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  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

    Page 1 of 29

    Document Title Installation, Operation & Maintenance Manual

    Revision Number A

    Revision Title Issued for Comment

    Supplier Name Ultraspin Technology Pty Ltd

    Ultraspin Oil Skimmer Products

    Skimmers: S1, S2 & Flat-packs

    Hoses

    Floats

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

    Page 2 of 29

    Important Notes to Read Before Commencing any Work

    Safety

    Before attempting to undertake installation, maintenance or repair work of any nature, the persons concerned should be alerted to the nature of the risks involved when working in a situation of a potentially hazardous nature. As it is not possible to cover every aspect of safety in a single article, care has been taken in preparation of the following notes, which should serve as a general guide to the most common situations likely to be encountered. It is necessary to point out that Ultraspin or any of its associates cannot accept responsibility for any form of personal injury, however caused. Therefore, every care should be taken to observe the normal rules of safety.

    Approvals

    The manual is intended as a guide only. If required, site-specific drawings, Council, Water, Electricity Authority and Government approval and professional advice shall be obtained prior to installing the equipment mentioned in this manual.

    Warning

    Certain instructions and advice carry this tag. This information should NOT be ignored or damage to equipment or personnel could result.

    Warranty

    The data is based on tests and experience which Ultraspin Technology Pty Ltd believe reliable and is supplied for information services only. Ultraspin Technology Pty Ltd disclaims any liability for damage or injury which results from the use of the enclosed data and nothing contained therein shall constitute a guarantee, warranty or representation (including free from patent liability) by Ultraspin Technology Pty Ltd with respect to the data, the product described, or its suitability for any specific purpose, even if that purpose is known to Ultraspin Technology Pty Ltd.

    Patents

    Ultraspin Technology Pty Ltd has patented features of the skimmer, hydrocyclone and processes covered in this literature. Processes or products in this manual should not be used without the prior written consent of Ultraspin Technology Pty Ltd.

    Update Data subject to correction and update without notice

    Copyright Ultraspin Technology Pty Ltd © 2010-2014; All rights reserved

    Standards

    This Ultraspin Separators are designed to comply with some or all of the following standards: NSW Land & Water Conservation, January 1997 Guidelines for the On-Site Treatment of Trade Waste Discharge to Sewer AS/NZS 4494:1998 Discharge of Commercial & Industrial Liquid Waste to Sewer – General Performance Requirements National Water Quality Management Guideline for Sewerage Systems, November 1998 A list of manufacturing standards is available on request.

    Design

    This manual is not a design guide. It does not provide a substitute for careful planning and a considered site design drawing prepared by qualified and experienced people. If there is any uncertainty with design the service of competent design engineers experienced in oily water and local requirements should be sought. If needed Ultraspin can provide a list of recommended designers.

    File Ref U:\Engineering\IOM Manuals\IOM Manuals for CURRENT Equipment\Standard Equipment\Skimmer\Oil Skimmers (IOM Manual).docx

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

    Page 3 of 29

    Here at Ultraspin, we would like to take this opportunity to thank you for purchasing an Ultraspin Oil

    Skimmer.

    Over the years we have designed and supplied high performance oily water separation systems to a

    variety of industries. Our systems use innovative hydrocyclone technology to separate oils, fats and

    solids from process and effluent streams. These separation systems are the result of research and

    development programs started in 1983 by the company Engineers. At that time Ultraspin staff

    designed the world’s first successful oil removal hydrocyclone systems. There have been many

    innovations and process developments since then and these form the core of current Ultraspin

    designs.

    We greatly appreciate your business and the opportunity to assist you. Your satisfaction is the

    greatest recognition we could ask for and we invite you to give us your feedback on our product and

    services.

    For any queries regarding the Oil Skimmer and any other Ultraspin related products please refer to

    our website www.ultraspin.com.au or feel free to call us on 03 8841 7200

    http://www.ultraspin.com.au/

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

    Page 4 of 29

    Table of Contents Table of Contents ................................................................................................................................ 4

    1. System Overview............................................................................................................................. 5

    1.1 Description .............................................................................................................................. 5

    1.2 Skimmer Features ................................................................................................................... 6

    1.3 How does it work? .................................................................................................................. 7

    1.4 Typical Applications ................................................................................................................ 8

    2. Purchase Options ............................................................................................................................ 9

    2.1 Skimmers Models and Flat-packs............................................................................................ 9

    2.2 Skimmer Set-up Options ....................................................................................................... 10

    2.3 Optional Purchases ............................................................................................................... 11

    3. Specifications ................................................................................................................................ 12

    3.1 Skimmer Specifications ......................................................................................................... 12

    3.2 Hose Specifications ............................................................................................................... 13

    3.3 Hose Float Specifications ...................................................................................................... 13

    3.4 Elbow Specifications ............................................................................................................. 14

    4. Assembly ....................................................................................................................................... 15

    4.1 Assembly of the S1 Skimmer ................................................................................................. 15

    4.2 Assembly of the S2 Skimmer ................................................................................................. 18

    5. Installation of the Oil Skimmers .................................................................................................... 22

    6. Routine Maintenance ................................................................................................................... 23

    7. Skimmer Spare Parts ..................................................................................................................... 27

    7.1 Parts Replacement ................................................................................................................ 27

    7.2 Spare Parts Recommendations ............................................................................................. 27

    7.3 Parts Ordering ....................................................................................................................... 27

    7.4 Shipping Components ........................................................................................................... 27

    8. Troubleshooting Guide ................................................................................................................. 28

    9. Drawings ....................................................................................................................................... 29

    9.1 S1 Skimmer ........................................................................................................................... 29

    9.2 S2 Skimmer ........................................................................................................................... 29

    9.3 Hoses ..................................................................................................................................... 29

    9.4 Elbows and Hose Floats ........................................................................................................ 29

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    1. System Overview

    1.1 Description

    Skimmers are designed to remove oil, fats and floating material from tanks, pits and open waters.

    Ultraspin skimmers are true self-adjusting, weir-type, oily water skimmers and are an important part

    of oily water treatment systems.

    IMPORTANT: It is important to understand that no type or brand of oil skimmer is a water treatment device. Removing free floating oil does not treat the water that lies below. Whilst an oil skimmer may form a part of an overall water treatment strategy – if the primary problem is cleaning the water, then water treatment equipment is needed and not just an oil skimmer

    1.1.1 Oil Recovery

    After the skimming process it may be necessary to drain the excess water and collect concentrated

    oil. For this purpose Ultraspin is able to provide the Oil Recovery System (ORS). These packaged

    systems include a pump, skimmer, hose and collection tank.

    1.1.2 Water Treatment Systems

    Ultraspin Skimmers are able to collect all contents of an oily water pit or tank regardless of oil

    composition and the addition of surfactants. They do not distinguish between fluid types and

    therefore do not treat the water. The skimmers can be used in conjunction with Ultraspin Water

    treatment systems capable of improving water quality through their unique water treatment

    process.

    For more information regarding the Oil Recovery System please refer to http://www.ultraspin.com.au/index.php/products/oil-recovery-system

    If you are interested in Ultraspin water treatment systems please refer to http://www.ultraspin.com.au/index.php/products/oily-water-separators

    http://www.ultraspin.com.au/index.php/products/oil-recovery-systemhttp://www.ultraspin.com.au/index.php/products/oily-water-separators

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    1.2 Skimmer Features

    • Skims in all directions

    • Equally effective with all oil types

    • Not affected by surfactants – chemicals or detergents

    • Fast oil removal flow rates

    • Self-adjusting; no operators required

    • Low capital and installation cost

    • Low operating and maintenance cost

    • Simple service and maintenance

    • Tolerates < 20mm debris

    • Easy to deploy

    • Operates when tilted

    • Flexibility with pump choice

    • Minimal safety precautions required

    • Robust construction

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    1.3 How does it work?

    The main components of the Ultraspin skimmer are a floating central ring, flexible bellows and a

    floating body assembly. The floating central ring sits in the centre of the skimmer with the bellows

    forming a sealed chamber between the body and the central ring. The flexibility in the bellows

    allows the ring to float independently of the skimmer body; this gives the skimmer its ability to self-

    adjust. The ring floats on the fluid in the pump-out chamber on the inside of the bellows. The body

    of the skimmer holds the components together and provides the floatation for the assembly.

    A hose and pump are connected to the skimmer outlet. As the fluid is pumped away the floating ring

    sinks, thus allowing fluid to flow over the top and into the pump-out chamber. As the flow is

    increased the ring sinks deeper into the fluid so that more fluid passes over the top of the ring and

    into the pump-out chamber, making the skimmer fully self-adjusting.

    To check out our skimmers in action, watch our video at

    http://www.ultraspin.com.au/index.php/products/oil-skimmer

    http://www.ultraspin.com.au/index.php/products/oil-skimmer

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    1.4 Typical Applications

    Ultraspin skimmers have been successfully employed in a large number of applications. Some

    examples are shown below.

    Dairy Factory Ultraspin skimmers are used in dairy factory waste water pits. They provide the feed to Ultraspin dairy treatment systems.

    Mining Industry Skimmers are often used in the clean-up of oil spills and feeding to treatment systems from oily water collection pits from heavy mine vehicle re-fuelling and maintenance operations.

    Food Processing Plant Ultraspin skimmers are able to work effectively in fat and oil collection tanks despite the contents of the tank solidifying in cold weather.

    Other Applications

    Oil Skimming from effluent collection pits, tanks and interceptors

    Oil spill clean-up

    As part of oily water separator systems

    Providing skimmed feed to oily water treatment systems

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    2. Purchase Options

    2.1 Skimmers Models and Flat-packs

    S1 Skimmer

    For smaller flows

    5m3/h for oily water and 7m3/h for general fluid

    Minimum working depth 800mm

    Fully assembled

    S2 Skimmer

    For larger flows

    15m3/h for oily water and 25m3/h for general fluid

    Minimum working depth 1000mm

    Fully assembled

    Skimmer Flat-pack

    Simple assembly required by the customer

    Available for S1 and S2

    Perfect if skimmer needs to be assembled inside a tank

    Lower in cost

    Easier to transport

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    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    2.2 Skimmer Set-up Options

    Two different set-up options are available for both the S1 and S2 Skimmer models.

    Option A: Bottom exit hose-assembly

    Requires a skimmer and hose

    Option B: Side exit hose-assembly

    Requires a skimmer, hose, hose float and elbow

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    2.3 Optional Purchases

    Suction Hose Kit

    Oil-resistant wire-reinforced suction hose with pre-fitted end

    3m and 6m available for S1 Skimmer

    6m available for S2 Skimmer Note: for all 6m length hoses a hose float is required

    Hose Float

    UV stabilized polyethylene hose float

    Note: a hose float must always be used with:

    Option A if combined hose length exceeds 6m

    Option B for all hose lengths

    Elbow

    Stainless steel elbow fitting

    Note: Only required for Option B

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    3. Specifications Please note that the specifications listed in this section are subject to change without notice.

    3.1 Skimmer Specifications

    S1 S2

    Dimensions

    Outside Diameter 856 mm 1370 mm

    Depth 430 mm 710 mm

    Dry Weight 7.5 kg 24.5 kg

    Connection 40 mm (11/2”) male camlock

    80 mm (3”) male camlock

    Nominal Hose Size 40 mm (11/2”) 80 mm (3”)

    Nominal Access Opening Required 630 mm 1050 mm

    S1 S2

    Specifications

    Maximum Flow General 7 m3/h 25 m3/h

    Oily Water 5 m3/h 15 m3/h

    Typical Fluid pH 5-11 pH 5-11 pH

    Temperature 0-70°C 0-70°C

    Minimum Working Depth Bottom exit 1000 mm 1200 mm

    Side exit 800 mm 1000 mm

    Type Material

    Material

    Bellows UV stabilised polyethylene poly-fabric

    Floating Ring UV stabilised polyethylene

    Floats 304 Stainless Steel

    Body 316 Stainless Steel

    Attachments 316 Stainless Steel

  • ULTRASPIN OIL SKIMMERS

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    3.2 Hose Specifications

    S1 S2

    Dimensions

    Length 3 m 6 m 6 m

    Nominal Bore 40 mm (11/2”) 80 mm (3”)

    Connections 40 mm (11/2”) camlock (m-f) 80 mm (3”) camlock (m-f)

    S1 S2

    Specifications Maximum Flow 5 m3/h 15 m3/h

    Minimum Bend Radius 150 mm 300 mm

    S1 S2

    Material

    Camlocks Stainless steel Gr. 316 Stainless steel Gr. 316

    Camlock Seal Nitrile Nitrile

    Ferrules Nickel plated brass Galvanised mild steel

    Hose Fabric Abrasion resistant PVC Abrasion resistant PVC

    Inner and Outer Wires Galvanised mild steel Galvanised mild steel

    3.3 Hose Float Specifications

    Dimensions

    Length 600 mm

    Diameter 300 mm

    Dry weight 9.8 kg

    Reserve Buoyancy 80 kg

    Materials Body UV resistant polyethylene

    Fasteners Stainless steel Gr. 304

  • ULTRASPIN OIL SKIMMERS

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    3.4 Elbow Specifications

    S1 S2

    Angle 90° 90°

    Nominal Bore 40 mm (11/2”) 80 mm (3”)

    Material Stainless steel Gr. 316 Stainless steel Gr. 316

    Connections BSP (m-f) BSP (m-f)

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    4. Assembly Assembly of skimmer is only required if skimmer flat-pack is purchased. If assembly is required,

    please follow the assembly instructions for the appropriate skimmer purchased following with the

    general installation procedure.

    4.1 Assembly of the S1 Skimmer

    4.1.1 Ultraspin Supplied Components

    Quantity

    Skimmer base fitted with weir rings and bellows 1

    Camlock 1

    Ball float 3

    Float arm 3

    M12 Eyebolt 3

    M10 x 25mm hex head set screw 6

    M10 flat washer 12

    M10 hex nut 6

    S1 Skimmer Hose (optional) 1

    Hose float (optional) 1

    Elbow (optional) 1

    4.1.2 Items Required

    Quantity

    17mm ring spanner 1

    8mm allen key 1

    Thread locking paste (Locktite 243) -

    Teflon Tape -

  • ULTRASPIN OIL SKIMMERS

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    4.1.3 Assembly Procedure

    Step 1: Apply thread locking paste to threads of each screw. Use the spanner and allen key to attach

    the loose float arm using the M10 x 25mm hexhead set screw, flat washers and hex nuts.

    Step 2: Turn the assembly over and apply thread locking paste to 3 threads of the bolts welded to

    the arms. Screw in the ball floats, ensuring alignment of the threads is correct. Repeat for all ball

    floats.

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    Step 3: Ensure all parts have been put together correctly before installation

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    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    4.2 Assembly of the S2 Skimmer

    4.2.1 Ultraspin supplied components

    Quantity

    Skimmer base fitted with weir ring, bellows and camlock 1

    Ball float 3

    Loose float arm 3

    Float brace 3

    M10 x 25mm hex head set screw 2

    M10 flat washer 4

    M10 hex nut 2

    M12 eye bolt 3

    S2 Skimmer Hose (optional) 1

    Hose float (optional) 1

    Elbow (optional) 1

    4.2.2 Items Required

    Quantity

    17mm ring spanner 1

    8mm allen key 1

    Thread locking paste (Locktite 243) -

    Teflon Tape -

  • ULTRASPIN OIL SKIMMERS

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    4.2.3 Assembly Procedure

    Step 1: Apply thread locking paste to threads of each screw. Use the spanner and allen key to attach

    the loose float arm using the M10 x 25mm hexhead set screw, flat washers and hex nuts. Repeat

    process for all arms, ensuring they are all level.

    Step 2: Turn the assembly over and apply thread locking paste to 3 threads of the bolts welded to

    the arms. Screw in the ball floats, ensuring alignment of the threads is correct. Repeat for all ball

    floats.

  • ULTRASPIN OIL SKIMMERS

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    Step 3: Unpack the float brace kit and layout as shown.

    Step 4: Place the float braces on top of the floats. Apple thread locking paste to the eyebolt, insert

    through the two float braces and screw fully into the ball float. Remove any residue from the thread

    locking paste. Repeat process for all other ball floats.

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    Step 5: Ensure all parts have been put together correctly before installation

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    5. Installation of the Oil Skimmers 1. Connect the suction hose to the pump or the connection pipe in the tank.

    This may be done permanently with a flanged connection or via a Camlock style quick

    connection

    2. Ensure that the skimmer does not wedge under or against items inside the tank as the level rises

    and falls

    3. Place the skimmer on the surface of the fluid to be treated

    The skimmer is to be installed with the suction hose connection on base of skimmer

    4. Prime the skimmer before drawing fluid through

    Leave the skimmer to float for 5 minutes. It will slowly fill with fluid through the 12mm hole

    in the base. It will be ready for operation once the fluid inside the floating weir ring is visible

    and at the same level as the surrounding fluid

    5. Once the skimmer is primed, start the suction pump

    Correct operation causes fluid to be drawn evenly between the floats and across the weir

    ring, which will have submerged slightly.

    S1 and S2 skimmers are used in conjunction with all Ultraspin treatment systems. The figure below

    shows how the installation of an Ultraspin Oil Skimmer aids in the process and function of the

    Ultraspin Oil Recovery System.

    If you are interested in the Ultraspin Oil Recovery System and would like more information please visit our website at

    http://www.ultraspin.com.au/index.php/products/oil-recovery-system

    http://www.ultraspin.com.au/index.php/products/oil-recovery-system

  • ULTRASPIN OIL SKIMMERS

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  • ULTRASPIN OIL SKIMMERS

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  • ULTRASPIN OIL SKIMMERS

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  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    6. Routine Maintenance The only routine care normally required for the skimmer is a periodic clean. No further

    adjustments are needed.

    To clean the skimmer, carefully remove it from the tank or pit. This may require lifting

    apparatus.

    Built up trash and sediment can be removed with a low-pressure clean water hose.

    The cleaning frequency will depend on the site conditions.

    Ensure there are no blockages at bottom chamber where hose is connected and the priming

    hole is located.

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    7. Skimmer Spare Parts

    7.1 Parts Replacement

    The bellows and weir ring assembly can be removed by loosening the lower ring clamp.

    The weir ring is removed from the bellows by undoing the upper ring clamp.

    Reassembly is the reverse of disassembly, keeping in mind that, to prevent damage to the

    ring, the ring clamp securing diaphragm to weir ring should not be excessively tightened.

    7.2 Spare Parts Recommendations

    Item Part No. Description Required Quantity

    S1 Skimmer

    1 BEL001 Support ring for S1 Skimmer bellows 5 ea

    2 BEL020 Bellows for S1 Skimmer 1 ea

    3 CAB005 Worm-drive clamp for Skimmer donuts 2 ea

    4.1 SK-A-0030-08 S1 Skimmer hose (3 metre) 1 ea

    4.2 SK-A-0030-15 S1 Skimmer hose (6 metre) 1 ea

    S2 Skimmer

    1 BEL021 Bellows for S2 Skimmer 1 ea

    2 BEL023 Support ring for S2 Skimmer bellows 5 ea

    3 CAB005 Worm-drive clamp for Skimmer donuts 4 ea

    4 SK-A-0060-07 S2 Skimmer hose (6 metre) 1 ea

    7.3 Parts Ordering The following information is required when ordering individual Ultraspin components:

    Client Original Purchase Order Number (or Ultraspin job number)

    Ultraspin Skimmer Model Number

    7.4 Shipping Components When returning any items to Ultraspin, clearly tag and adequately pack all items for shipment to

    Ultraspin. To ensure prompt attention, advise Ultraspin before returning components.

    Correspondence must advise the dispatch date, contents, and delivery details.

    Parts replacement should only be carried out if required.

    If unsure please contact Ultraspin on 03 8841 7200

  • ULTRASPIN OIL SKIMMERS

    INSTALLATION, OPERATING AND MAINTENANCE MANUAL

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    8. Troubleshooting Guide The following table may provide some assistance in determining and fixing skimmer related

    problems. It can be applied for both the S1 and S2 skimmer models.

    Problem Cause Remedy

    Skimmer sitting too low in fluid Suction pipe too heavy for skimmer model

    Shorten pipe or use lighter hose or use hose floats

    Skimmer tilted at excessive angle

    Suction pipe too heavy for skimmer model

    Shorten pipe or use lighter hose or use hose floats

    Suction pipe restricting movement of skimmer at either high or low level

    Position the skimmer to allow for more freedom of movement

    Skimmer weir runs dry

    Skimmer is not primed before operating

    Stop pump and allow skimmer to self-prime through small hole in base

    Pump suction rate is too high Lower suction rate

    Skimmer hung up on obstruction Rearrange pump or remove obstruction

    Skimmer not supplying fluid to pump

    Blockage in skimmer, suction hose or piping

    Backflush skimmer through pipe

    Manually unblock skimmer weir ring

    Reconsider debris size entering tank

    Skimmer supplying fluid but not removing surface oil layer

    Weir ring sitting too low Clean the bellows to remove built up sediment

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    9. Drawings

    9.1 S1 Skimmer

    I-S-0040-01 S1 Skimmer Sales Drawing

    I-A-0271-01 S1 Skimmer Assembly Drawing

    9.2 S2 Skimmer

    I-S-0050-01 S2 Skimmer Sales Drawing

    I-A-0058-20 S2 Skimmer Assembly Drawing

    9.3 Hoses

    I-S-0045-01 S1 Skimmer Hose Drawing

    I-S-0055-01 S2 Skimmer Hose Drawing

    9.4 Elbows and Hose Floats

    I-S-0040-01 S1 Skimmer Sales Drawing

    I-S-0050-01 S2 Skimmer Sales Drawing