................................................................... 134

APPENDIX J: WATER DOSAGE PUMP ......................................................................................... 151

ACRONYMS AND TERMS

The incinerator “10 commandments”

• In case of abnormal operation, contact TeamTec.

Incineration of solid and liquid waste

Plastic, Cardboard, Wood

Solid and liquid waste that is prohibited to be burned

IMO Annex VI regulation 16 prohibits incineration on ship of certain products, such as

Solid Waste handling

Service network for TeamTec (Golar) incinerators.

For more information please visit our web pages: www.teamtec.no

Capacity: 800 000 Kcal/h (930KW)

Combustion chamber Max. 1200 °C

Flue gas fan El. power 22 / 251.3 kW From incinerators electrical

Negative pressure: 10-35 mmWC In combustion chamber

Total weight: 4545kg

Outline dimension: 2416 x 1944 x 2097 (L x W x H) See dimension drawing.

Burner (fixed on combustion chamber)

Diesel Oil viscosity Max. 13 cSt at 40°C

Burner air blower each: Max. 1,500 m2/h

Oil pump: Working press. 16 bar

El. Motor 2800/3400 rpm.

Ignition transformers: 230V / 10,000V

Outline dimension: 845 x 539 x 387 (L x W x H) See dimension drawing.

Diesel oil booster pump (optional)

El.motor: See Burner motor

Outline dimension: 422x170x200(L x W x H) See dimension drawings.

Flue gas fan (bulkhead mounted)

Capacity: 12,500 std. m³/h at 300°C At 200 mmWC total back

Flue gas duct dimensions DN 400/400

El.motor: 380/440V, 18/21.3kW 1465/1768 rpm variable

Outline dimension: 1765 x 1625 x 1580 (L x W x H) See dimension drawing.

Control speed: 0-1800 rpm

Flue gas damper.

Actuator motor: Drive force 20Nm. Travel

Dimension between flanges: 300 mm See dimension drawing.

Sluice (fixed on top of incinerator unit) (Optional)

Opening / volume 400 x 500 mm / 125 litres

Test pressure: Cylindrical tanks 1 bar

Corrosion Protection: Internal coated with one layer of Carboline

Weight: 490 / 566 or 605/750 kg.

Outline dimension: (L x W x H) See dimension drawing.

Water tank (Optional)

Test pressure: Rectangular tanks 0.2 bar

Corrosion Protection: External coated with one layer of Carboline

Outline dimension: (826 x 1026x 2188) See dimension drawing.

Sludge circulating pump. (installed on sludge tank)

Capacity: 6 m3/h at 1.9 bar discharge pressure.

El. motor: 4.8/4.7 Amp 2880/3480 rpm

Sludge filling pump (if dual sludge tank system)(Optional)

Sludge transfer pump (optional on dual sludge tank system)(Optional)

Sludge dosing pump (fixed on combustion chamber)

El. Motor: 0.37kW IP55 885/1062 rpm