WEIR TANK

Non Entry Systems LTD

NESL Weir Tank

Operation Manual

Contents
1. Overview ......................................................................................................................................... 3
1.1 Weir Tank System ................................................................................................................ 3
1.2 System Components ............................................................................................................ 3
1.3 Cut Away View ..................................................................................................................... 4
1.3 Tank Capacities & Retention Times. .................................................................................... 4
2. Equipment Classification ................................................................................................................. 4
2.1 Equipment Layout Schematic ..................................................................................................... 5
2.2 Dimensions and weight............................................................................................................... 6
3.0 Detailed Description.................................................................................................................. 7
3.1 Running the Weir tank in Auto Level Mode .............................................................................. 8
3.2 Level Warning System ............................................................................................................... 9
3.3 Emergency Stop ( E-Stop ) System .......................................................................................... 10
4.0 System Operation and control .............................................................................................. 11
4.1 Valve operation, inlets and outlets ......................................................................................... 13
4.2 Lobe pump ........................................................................................................................ 16

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1. Overview

1.1 Weir Tank System

The NESL Weir Tank system is designed to be used with the NESL Manway Cannon
system to enable recirculation of the cannon jetting medium. This greatly reduces the
quantity of additional fluid required to clean the tanks and gives a method of primary
sludge separation.

1.2 System Components

Based on a standard 20 ft ISO container the following equipment and functions are
built in:

 Sludge discharge pump 40 M3/Hr Variable speed (ATEX).

 Internal pipework with selection valves.
 All tanks double skin.
 Four Compartment Weir systems with Final screen stage.
 Removable Vent stack with fan (ATEX).
 Automatic Level control with alarm and pump cut out (ATEX).
 Inspection hatches and Roof Handrails (Not shown).
 Electrical Panel with all controls (ATEX).
 Recessed connections for sludge inlets.
 Inlet Protection screen for cannon Pump.

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1.3 Cut Away View

c
b

1.3 Tank Capacities & Retention Times.

Volumes of weir sections.

a. Primary Sludge: 7.05 m3

b. Secondary Sludge: 6.7 m3
c. Clean Stage: 8.0 m3

TOTAL LIQUID VOLUME 21.75 m3.

Retention time @ 25 m3/Hr = 52 min

2. Equipment Classification
 Weir Tank ATEX Grp 2 Cat 2 (Zone 1) *

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2.1 Equipment Layout Schematic

COMPRESSOR GENERATOR
BY OTHERS BY OTHERS

MANWAY CANNON SYSTEM

NITROGEN GENERATOR

SAFE AREA
SLUDGE PUMP OFF

ZONE 2

WEIR TANK

ZONE 1
CENTRIFUGAL PUMP

LOBEL PUMP

MANWAY CANNON
ONLY ONE SHOWN

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2.2 Dimensions and weight

Total weight empty (Shipping Weight): 9,612 kg

Total weight operating (Based on water): 31,362 kg

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3.0 Detailed Description

The electrical system for the weir tank unit is supplied from a generator ( customer supply ). The
control desk and generator are to be sited a maximum of 80 metres away from the weir tank system.

The system consists of pumps, level controls operator signalling and is defined in NESL electrical
drawings 01-EL-3068 and 02-EL-3068.

The Weir tank unit has three motors which are the lobe pump, blower fan and the progressive cavity
pump.

The control system manages the pumps and also the external 45kW centrifugal pump when the
system is run in “Auto” mode. The control system is powered by a 110Vac control transformer which
also powers the alarms.

The 110 volt control is powered immediately on switch on. The blower fan will run and the High-High
level circuit will be operational.

The control system must be reset by pressing the reset button. Upon depressing this the “Control
on” lamp will be illuminated.

To reset the system the following items must be true and healthy:

1. Local emergency stop button ( on control panel ) must not be activated.

2. The emergency stop button on the control desk must be connected by the control cable and
must not be activated.
3. The emergency stop button on the 45kW centrifugal pump control unit must be connected
by the control cable and must not be activated.
4. The High-High level must not be activated by the High-High level float switch.
5. The blower motor must be running and healthy.

The sludge pump is started manually. The correct start up and operation is conditional on the flow
sensor and the over pressure monitors which are fitted.

The lobe pump is started manually from the weir tank control panel. All the motors are protected by
over current and short circuit systems.

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3.1 Running the Weir tank in Auto Level Mode

The 45kW centrifugal pump is connected and set to REMOTE operation.

The Lobe pump and the progressive cavity “sludge pump” are stared and managed manually.

The 45kW centrifugal pump in this state is now under the control of the Weir tank controls and
operations are as follows:

Assume the weir tank is empty to start.

1. Begin filling process.

2. The level will rise to the High level float switch.
3. At this point the 45kW centrifugal pump will start and the liquid level inside the weir tank
will begin to fall.
4. When the level is reduced to the Low level the 45kW centrifugal pump will stop and level
should begin to rise again at a rate dependant on the conditions of pumping by the lobe
pump and the sludge pump.

When in Automatic mode the level should cycle continually between the Low level and the High
level float switches.

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3.2 Level Warning System

As previously explained above, when the fluid level inside the weir tank hits the High level float
switch the 45kW centrifugal pump will start and the fluid level inside the weir tank should lower
rapidly.

If however the level does not lower in a set time the amber warning light will begin to flash to alert
the operator. This amber warning light will flash until the level is below the High level float switch.

The time can be set as a warning to the operator that the level has not lowered sufficiently in the set
time or as an indication that the High or Low level has been reached and that the system is now
cycling.

If the system should for any reason fail and the fluid level inside the weir tank reached the High-High
level float switch then the system will shut down (all pumps will stop). The level will need to be
pumped down to below the High-High level and the system will need to be reset as per the system
start up procedure.

When the level is reduced to the Low level indicator, the 45kW pump will stop and again the level
will begin to rise in accordance with the set conditions of the lobe pump and the sludge pump.

If the level does not rise in a set time the amber warning light will flash to alert the operator.

The low level time can be set independently of the high level time by means of adjusting the timers
in the main system control panel.

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3.3 Emergency Stop ( E-Stop ) System

The blower motor is designed not to stop when any E-Stop is activated. This is designed so that fume
extraction will continue with the system stopped, and also to prevent any gas build up in the
operator area.

The 45kW centrifugal pump will shut down if the E-Stop is depressed. It will also shut down the weir
tank control panel when it is connected. It will do this in either local or remote modes as defined at
the 45kW pump control panel. The 45kW pump is designed to be used as a stand alone unit if
required.

If the E-Stop is depressed on the weir tank container control panel then the shut down the system.
The weir tank e-Stop requires the unit to be “reset” prior to carrying on any operations.. If the 45kW
centrifugal pump is connected and is set in remote mode this will also shut down.

If the E-Stop is depressed on the control panel / desk of the manway cannon control container, or
one of the gas monitors detect a level above the shut down limit then the weir tank will shut down
along with the 45kW centrifugal pump if connected and set in remote mode.

If for any reason the system will not activate please check that all the Emergency stop buttons
shown below are not depressed.

Desk E-stop

Power pack E-stop

Weir tank E-Stop

Centrifugal pump E-stop

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4.0 System Operation and control

Control panel

Sludge pump Lobe pump

running running
indicator light indicator light

Sludge pump Indicator

start push system ready
button to operate

Sludge pump Reset push

stop push button
button

Emergency Lobe pump

stop button
stop push
button

Mains
Lobe pump
isolator
start push
switch
button

Operation of the system is dependant on the complete hook up of the system. Only when the
“control on” light is on will the system be able to start.

There is a separate control panel located in

the pump / control room which operates
the light. Use the isolator switch on this
panel to turn the light on / off.

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Apart from the control panels shown above, the only other controls for the system are the
manual ball valves. These are all shown below with a description of the purpose and function
of each of the valves.

The unit comes complete with 3 level sensors for fluid levels within the third ( lowest ) weir
tank which will alarm upon activation of the high-high level. Flashing level warning lights are
also provided. Alarm function is detailed later.

The PCM progressive cavity pump is provided in the control room for pumping of the weir
tank media from tank b and c back to a or for pumping to an external source. The PCM pump
has a small hand wheel located on the rear of the electric motor. This is used to control the
speed of rotation of the PCM pump.

There are 4 main cables within the system which must be connected in order for the system
to operate.

1. The mains power cable. This is connected to the mains power reel which is supplied with
80 mtr of cable. The end of the 90 mtr cable is for connection to an external generator
set ( not supplied )
2. The Centrifugal pump mains cable. This cable comes complete with EX receptacle. The
receptacle is for connection to the mains connection on the centrifugal pump.
3. Centrifugal pump e-stop cable. This cable is the signal cable for the e-stop on the
centrifugal pump control panel.
4. Desk e-stop cable. This cable is for connection to the manway cannon control container.
This allows the e-stop button on the control desk to stop all weir tank functions if
depressed by the operator.

Without the cables connected the “control on” light on the control panel will not illuminate.

An electric lobe pump is supplied with the system. This pump is used to fill the weir tank with
media. The lobe pump comes complete with electric cable which requires a generator for
power. The pump has a simple on / off control panel. With the pump connected to the weir
tank inlet and the correct valves open the weir tank can be filled. The lobe pump comes
complete with viton lobes for increased fluid handling ability.

Also provided is a mast for the centrifugal blower outlet on the weir tank container. This
must be placed in the roof mounting point prior to filling the weir tank with any fluids. This
mast will remove any gasses to a height away from the container.

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4.1 Valve operation, inlets and outlets

The control end of the container houses the pumping system for internal pumping and also
for pumping product from the unit.

The valve actuations are shown below.

There are 4 valves on the main

manifold.

Lowest valve is for pumping from

tank A

Second valve up is for pumping from

tank B

Third valve up is for pumping from

tank C but prior to final filter.

Top valve is for pumping from tank C

after the final filter/

Externally there is a valve to be attached to

this inlet line. This is main product inlet
which will be supplied by your lobe pump
or similar.

You must ensure that this valve shown

above the pump is closed when pumping
product into the weir tank

The valve shown above is the main product outlet. This is direct from the progressive cavity pump
and will discharge from the weir tank to your desired location. Ensure the valve above is closed for
discharge or you return product into tank A or out of the inlet line if the inlet valve is open.

If operating the progressive cavity pump you must ensure that the pump has valves open for both
suction and discharge.

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On the other end of the container is the

recess panel which contains the alarms and
the warning beacons.

There is a single manual valve located in this

recess panel. This valve is for connection to
the centrifugal pump .

The suction point for this valve is in the final

filtered side of tank C and the product will be
suitable for running through the pump after
this point.

Operation instruction for the centrifugal

pump is given in the manway cannon
instruction manual.

The progressive cavity pump is variable speed and the speed of rotation can be changed with
the operation of the hand wheel on the side of the pump itself.

The system is not designed to have product pumped from tank to tank apart from pumping
to tank A from B and C.

When operating the progressive cavity pump ensure that there is an open fluid path for the
pumped liquid.

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When the unit arrives you will notice that on the roof of the container all of the roof hatches
are bolted shut and there is a small white plastic hole cover .

The small plastic cover needs to be removed and the ventilation mast must be installed. The
mast simply slides into the hole.

With the roof covers, unbolt the lock side ( one bolt only, the hinges have 2 bolts ) and check
that all tanks are clean and that the filters are not obstructed and secure.

Picture above shows the tanks with the Picture above shows the plastic vent cover
locking bolts removed, open and ready for removed and the ventilation mast
inspection installed on the unit

The tanks have been manufactured with fully bolted manways between the tanks. These can
be removed for cleaning if required but the simplest option is to clean the tanks accessing
them from the roof hatches.

If the outer manway is removed from the skid you must ensure that the seal is replaced and
that the bolts are re-installed with thread sealant to prevent product leaks through the
threads.

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4.2 Lobe pump

The lobe pump supplied with the system is a simple ATEX approved unit which is for the sole
purpose of supplying product to the weir tank.

The lobe pump is a zone 1 product ( ATEX Group 2 Cat 2. )

The lobe pump is to be connected to the weir tank by the appropriate 110v electrical cable (
marked and stored inside the weir tank control area ). The hose connections for the sludge
will be connected to the weir tank as described in previous sections.

The unit comes on a steel skid comprising a set of fork pockets for ease of handling.

The unit is controlled by the lobe pump ( on and off ) buttons on the weir tank control panel.

Ensure that the hoses are correctly connected to the pump. An arrow shows the direction of
flow for the pump.

Any required maintenance for the lobe pump will be shown in the pump manufacturers
documentation supplied with the documentation package

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