EPC60 Retrofit.pdf

EPC 60 Retrofit

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MACE

1965 1974

EPC30

1979

EPC60

1985 2008

IPC 231

EPC41 EPC400

1999

EPC50

EPC 60 Retrofit

Automation development

Presenter

Presentation Notes

If we look at the different older type of control units we have the <CLICK> MACE that where introduced in 1965. This is a very old system based on camshaft operation. <CLICK> In 1974 the IPC 231 was introduced together with the new WHPX separator. This was the first electronic control system. <CLICK> In 1979 we introduced the replacement for the IPC 231 the EPC 30 control system. The EPC 30 was later complemented with a MARST 1 system for ALCAP operation. <CLICK> The EPC 41/400 was introduced in 1985 replacing the EPC 30 and EPC 30 with MARST 1. The EPC 41 is the control system for conventional separators and the EPC 400 is used for ALCAP separators. <CLICK> The EPC 50 control system was introduced with the new S-type separator introduced in early 2000 and in 2008 <CLICK> we introduced the newest EPC 60 control system. The EPC 60 system is replacing all older systems and are introduced to all applications within Alfa Laval.

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EPC 60 Retrofit

Reason to upgrade

MACE, IPC 231 and EPC 30: Not possible to get parts anymore EPC 41/400: The electrical components on the EPC print card is difficult to get hold of. In many cases we must special order parts.

Presenter

Presentation Notes

The components used on the print card is now obsolete on the really old EPC’s and impossible to get hold of anymore. This means we can not support the electronic in these old systems and upgrading to the EPC 60 retrofit is the only solution. We have the same problem with the newer EPC 41/400 systems the components we use on the print card are difficult to get hold of and will be absolute in a couple of years

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EPC 60 Retrofit

Reason to upgrade

• EPC 60 is using the latest technology

• Easy and logical human interface

• Supporting remote monitoring with Modbus TPC

• Easy fault finding and replacement with separate I/O’s

• Built in P&I temperature controller

• Possible to utilize future upgrades

Presenter

Presentation Notes

We are buying the components from a well known OEM electronic supplier securing the quality and deliverance of parts. The human interface is easy to understand and are very intuitive. Can you operate one EPC 60 you can operate all EPC 60. We are using Modbus TPC for remote communication and the EPC 60 Retrofit are ready for remote monitoring. No problem incorporate the EPC 60 to the engine room control system. The I/O’s in he control system are single unites and can easily be changes if needed. All the I/O’s have built in LED with different colour that will make it easy to find the faulty I/O. The EPC 60 Retrofit have a built in P&I temperature controller to secure high and stabile temperature on the oil. The EPC 60 Retrofit is ready to incorporate future improvements and upgrades.

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• Capable of replacing: IPC 231 EPC 30 EPC 41 EPC 400

• Compatible with: MAPX MOPX WHPX MMPX LOPX FOPX MFPX

EPC 60 Retrofit

Replacing opportunities

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3210

bar

4

MPa

bar

6

4

0

2

8

100,2

0 1,2

0,4 0,80,6

12

1

16 15

0

1 2

34

56

810

EHS Heater

Power cabinet

EHS Heater

Water block

EPC 400/41 Control cabinet Starter

Air block

Water transducer

Temperature sensorPT 100

Vibration switch

PS 41 PS 42

EPC 60 Retrofit


Presenter

Presentation Notes

This is a flow chart over a FOPX system before a upgrading. �We have the EPC 400 system connectedd to the starter cabinet, power to the EPC is coming from the starter cabinet. The EPC 400 controlling the heater with its built in P&I controller. �On the outlet pipe we have the water transducer controlling the water content in the clean oil and we also have the pressure switches. The air block is controlling the valves in the system and the water block is controlling the operation of the bowl.

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16 15

0

1 2

34

56

810

EHS Heater

Water block

EPC 60 Control cabinet kit Starter

Air block

MT 60

Heater control box

Temperature sensorPT 100

Vibration switchreplacing coil

Transformer kit

Pressure transmitter kit

MPa

bar

6

4

0

2

8

100,2

0 1,2

0,4 0,80,6

12

1

Power cabinet

To cover the customers need regarding supply voltage to the system we have two different transformer kits available. This is for the EPC operation and valve/ SRV operation.

Transformer kit

The EPC 60 Retrofit is connected to the heater in another way than the old system so we need a heater control box to redirect the signals to and from the heater cabinet.

Heater control box

We need to change the old pressure switches into a pressure sensor working on a 4-20mA signal to be able to communicate with the EPC 60.

Pressure sensor kit

Since the EPC 60 uses 4-20mA signals to communicate with the MT board we need to change to the new MT 60 board.

Transducer kit

We need to protect the new EPC 60 against cut-off voltage peaks generated in the coils on the water block. We mount these protectors on the exiting coils.

Water block kit

We need to protect the new EPC 60 against cut-off voltage peaks generated in the coils on the water block. We mount these protectors on the exiting coils.

Air block kit

The new EPC 60 needs two temperature signals and we supply a new 2xPT 100 sensor if not available in the old installation.

Temperature sensor kit We have two different cabinets available; one for conventional separators: WHPX, MOPX, MMPX and one for ALCAP; FOPX, LOPX and MFPX. The cabinets are the same but the program is different.

Control cabinet kit

EPC 60 Retrofit


Presenter

Presentation Notes

This is what the system will look like after the upgrading. <CLICK> We upgrade the control cabinet, the new EPC 60 retrofit cabinet will fit straight into the space of the old cabinet with no extra work. There is two different programs available one for ALCAP and one for conventional separators. <CLICK>The EPC 60 Retrofit needs 24VDC for operation and the internal transformer has 110VAC or 230VAC as primary supply and 24VDC as secondary supply. If there is no 230/110 VAC available we also have a 380/480VAC primary 230VAC secondary transformer available. <CLICK>All coils will produce a cut-off power peak and we need to protect the I/O’s against this. We mount the surge protectors on the coils, the LED will light up when the coil is activated. <CLICK>We do this on both the water block and air block. <CLICK>If the system has a electric heater we also need a heater control box. The new EPC 60 is communicating differently than the old EPC 400/41 and we need the heater control box to convert the signals. This box is mounted in-between the heater cabinet and the EPC. If there is a steam/ thermal heater in the system we can utilize the same SRV but then we need 24VAC to the cabinet also. We have the transformer kit with 230VAC primary and 24/48VAC secondary for these installations. <CLICK> The transducer also need s to be upgraded, the new EPC 60 is using a 4-20mA signal. <CLICK> We change the old pressure switches to pressure sensors. The new I/O’s is working on 4-20mA. <CLICK> We need two temperature signal to the new EPC 60 system, one for safety and one for heater control. If there is not two temp sensors available in the old system we change to the double PT 100 sensor.

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EPC 60 Retrofit

Selection process

Presenter

Presentation Notes

There is two ways to do this; you as customer check the installation and decide what kits are needed for the upgrading according to the Selection manual. �Then you fill inn the selection checklist and return to the sales company where we then order the parts according to this list.


EPC 60 Retrofit

Preparation process

• Done by the crew or Alfa Laval service

engineer

• Check that all the parts has arrived

• Prepare the installation

• Install new cables if necessary

• Mount new cabinets (Heater, transformer)

• Wright down all parameters from the old cabinet

Presenter

Presentation Notes

The preparation can be done by the crew or by an Alfa Laval service engineer. Control that all the orders parts has arrived Prepare the installation for the installation part Install new cables in parallel with old cables if necessary Mounting the new cabinets and prepare the installation of new cables. Wright down all the old parameters for installation in the new program unit


EPC 60 Retrofit

Installation

• Done by the crew or Alfa Laval service

engineer

• Install tall the new parts

• Mount new cabinets (Heater, transformer)

• Install new cables if necessary

• Connect all the cables

Presenter

Presentation Notes

The installation can be done by the crew or by an Alfa Laval service engineer. The installation phase will consist of: Remove the old parts Install all the new parts including cables Connect all the cables


EPC 60 Retrofit

Commissioning

• Done by Alfa Laval Service engineer

• Control of the installation

• Programming of the new EPC 60

• Function test

• Start up

Presenter

Presentation Notes

We recommend that the commissioning is done by a Alfa Laval service engineer to secure that all the new parts are mounted and connected. The service engineer will: Control the installation Program the new EPC 60 with the parameters from the old EPC gathered in the preparation phase. Function testing the installation Start up the separator system with the new EPC 60

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EPC60 Retrofit.pdf

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Transcript of EPC60 Retrofit.pdf